Saturated steam generator

heat-recoveryhigh-pressureindustrial

Overview
In an environment of rising energy costs and tight environmental regulations, the BHS Corrugated integrated steam system minimises energy losses and improves corrugated board production efficiency. BHS Corrugated supplies a coordinated, single-source solution fully integrated into the corrugator: development, installation and commissioning tailored to production needs.

Main steam reduction station

• Automates pressure regulation for the main steam supply when boiler pressure exceeds 16 bar to maintain constant system pressure.
• Constructed from low-maintenance, high-grade fittings; pressure controlled electronically via a PLC-driven control valve.
• Includes an automatic heating function for the entire corrugator.
• Delivered fully pre-piped and assembled in accordance with country-specific regulations.
• Equipped with overpressure safety devices to prevent exceeding maximum limits.

SF power trap station (Single Facer)

• Machine condensate is conveyed into the condensate system by a mechanical condensate pump.
• Automatic blow-off valves secure the required differential pressure for the machine.
• Components and layout are designed to ensure reliable machine function and long service life.
• Supplied fully assembled and in compliance with local regulations.

SF control station (Single Facer)

• Provides inlet and differential pressure control for the Single Facer to ensure energy-efficient operation across production conditions.
• Integrated spray steam generation removes the need for an external central spray steam supply.
• Delivers investment and operating cost advantages compared with a central spray steam system and improves Single Facer operation.
• Modular design allows inclusion of an integrated mechanical condensate pump (optional) to return condensate to the condensate system.
• Supplied fully assembled, electrically and pneumatically prepared and built to country-specific standards for quick and safe installation.

DF compact station (Double Facer)

• Designed for individual steam pressure control of heating sections to allow fast response to temperature changes from different paper types and grammages.
• Fast pressure reduction and differential pressure control provide quick, reliable adaptation to production requirements.
• Condensate is returned to the condensate system using mechanical condensate pumps.
• Optional automatic saturated steam switchover from spray steam prevents overheating at low steam pressures.
• Available for all heating-section layouts; suitable for new and existing installations and delivered fully assembled for connection.

DF expansion station (Double Facer)

• Optional add-on module enabling stable production with steam pressures down to 1.5 bar across heating sections while maintaining high resource and energy efficiency.
• Delivered fully assembled and compliant with country-specific regulations.

Condensate tank station

• Central component of a closed steam-and-condensate system enabling condensate recovery at higher pressure levels.
• Generates significant resource and energy savings (up to ~20% compared with systems without condensate recovery).
• Supplies spray steam to machines lacking their own spray steam generation.
• Delivered fully assembled, pre-piped and built according to country-specific regulations; includes overpressure safety devices.

Benefits

• Seamless interaction of modules for high project reliability.
• Efficient and cost-optimised steam usage with condensate recovery.
• Single-source delivery: development, installation and commissioning.
• High availability and long service life through durable components and globally available spare parts.
• Quick, safe installation due to fully assembled, pre-piped and pre-prepared stations.

Technical specifications

• Fully integrated steam system designed for corrugators.
• PLC-controlled pressure management (control valve) for main steam reduction.
• Main steam reduction activation at boiler pressures above 16 bar.
• Automatic heating function for the corrugator included in main station.
• Mechanical condensate pumps for machine condensate return.
• Automatic blow-off valves to secure differential pressure for machines.
• Integrated spray steam generation for Single Facer (eliminates central spray steam requirement).
• Modular station design; optional integrated mechanical condensate pump available.
• Condensate recovery yields up to ~20% resource and energy savings vs. no recovery.
• Stations supplied fully assembled, pre-piped, electrically and pneumatically prepared; compliant with country-specific regulations and equipped with overpressure safety devices.
• Suitable for retrofit and new installations; supports various heating-section layouts and paper grammages.