Here’s a complete technical explanation:
🔹 1. What is a CRS (Condensate Recovery System)?
A Condensate Recovery System (CRS) is a setup used in steam-based industries to collect, return, and reuse hot condensate (steam that has condensed back into water after heat transfer) to the boiler feed tank.
Instead of draining the condensate, which still contains high thermal energy, the CRS recovers that heat, thus saving fuel, water, and chemical treatment costs.
🔹 2. Working Principle
Steam Usage:
Steam from the boiler goes to process equipment (like heat exchangers, dryers, etc.).
Condensate Formation:
After transferring heat, steam condenses into hot water (condensate), usually around 80–100°C.
Condensate Collection:
Condensate is collected in condensate receivers through pipelines.
Pumping & Return:
A condensate recovery pump (mechanical or electrical) sends the hot condensate back to the deaerator/feed water tank or directly to the boiler feed line.
Recycling:
The returned condensate reduces the need for fresh cold make-up water, minimizing heat loss and saving boiler fuel.
🔹 3. Mechanical Components / Drawing Description
A typical CRS mechanical layout includes:
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[Steam Users] → [Condensate Line] → [Condensate Receiver Tank] 
→ [Condensate Recovery Pump] → [Return Line] → [Feed Water Tank / Deaerator] → [Boiler]
Main Components:
Condensate collection tank (stainless steel or mild steel)
Steam trap assembly
Pressure and temperature gauges
Condensate recovery pump (electric or mechanical)
Check valve & NRV
Return piping to feed tank
Would you like me to create a mechanical drawing (schematic) of this system? I can show a labeled flow diagram.
🔹 4. Benefits of a CRS System
✅ Fuel Savings: Less heat energy is needed to convert feed water to steam.
✅ Water Savings: Reduced makeup water requirement.
✅ Chemical Savings: Reused condensate needs less treatment.
✅ Reduced Blowdown Loss: Lower TDS due to reuse.
✅ Lower Carbon Emission: Reduced fuel consumption = lower CO₂ output.
✅ Increased Boiler Efficiency: Feedwater enters hotter, saving firing time.
🔹 5. Profit and Payback Calculation Example
Let’s calculate an example:
Assumptions:
Condensate recovered: 1,000 kg/hr
Condensate temperature: 90°C
Feed water temperature without recovery: 30°C
Operating hours: 20 hr/day
Fuel cost: $0.80/m³ of natural gas
Boiler efficiency: 80%
Heat saved per hour:
So, fuel saved = 250,800 / 35,000 = 7.17 m³/hr
Daily fuel savings = 7.17 × 20 × 0.80 = $114.72/day
If CRS installation cost = $20,000
→ Payback: ~6 months (very common in industry)
🔹 6. Summary Table
Parameter
Typical Value / Result
Condensate Temp
80–100°C
Energy Savings
10–20% of fuel
Water Savings
15–25%
Payback
4–8 months
Key Benefit
Reduced fuel & chemical costs
Would you like me to draw and label the mechanical schematic of the Condensate Recovery System (CRS)?
I can generate it for your presentation or report (clean, labeled, and in an industrial style).