Metered testing demonstrated that GEM™ Steam Traps reduced steam consumption by 20–30% compared with the mechanical traps previously installed on the site’s steam baths and kettle boiler, used for pickling and treating iron wire strands.
As the facility’s primary energy source, steam is fundamental to production and represents a significant operating cost. Recurring mechanical trap failures were therefore causing avoidable steam losses, reduced process performance and additional expenditure. The Energy Manager commissioned monitored trials to quantify the potential savings, assess condensate performance and verify operation across varying loads.
Steam meter readings confirmed that GEM™ Steam Traps reduced energy consumption while operating effectively across a wide range of condensate loads. The resulting savings supported a rapid payback and led to the wider adoption of GEM™ across these production applications.
Reflecting on the monitored trial and wider project, the Energy Manager commented:
I decided to carry out monitored tests to quantify the amount of steam that could be saved with the GEM traps and whether there would be a reduction in condensate. The test results together with the steam meter readings have proved that the GEM traps save energy and operate well over a wide range of condensate loads. The fact that such a small device can obtain such important savings and provide a fast payback is really good news. Thermal Energy International supported us throughout the project and we hope to continue this collaboration at other sites and with other projects.
