Driving Energy Efficiency in the Paper Industry with Smart Steam Trap Monitoring by Emerson

A significant yet often underestimated opportunity for enhancing efficiency lies in the optimization of steam systems, particularly through improved monitoring and maintenance of steam traps.

These crucial components play a pivotal role in discharging condensate while preserving live steam. However, their malfunction can lead to either steam wastage or condensate accumulation, adversely affecting system performance and efficiency.

Understanding the “Steam Trap Problem”

According to industry estimates, 15–30% of steam traps fail annually, resulting in substantial energy losses. In large-scale paper mills, where vast networks of steam traps are deployed, these failures can translate into millions of euros in wasted energy and increased CO₂ emissions—a scenario with significant ramifications for EU ETS reporting and compliance costs.

Steam is indispensable in paper production, especially in the drying phase, where thermal efficiency is paramount. A single malfunctioning steam trap can contribute hundreds of tons of CO₂-equivalent emissions annually. When extrapolated across multiple traps, the environmental and financial consequences become severe, underscoring the need for effective monitoring solutions.

Emerson’s digital solutions: Rosemount™ 708 Wireless Acoustic Transmitter and Plantweb Insight™

Emerson’s innovative solution addresses this challenge by integrating the Rosemount™ 708 Wireless Acoustic Transmitter with Plantweb Insight™ analytics. This combination provides real-time wireless steam trap monitoring and delivers actionable insights for maintenance and performance optimization.

Key Features:

• Continuous Monitoring: Utilizing acoustic sensors, the Rosemount™ 708 detects ultrasonic signatures indicative of steam trap activity, pinpointing leaks, blockages, or blow-through conditions;
• Wireless and Non-invasive: The transmitter, employing WirelessHART® technology, can be seamlessly installed without halting operations, making it ideal for retrofitting legacy systems;
• Advanced Analytics: Plantweb Insight™ aggregates data from numerous traps, applying diagnostic algorithms to generate performance dashboards, alerts, and maintenance suggestions;
• ETS-Ready Reporting: By quantifying steam losses and their CO₂ equivalence, this system facilitates precise carbon accounting, thereby aiding in the reduction of ETS compliance expenses.

Beyond steam trap monitoring, Plantweb Insight™ extends its capabilities to ensure mechanical integrity and reliability across paper mills. WirelessHART vibration monitors integrated into the Plantweb Insight™ platform can observe vibration and PeakVue+ levels in critical areas like the drying section, enhancing overall system performance.

At Emerson, we are dedicated to supporting the Pulp & Paper industry in overcoming these challenges through advanced measurement technologies. Our solutions are designed to enhance operational efficiency, reduce environmental impact, and promote a greener future for the industry.

About Emerson

Emerson is a global industrial technology leader that provides advanced automation. With an unmatched portfolio of intelligent devices, control systems, and industrial software, Emerson delivers solutions that automate and optimize business performance.

We help customers in critical industries, like energy, chemical, power and renewables, life sciences, pulp & paper, and factory automation, operate more sustainably while improving productivity, energy efficiency, reducing emissions, and enhancing reliability.

Headquartered in Saint Louis, Missouri, Emerson combines innovative technology with proven operational excellence to power the future of automation