Condensate Recovery Tank – Boiler & Steam Pressure Vessels

Efficient Steam Condensate Collection, Storage, and Reuse

Condensate Recovery Tank - Boiler Pressure Vessel

Introduction

A Condensate Recovery Tank (CRT) is a specialized boiler auxiliary pressure vessel designed to collect, store, and return condensed steam from industrial and commercial processes back to the boiler system. By recovering and reusing condensate, these tanks enhance energy efficiency, reduce water and fuel consumption, and protect boiler systems from thermal shocks and water treatment issues.

At NORDSTONE., we design and manufacture ASME-certified condensate recovery tanks with robust construction, precise thermal design, and compliance with international standards, including ASME Section VIII, NB, and PED certification.

What is a Condensate Recovery Tank?

A Condensate Recovery Tank is a pressurized or atmospheric vessel that receives condensate from steam systems, allowing it to cool, separate non-condensable gases, and store it for return to the boiler feedwater system. This reduces energy consumption, minimizes chemical treatment costs, and ensures consistent boiler operation.

Key components include:

  • Cylindrical or horizontal vessel shell designed for pressure and temperature requirements
  • Condensate inlet connection from steam traps and process condensers
  • Vent for non-condensable gases
  • Outlet to boiler feedwater system
  • Internal baffles or demisters to separate flash steam
  • Manways for inspection and maintenance
  • Instrumentation ports for level, temperature, and pressure monitoring

Condensate recovery tanks are critical for energy optimization, environmental compliance, and long-term boiler system reliability.

Types of Condensate Recovery Tanks

Pressurized Condensate Recovery Tank

  • Handles high-pressure condensate
  • Suitable for industrial and power plant steam systems
  • Equipped with safety valves and level instrumentation

Atmospheric Condensate Recovery Tank

  • Receives condensate from low-pressure steam systems
  • Flash steam is safely vented to the atmosphere
  • Simplified design for commercial and medium industrial applications

Vertical / Horizontal Condensate Tank

  • Vertical configuration for space-limited installations
  • Horizontal configuration for high-capacity recovery systems

Flash Recovery Condensate Tank

  • Captures and reuses flash steam for energy savings
  • Enhances overall boiler efficiency

Custom Industrial Condensate Recovery Tank

  • Tailored design for specific condensate flow, pressure, and temperature
  • Optimized inlet/outlet, venting, and storage for process integration

Key Features of Condensate Recovery Tanks

Energy & Water Efficiency

  • Recovers and returns condensate to the boiler system
  • Reduces fuel and water consumption
  • Minimizes chemical treatment requirements

High-Pressure & Temperature Capability

  • Design Pressure: 6 to 25 bar (pressurized)
  • Operating Temperature: up to 180°C
  • Suitable for high-pressure and low-pressure steam systems

Robust Mechanical Design

  • ASME Section VIII certified
  • PED, NB, and international code compliance
  • Cylindrical or horizontal shell with dished ends
  • Reinforced nozzles, manways, and lifting lugs

Material Selection

  • Carbon Steel – SA516 Gr.60/70, SA387 Gr.11/22
  • Stainless Steel – SS304/304L, SS316/316L
  • Alloy steels – SA213, SA335, high-performance alloys
  • Internal coatings for corrosion protection and water treatment compatibility

Operational Efficiency

  • Flash steam separation for maximum condensate recovery
  • Low maintenance with manways and drain connections
  • Optional storage section to balance feedwater demand

Safety & Reliability

  • Vent valves and safety relief connections
  • Hydrostatic and pneumatic testing for vessel integrity
  • Instrumentation for level, temperature, and pressure monitoring

Design & Engineering Considerations

Process Design

  • Condensate flow rate and boiler demand analysis
  • Flash steam recovery and venting calculation
  • Tank sizing for storage and boiler feedwater balancing
  • Integration with condensate return lines, pumps, and traps

Mechanical Design

  • Pressure vessel design per ASME Section VIII
  • Thermal and pressure load analysis
  • Reinforced nozzle, flange, and manway design
  • Compliance with PED, NB, and international codes

Operational Parameters

  • Design Pressure: 6 to 25 bar (pressurized)
  • Operating Temperature: up to 180°C
  • Diameter: 0.5 m to 3 m (project-specific)
  • Height/Length: 2 m to 8 m
  • Storage Volume: 500 L to 50,000 L (customizable)

Applications

Power Plants
  • • Recovers condensate from turbine extraction and steam lines
  • • Protects boilers and reduces feedwater heating requirements
  • • Enhances overall plant thermal efficiency
Industrial Process Boilers
  • • Returns condensate from chemical, pharmaceutical, and food industry processes
  • • Reduces water and energy consumption
  • • Improves boiler efficiency and reduces operating costs
Commercial Steam Systems
  • • Suitable for hotels, hospitals, and district heating
  • • Provides consistent and reliable boiler feedwater supply
  • • Reduces environmental impact and operational costs

Quality Assurance & Testing

All condensate recovery tanks undergo rigorous QA/QC procedures:

Non-Destructive Testing
  • Ultrasonic testing (UT) for weld and shell integrity
  • Radiographic testing (RT) for weld inspection
  • Dye penetrant & magnetic particle inspection
Pressure Testing
  • Hydrostatic testing
  • Pneumatic testing
Certification & Documentation
  • Material traceability (MTC – EN 10204 3.1)
  • ASME U-stamp and NB certification available
  • Third-party inspection (TUV, BV, Lloyds, DNV, SGS)

Optional Features & Packages

  • Vertical or horizontal configurations
  • Flash steam recovery system
  • Instrumentation for water level, temperature, and pressure
  • Insulation and cladding for thermal efficiency
  • Skid-mounted or modular designs
  • Custom inlet/outlet arrangements for integration with condensate pumps

Why Choose NORDSTONE.?

  • 20+ years of expertise in boiler and steam pressure vessels
  • Advanced thermal and mechanical design capabilities
  • ASME-certified fabrication for global compliance
  • Custom-engineered condensate recovery tanks for industrial, commercial, and power applications
  • Full QA/QC, documentation, and third-party inspection support
  • Proven reliability in high-pressure and high-temperature steam systems
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Ready to Discuss Your Condensate Recovery Tank Requirements?

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