Condensate Return Unit | Gestra

GESTRA Condensate Return Unit – Condensate Return Module

The GESTRA condensate return unit collects condensate from steam consumers or flash vessels and returns it to the feedwater tank, typically via a deaerator. The setup can be configured with a rectangular or cylindrical tank, electric pumps on a skid, or a steam-driven mechanical pump.

Operation

Condensate level is measured using a conductive electrode. At the upper switch point, a pump start command is issued, and at the lower point, a stop command. The standard SDR version includes two pumps, each for 100% flow, with alternating operation and common monitoring.

SDR Technical Specifications

• Condensate flow: 1–10 t/h
• Tank volume: 340–2500 L
• Operating pressure: 0.1 bar(g)
• Operating temperature: up to 100 °C
• Tank material: S235JRG2 or stainless steel 1.4571
• Optional pump control panel NRSP
• Instruments: level indicator, thermometer, pressure gauge, level electrode, check and isolation valves.

Selection Criteria

Selection is based on:

• condensate flow and temperature,
• available pump head,
• pressure in the deaerator or feed tank,
• need for single or dual pump,
• tank material,
• open or closed return system,
• need for water replenishment via float or solenoid valve.

For stainless steel SDR tanks, GESTRA sets a chloride limit of 50 mg/L for make-up water or returned condensate, a critical parameter to avoid corrosion.

Applications

Used in steam boiler rooms, heat exchangers, process condensate lines, steam HVAC systems, food industries, chemical plants, and facilities where recovering hot condensate reduces water and thermal load losses.

FAQ

When is a mechanical pump selected?
When an electric pump is not desired or when steam drive is available.

Why is level control required?
To prevent overflow, dry pump operation, and unstable return to the feedwater.