All manufacturing, processing, and industrial facilities generate some degree of heat from direct heating processes, heated combustion gases that simply go outside, and heat that comes off of hot surfaces. Most of this heat is lost by dissipation throughout the building, escaping outside, or by building up to the point that cooling systems are needed to regulate temperatures.
Instead of letting heat escape or spending money trying to counter it, it’s possible to boost energy efficiency by recovering and repurposing that heat for other operations.
Some estimates indicate that between 20% and 50% of industrial energy input is lost in the form of waste heat. But there are ways to avoid this costly inefficiency. Here we’ll explore ways to recapture heat energy, reduce consumption, and improve sustainability through industrial waste heat recovery.
Savings Enabled by Waste Heat Recovery
The primary benefit of recovering waste heat and repurposing it for other heat processes is cost savings. First, reusing heat reduces energy demand which will save your organization money. This will lower your emissions while reducing your facility’s energy usage and energy consumption.
Some of the most common applications for recovered heat energy include:
- Heating for industrial processes.
- Converting the heat to electricity, which can vary in value based on local demand and local energy prices.
- Providing heating for a district grid.
Widespread participation in heat recovery could save as much as $160 billion through thermal energy optimization alone (this is approximately the same amount that the European Union spends on natural gas imports). These are significant savings, especially since global industrial heating is both a significant expense and prices continue to rise. Heating prices have risen precipitously and are likely to either flatten or continue climbing, making saving one of the most powerful tools every industrial company has. For example, refineries and cement manufacturers are becoming more competitive by incorporating heat waste recovery technology into their processes.
Cashing In on Waste Heat Savings
To maximize your savings, it pays to know what different options for waste heat recovery are available, what works best for your type of facility, and what the ROI is for different options. Some of the most efficient solutions will be easy to install and maintain, give a quick timeline for utilization, and have a clear payback period so you can forecast savings in definite numbers.
There are many ways to approach waste heat recovery and reuse, including:
- Making incremental improvements. Instead of implementing new equipment and processes all at once, it’s possible to take a gradual approach. Roll out slow changes like installing new process controls, upgrading them with advanced technology over time, and adding high-tech heat exchangers.
- Explore new technologies. Look into larger-scale changes and improvements like thermal energy storage systems, converting waste heat to power, installing heat pumps, mechanical vapor recompression, Qpinch heat transformers, or adding new thermocompressors for waste heat recovery.
- Completely redesign these systems. This option is more complex and may have a longer pack period, but it offers the biggest energy transformation. Reconfigure building systems with new reactor designs to recover waste heat instead of recooling, add new reboilers, redesign facility dryers, replace condensing turbines with electrical drivers, and make a set point change.
The biggest improvements can come from a cohesive, systematic approach to thermodynamic efficiency across your entire site rather than in one isolated building. Consider adopting a widespread plan across multiple business units in these three steps:
- Create a waste heat recovery program with ongoing monitoring and recommendations for process improvement. Prioritize a connected, real-time data system and training for employees so they can use it effectively.
- Compare different heat recovery technologies and heat integration plans to find the right solutions for your operations and set up. Involve your local utility company, industry-specific experts, and heat recapture technology vendors to get a complete picture of what is most beneficial.
- Consider how new business models like energy-as-a-service (EaaS) models can help you make investments without upfront financing. Service providers who offer EaaS options may give you access to equipment for joint savings/sharing or for a reasonable fee. The right options will match your energy goals, future growth plans, and current financial outlook.
Contact Baelz North America for Waste Heat Recovery Solutions
Saving money while reducing your company's energy is the right path forward for virtually all organizations in the industrial sector, especially as energy costs continue to grow and sustainable manufacturing becomes a priority. At Baelz North America, we can help companies identify opportunities for savings with heat waste recovery solutions for their needs and goals. We offer extensive in-house design services for hardware and software systems and we specialize in developing future-proof systems for ongoing savings and adaptability. Contact us today to discuss your potential savings or request a quote to start your program.