taiz 
Background 

A leading manufacturing facility sought to improve its energy efficiency and reduce its carbon footprint. The facility had significant waste heat generated from its industrial processes, which was being vented into the atmosphere. Recognizing the potential to reclaim this wasted energy, the facility partnered with us to implement a waste heat recovery system.

Challenge

The primary challenge was to design a system that could efficiently capture and reuse the waste heat from exhaust air to preheat combustion air without disrupting ongoing operations. Additionally, the solution needed to demonstrate clear fuel savings and a reduction in greenhouse gas emissions.

Solution

Using advanced Computational Fluid Dynamics (CFD) modelling, we designed a bespoke heat recovery system. The CFD simulations allowed us to visualize and optimize the heat exchange process, ensuring maximum efficiency. The system captured waste heat from the exhaust air and transferred it to the combustion air, significantly raising its temperature before entering the combustion chamber.

Implementation

The heat recovery system
was installed seamlessly into the existing infrastructure. The CFD models were
used to guide the installation, ensuring that all components were correctly
positioned for optimal performance. The system was monitored and adjusted in
real-time to maintain efficiency.

Results

The implementation of
the waste heat recovery system led to substantial benefits:

  • Fuel Savings: The preheated combustion air reduced the amount of fuel required,
    resulting in a decrease in fuel consumption.
  • Carbon Footprint Reduction: By lowering fuel usage, the
    facility reduced its carbon emissions, thus, contributing to a greener
    operation.
  • Operational Efficiency: The optimized heat exchange
    process enhanced overall system performance without disrupting production.

By leveraging advanced technology, the manufacturing facility not only achieved significant cost savings but also took a substantial step towards sustainability. This project exemplifies how innovative solutions can drive efficiency and environmental responsibility in industrial operations.