Challenge:
A leading aluminium company in the UK is dedicated to enhancing energy efficiency and minimising carbon emissions by optimising energy consumption and recovering waste heat from its high-temperature production processes. The aluminium manufacturing process involves high-temperature operations, leading to substantial waste heat losses, particularly from furnaces and exhaust gases.
Solution:
We conducted a comprehensive energy audit to assess heat loss areas and potential recovery opportunities. We analysed thermal inefficiencies within the production line and identified a viable waste heat recovery system tailored to their needs.
The proposed solution involved integrating high-efficiency heat exchanger systems that captured waste heat from the hot spots in the operation and redirected it for preheating other demanding locations. This approach significantly reduced the primary energy demand required for heating, improving energy utilisation and cost savings.
Key steps:
- Energy Audit & Feasibility Study: To quantify waste heat potential, a detailed analysis of the client’s existing thermal systems was conducted. This step included intensive 3D modelling for the furnaces and overall system modelling to quantify the waste heat and the potential recovery.
- Technology Selection: A group of gas-to-gas heat exchangers was chosen to maximise heat recovery efficiency.
- System Design & Engineering: The waste heat recovery system was designed to integrate seamlessly with the existing production infrastructure, ensuring minimal operational disruption. The decision metric included techno-economic optimisation for the system.
Outcomes:
- 12% Energy Savings: The new integrated heat recovery system reduced the client’s energy consumption by 12%, leading to significant cost savings.
- Reduced Carbon Footprint: The project decreased CO₂ emissions, supporting the client’s sustainability targets.
- Improved Process Efficiency: The client achieved more stable and efficient production conditions by effectively utilising waste heat.
- 80% Return on Investment (ROI): The investment in the heat recovery system was recouped under two years.
Additional information can be provided upon request.
