Heat Recovery, Reduction & Re-use

Industrial processes can consume vast quantities of energy within the process which has an environmental and financial impact.

Operational’s “efficient technology” approach provides innovative solutions for new installations and to optimize, recover and reuse energy whereever possible in existing process plant.

Often, there are waste heat or flue gases that are continuously throwing heat into the atmosphere. This energy can be harnessed and put back into the process.

Operational has saved thousands of kilowatts and many thousands of Euro’s for our clients.

• Ceramic tile manufacturer, Operational has collected heat at 290 C from the main tile firing oven flues into a thermal oil system. The thermal oil then transfers the energy efficiently through the factory to the dryers used to drive moisture from the clay after the tiles are formed.
  By harnessing the energy in the oven flues Operational has provided all the energy needed by the drying process.
  This has reduced energy use by 4,845 MWh per year and saved € 136,000.
• Non woven Textile: Operational’s “efficient technology” was applied to a building material producer making a non-woven textile reinforcement material.
  In this case heat was recovered into medium temperature hot water and used to pre-heat the ovens and provide the factory with hot water.
  The first installation recovered 800 kW of heat worth €156,000.
  Our client has been so impressed with the results of our efficient technology approach that two more systems have been ordered and installed.
• Bakery: Operational recovered 200kWh from bakery oven flues into a site wide hot water system. This hot water was used to heat provers, basket wash and boiler feed water. The energy value was over £40,000 per year with a green house gases reduction of 350 tonnes.
• Thermal Oxidiser: By applying Operational’s “efficient technology” a Rotogravure décor printer was able to improve the thermal efficiency of their thermal oxidiser to save £76,000 of gas per year. Return on investment was 1 year.

For more examples go to our case study downloads or call us to find out how Operational can make your technology more efficient.

Hardware:

Vits Ovens; Feco; Fleissner: Greenbank; JLS; KBA/LTG Megtec; Pagendarm; Siti; Sprimag; Valmet; Spooner; APV.

Case studies:

Azulev – Decorative ceramic tiles – Heat recovery via thermal oil from firing oven to pre-dryer.
Owens Corning – Non-woven textile building material. Instrumentation for oven control.
Amcor – Flexible Packaging Printer. Up grade fan performance, increase nozzle velocities, improve heat transfer efficiency and product quality and throughput.