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Energy efficiency in heat generation: reducing consumption with a new steam generator

Context and objective

Heat generation represents one of the main items of energy consumption for manufacturing companies. The use of obsolete or oversized systems compared to actual production needs can result in high consumption of natural gas and electricity, directly impacting operating costs.

For this reason, the company decided to replace the existing diathermic oil generator with a modern water-based steam generator, which is more efficient and sized to the actual production needs. The goal of the intervention was to reduce methane and electricity consumption, improving system performance and recovering heat from the flue gas.

The intervention

Implementation of the new system included:

1

Installation of a water steam generator

More efficient than the previous thermal oil generator and designed to adapt to actual production needs.

2

Adoption of an economizer

The system has been equipped with a device to recover heat from the flue gas, which is used to preheat the combustion air, further improving the efficiency of the system.

3

Optimization of sizing

Choosing a generator proportionate to demand has avoided waste and improved overall energy management.

The total investment for the intervention was €130,000, with a significant economic return due to the energy savings and incentives obtained.

Results and benefits

The adoption of the new steam generator has brought concrete and quantifiable benefits:

Reduction of 120,000 Sm³/year of methane

with economic savings of about 40,000 €/year.

Savings of €5,000/year on electricity consumption

Through process optimization.

Achievement of 87 TEE/year

With an additional economic benefit.

Economic and operational impact

Lower energy costs

Reduced consumption of natural gas and electricity.

Improved operational efficiency

Better performing system and reduced thermal waste.

Economic incentives

Partial recovery of the initial investment through Energy Efficiency Certificates (EEE).

Lower environmental impact

Reduction of CO₂ emissions from methane combustion.

The installation of the water-based steam generator has optimized heat production, achieving significant energy and economic savings. With a more efficient system and heat recovery from flue gas, the company has improved the sustainability and competitiveness of its production process.

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