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Heat recovery from cogeneration water: optimizing consumption and reducing methane

Context and objective

Optimizing thermal energy in industrial processes is a strategic lever for reducing operating costs and improving overall plant efficiency.

In this context, the company decided to use the waste heat from the water leaving the cogeneration unit to preheat the air entering the dryer, thus reducing the consumption of methane gas required for the drying process. This intervention makes it possible to make use of the thermal energy already available, lowering consumption and improving the sustainability of the plant.

The intervention

For heat recovery, a series of air/water heat exchangers, positioned above the dryer, was designed and installed. The design followed precise operating parameters, including:

1

Temperatures of inlet water and air

To ensure maximum heat transfer without altering plant operating conditions.

2

Flow rate of available water

To make the best use of waste heat without compromising the performance of the cogeneration unit.

3

Air flow rate

To optimize preheating and maximize energy saving.

The investment for the installation was €35,000, with a rapid payback due to energy cost savings.

Results and benefits

The implementation of the heat recovery system has brought concrete and measurable benefits:

Reduction in methane consumption by about 50 percent

equal to a savings of 250,000 Sm³/year.

Economic savings of about 80,000 €/year

due to the lower need for natural gas.

Economic and operational impact

Improved energy efficiency

Waste heat recovery to reduce fuel consumption.

Optimization of the drying process

Less dependence on methane gas without altering production performance.

Operating cost savings

Direct reduction in natural gas supply expenditure.

Increased environmental sustainability

Lower CO₂ emissions due to reduced fossil fuel consumption.

The adoption of air/water heat exchangers has optimized the use of available thermal energy, providing significant savings on methane gas costs and improving the overall sustainability of the production process. With a low investment and immediate economic impact, this intervention demonstrates the effectiveness of energy recovery in industry.

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