Industrial waste heat recovery (WHR) is the process of capturing the waste heat generated by industrial processes and repurposing or reusing it.
Industrial processes typically use and/or produce vast amounts of waste heat, which is often underutilized or overlooked entirely. However, companies can increase the energy efficiency of their operations by reusing this waste heat.
Repurposing Industrial Waste Heat
In some instances, the waste heat generated by one industrial process can be used to facilitate a secondary on-site process. Known as ‘process waste heat recovery’, this allows waste heat to be utilized within a plant’s process streams.Â
However, secondary processes rarely require all of the waste heat that’s produced on site, which means a significant amount of heat is released into the atmosphere and/or via wastewater. Furthermore, some sites simply don’t need heat to facilitate secondary processes, meaning that all of the heat used or generated is wasted.Â
Fortunately, there are additional ways to utilize this waste heat in order to increase the sustainability of industrial operations. By converting waste heat to clean, carbon-free electricity, for example, industrial firms can reduce CO2 emissions, increase energy efficiency and decrease costs.Â
Industrial Waste Heat Recovery with HeatPower
Climeon’s HeatPower technology is designed to efficiently convert low-temperature waste heat into clean electricity. By capturing and reusing waste heat from industrial processes, HeatPower helps reduce emissions and allows facility owners to generate more sustainable power on-site.
HeatPower uses the Organic Rankine Cycle (ORC), a proven technology that turns waste heat into electricity through a closed-loop system. In this system, waste heat—such as cooling water, condensed steam, or thermal oil—is fed into a heat exchanger, which acts as an evaporator. The evaporator transfers the heat to the working fluid, causing it to vaporize.
The vaporized fluid is then directed to a turbine, which drives a generator to produce electricity. Afterward, the fluid is cooled in a second heat exchanger, acting as a condenser, where it returns to its liquid form. A pump circulates the fluid, ensuring the process continues in a loop.
Continuous Clean Electricity from Low-Temperature Heat Sources
HeatPower’s closed-loop design ensures that clean electricity can be generated continuously, as long as both the waste heat and cold sources are available. This provides facility owners with a reliable and uninterrupted power supply, even during periods of high energy demand. By using HeatPower ORC Industrial Waste Heat Recovery Systems, facility owners can generate carbon-free electricity whenever their industrial processes produce waste heat, significantly reducing reliance on external power sources.
This continuous, on-site electricity generation not only lowers energy costs but also improves energy security by reducing exposure to fluctuating electricity prices. Moreover, it enhances overall sustainability by maximizing the use of otherwise wasted energy, contributing to lower carbon emissions and a smaller environmental footprint.
Discover how Climeon’s ORC waste heat recovery systems are driving sustainability at Neo Group’s PET Resins plant.
What Are the Benefits of Industrial Waste Heat Recovery Technologies?
Using waste heat to generate sustainable power in an industrial environment can be advantageous for many reasons, such as:
Reduced CO2 Emissions
Industry is the third largest emitter of CO2, both throughout Europe and worldwide (IEA, 2022). Despite widespread calls for environmental reform, industrial emissions have risen by more than 70% since 2000. As a result, heavy industries, such as cement, iron and steel, are not on track to achieve the ‘Fit for 55’ emissions targets by 2030.
Increasing industrial energy efficiency is key to reducing harmful emissions and waste heat recovery delivers a viable, proven solution that can be applied across a variety of industrial sectors.Â
By using waste heat to generate clean electricity, industrial firms can generate meaningful and verifiable emissions reductions, thus minimizing their environmental impact and enhancing the sustainability of their brand.Â
Lower OPEX
The recent increase in energy prices has highlighted the need for reliable, low-cost energy, particularly for commercial entities. As industrial waste heat recovery systems convert an overlooked byproduct into a valuable commodity, industrial plants can reduce their energy expenditure by generating electricity on site and minimizing their reliance on fuel-powered generators or high commercial energy tariffs.
As governments seek to incentivize industrial firms via carbon taxes, companies can further reduce their OPEX by lowering emissions and meeting applicable environmental targets. As a result, integrating waste heat recovery systems into industrial sites gives companies the opportunity to lower operating costs while reducing their carbon footprint.
Increased Energy Stability
Access to reliable energy sources is critical in an industrial setting. While the recent energy crisis raised concerns regarding the accessibility of electricity in some regions, energy stability is also an issue when transitioning to renewable power.
Climeon’s HeatPower 300 Industry units produce non-weather dependent, on-site clean energy, which ensures continued access to sustainable power and safeguards access to reliable, clean energy.
Modular and Scalable
The modular and scalable design of Climeon’s HeatPower technology ensures that industrial waste heat recovery systems can be tailored to the specific needs of industrial companies and sectors. From single units for moderate industrial waste heat generators to integrated systems for high waste heat outputs, Climeon’s HeatPower system provides a flexible and effective method of sustainable power generation.Â
Industrial Waste Heat Recovery with HeatPower
Delivering environmental, financial and operational benefits, Climeon’s HeatPower technology provides industrial companies with the opportunity to accelerate their sustainability strategies, reduce emissions and generate cost savings.Â
While heavy industries have long been associated with fossil fuels and high emissions, new technologies, like industrial waste heat recovery, herald a new era of sustainable industrial processes.
