The Challenge
Multi-zone industrial ovens are energy-intensive, with hot exhaust streams often released unused into the atmosphere. The question was: how much could be recovered, and what would the payback look like?
What We Found
Our pinch analysis revealed:
- 189 kW maximum heat recovery potential
- 784 MWh annual energy savings
- More than 7,800 tonnes CO₂ reduction potential
- 4–5 year payback for the best system designs
The Engineering Approach
Through stream data collection, composite curve development, and heat exchanger network design, we assessed targeted recovery strategies:
- Combustion air preheating for zone-specific efficiency
- Water heating systems from 8°C to 70°C
- Thermal oil heating up to 175°C for high-load applications
The Results
- Annual savings potential of £56,000–£81,000
- Validated ROI through thermodynamic and economic modeling
- Additional benefits from Climate Change Levy and ETS tax savings
Why It Matters
This wasn’t a desktop exercise — the results are based on real oven operating data and validated models, ensuring confidence in both energy and financial returns.
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