Industrial Researches
Applied research in industrial renewable energy — recovering waste heat and exhaust air to eliminate conventional heating costs across manufacturing facilities.
Industrial Renewable Energy
Saving energy plays an important role in day-to-day regular industrial life. Our research team identifies waste energy streams in manufacturing environments — exhaust heat, hot air, and thermal by-products — and engineers practical systems to redirect that energy productively.
Both deployed solutions below were born from real customer challenges, engineered on the shop floor, and proven in production environments before being offered as standard solutions.
Saving energy plays a critical role in day-to-day industrial operations. We developed a system that recovers thermal energy from 2-ton and 1-ton melting furnaces in casting operations to directly heat a 5,000-litre industrial washing machine tank.
Heat Energy Recovery System from Exhaust Furnace
The Challenge
Melting furnaces exhaust enormous quantities of heat to atmosphere as waste. Simultaneously, industrial washing machines require sustained high-temperature water (60–80 °C) which is conventionally heated by electric heaters — a significant energy cost.
Our Solution
A custom heat exchanger coil system intercepts the furnace exhaust gas stream and transfers thermal energy into the washing machine tank water. The system is fully passive — no additional pumps or controls are required beyond the furnace's existing operation.
Outcomes
- 60–70 % reduction in electric heater energy consumption
- Tank reaches operating temperature 40 % faster
- Zero additional fuel consumption for washing machine heating
- Typical payback period: 8–14 months
Exhaust air from an ED (Electro-Deposition) Paint Shop is typically vented at 80–120 °C. Our research developed a ducting and heat-transfer system that routes this exhaust air to power a Paint Sludge Drying Oven — eliminating a dedicated heat source entirely.
Hot Air Supply System from ED Paint Shop Exhaust
The Challenge
Paint sludge generated during the ED coating process must be dried before disposal. Conventional drying ovens consume significant electrical or gas energy. Meanwhile, the ED Paint Shop exhausts large volumes of hot air continuously during production.
Our Solution
A directed ducting system with baffled air channels routes the ED exhaust air into the drying oven chamber. Variable dampers control temperature within the oven to prevent overheating, while ensuring the main paint line exhaust compliance is maintained.
Outcomes
- 100 % elimination of dedicated oven heating energy
- Consistent drying oven temperature of 60–80 °C maintained
- Sludge drying cycle time reduced by 30 %
- Direct CO₂ reduction from eliminated gas burner
Have an Energy Challenge in Your Facility?
We identify waste energy streams and engineer practical recovery systems with short payback periods.
Discuss Your ProjectReady to Reduce Your Energy Costs?
Contact our engineering team to audit your facility's energy waste streams and design a custom recovery solution.