Manufacturing industry is under more pressure than ever to remain sustainable and efficient with the increasing burden of rising energy prices. Operational has developed key skills in maximising efficiency, recovering energy and developing benefit from waste streams:
- Process optimisation and dryer systems
- Thermal efficiency schemes
- Heat from waste systems
- Energy recovery systems
- Project management and engineering services
- Provide the essential information required for front end design
- Provide economy by optimisation of specifications
- Provide performance acceptance and commissioning
- Design and feasibility studies
In the food industry, Operational has provided many heat recovery systems to take waste heat from ovens and convert the energy into useful forms of energy such as boiler feed water, hot water for wash down and warm air ventilation. Often the recovered energy can be an efficient substitute for expensively generated steam. Typical projects of this type provide capital pay back in less than two years.
Case Study 1
Operational was able to recover 800 kW of heat from an oven forming coated non-woven textile. The challenge was not only to recover the heat but to prevent fouling of the exchangers from dust and fibres. This was achieved by careful selection of equipment and a bespoke in situ cleaning system. This customer is now saving more than £180,000 per year from their gas bills.
Case Study 2
A printing company needed to reduce their atmospheric emissions. Operational converted the existing oxidiser to meet the latest environmental standards and improved the thermal performance to an extent that it is now possible to recover up to 500 kW of excess heat in to thermal oil. The operating conditions of the factory meant the heat recovered had a value of £60,000 and the equipment paid for itself within a year.