31% less energy spent without interrupting production

Scope

The project included mechanical, electrical and control components: a system for collecting and utilizing waste heat from the paint shop and enamel shop, a new gas plant, absorption heat pumps, hot water solar collectors, six compressor units, a complete mechanical installation with pipework and a complete control system that connects all of this into one unit.

Approach

An industrial facility with high heat loads requires a different approach than an office building — each process has its own temperature, its own consumption profile, and its own dynamics. That’s why we started by measuring: how much heat is generated in the paint shop, how much in the enamel shop, how much is released into the atmosphere, and at what times.

Based on this data, we designed a recovery system that returns waste heat to the process, instead of losing it. Absorption heat pumps and solar collectors take over part of the load from the gas system. And the control system orchestrates it all — turning sources on and off according to actual need, not according to a schedule.

The most challenging part of the job was to do everything without interrupting production. We planned each operation so that the plant would continue to operate while we worked around it.