Closed-loop cooling circuits
Water-cooled components in melting and recycling systems should remain in use for as long as possible and be maintenance-free. One of the keys to success is a well-functioning cooling system that is specially adapted to the system. The systems we plan are preferably designed as closed-loop cooling circuits in order to ensure optimum monitoring (leakages, temperatures, flow rates, etc.) and control.
Utilize waste heat.
Furthermore, closed-loop cooling circuits with dry coolers have the advantage over evaporative coolers of not falling under the requirements of the 42nd BImSchV. The waste heat generated in the units can also be decoupled and reused in our closed-loop cooling circuits. Our many years of expertise and our in-depth understanding of the core thermal engineering processes in our customers' plants ensure that all interventions for waste heat recovery in existing systems are carried out without negative consequences for production.
You can find a recent publication by us on the subject of waste heat recovery in the publications of the VIK Verband der Industriellen Energie- und Kraftwirtschaft e.V. from 03/23, for example. The article is available for free download here:
Promoting ecology.
Together with selected partners from the energy industry and energy technology, we develop holistic waste heat recovery concepts for you on request, which include technical feasibility, ecological and macroeconomic considerations, funding management and all other criteria necessary for an investment decision. Would you like to check whether your cooling water circuits also have potential for extracting waste heat? Are you unsure why your cooling system regularly overheats? Do not hesitate to contact us.
The six KSK quality criteria in the cooling systems.
Clearly arranged
Can't find your way around the pump station of your electric arc furnace? Even a glance at the operating instructions doesn't help? At this point you may also be thinking: What operating instructions? Even if it's sometimes just something as simple as the documentation: clear and understandable layouts, diagrams and instructions - including for waste heat recovery - can make work much easier at the end of the day, can't they?
Functional
A modern cooling circuit (with waste heat recovery) should be able to do more than just cool. Much more! Does your current cooling circuit only detect a leak in the electric arc furnace when you can already see a plume of steam? Is the flow temperature in your hot gas duct controlled by climate change and not by you at the control panel in the pump station? Then we should have a chat.
Innovative
Every unit to be cooled is different, every customer has their own ideas. It goes without saying that every cooling circuit we design is therefore unique. We always remain true to our basic design, but whether we should integrate a diesel pump or a city water pipe for emergency cooling is up to you. Just like the decision as to whether you want to integrate waste heat recovery or not. And even if there is less space available for your new pump station: We will find a solution.
Perfect fit
Safe cooling of the circulation water heated in the cooling circuit must be guaranteed at all times. But why not use as much of this waste heat as possible for other purposes? With the innovative waste heat recovery solutions of our versatile cooling systems, you can easily meet the constantly growing challenges in energy management. Waste heat recovery is just one of them.
Maintenance-friendly
No long distances to the control room or the system to check measured values or set the cooling circuit to maintenance mode - in a KSK pump station (with or without waste heat recovery) you will find everything in one place: control cabinets with control panel, pump technology, sensors, water treatment, leakage monitoring and much more. It goes without saying that we ensure that all purchased parts installed are absolutely suitable for use in steelworks. This means that once the pump station has been commissioned, you can concentrate fully on your day-to-day business. Because unlike suppliers, colleagues and customers, our cooling circuit always does what it is supposed to do all by itself: cooling reliably around the clock.
Economical
Well-designed process engineering cooling systems (with or without waste heat recovery), combined with a deep understanding of the components to be cooled, ensure that we dimension pumps, recoolers and the like in an economically sensible way. We can also rely on a strong network of partners and suppliers with whom we have been working for years to put together the purchased components in our cooling circuits. You don't know in which building you should install the new pump station? Then ask about our KSK Plug & Play container solution, including waste heat recovery on request. We pre-install the entire pump technology, control cabinets with control panel and even the dry cooler in a transportable container, all you have to do is connect cables and water pipes on your premises. As a result, you save on both investment and operating costs, making the new cooling circuit a complete success for maintenance, operation and purchasing!
Further content on the topic of waste heat recovery
Waste heat recovery refers to the use of heat that is generated as a by-product of an industrial process. This unused heat can be used efficiently in many different ways in various industries and companies. Effective waste heat recovery not only makes economic sense, but also helps to conserve resources and reduce environmental pollution.
What contribution can waste heat recovery in the German steel industry potentially make to achieving the EU climate targets?
Waste heat recovery in the German steel industry can make a significant contribution to achieving the climate targets of the European Union (EU). The EU has set itself the target of reducing greenhouse gas emissions by at least 40% by 2030 compared to 1990 levels. Increasing waste heat recovery in the steel industry can help to achieve this target. It is estimated that waste heat recovery in the German steel industry can make a quantitative contribution of up to 10% to achieving the EU's climate targets due to legal requirements and technical improvements - at least according to publicly available statistics and analyses.
What does waste heat recovery mean in the steel industry?
Waste heat recovery is a process in which the waste heat generated during the production of steel is used to generate energy. Waste heat is generated during the production of steel by heating pig iron, steel or scrap. This waste heat can be reused in the form of heat, steam or compressed air for various processes in the steel industry. For example, it can be used to heat rooms, operate machines or generate electricity.
In Germany, waste heat recovery is already widespread in the steel industry. Many companies use the waste heat generated during steel production to increase their energy efficiency and reduce their carbon footprint. However, many companies are also encouraged to further expand waste heat recovery in their operations due to legal requirements and technical improvements.
Are there guidelines for waste heat recovery?
The legal requirements include EU directives aimed at increasing energy efficiency in the steel industry and reducing CO2 emissions. For example, the European Commission has adopted the Energy Efficiency Directive (EED), which obliges companies to reduce energy consumption in their operations and expand waste heat recovery.
There are also specific directives aimed at promoting waste heat recovery in the steel industry, such as the Energy Efficiency Directive for the Steel Industry (EESI). These directives are part of the EU's Energy Efficiency Action Plan and are intended to encourage the steel industry to make more efficient use of the waste heat generated during the production of steel.
In addition, companies are motivated to increase waste heat recovery in their plants through technical improvements and new techniques. There are various methods that can be used for waste heat recovery in the steel industry. One of these is the use of heat recovery systems - such as those from KSK - which make more efficient use of the waste heat generated during steel production. These systems can use the waste heat generated during the production of steel to operate building heating systems, to feed it into local and district heating networks or to generally increase energy efficiency. The use of waste heat from the steelworks to operate combined heat and power processes is also a popular method of using the waste heat generated during the production of steel more efficiently.
Overall, it can be said that waste heat recovery in the German steel industry can make a quantitative contribution of up to 10 % to achieving the EU's climate targets. Legal requirements and technical improvements are encouraging companies to further expand waste heat recovery in their plants. This enables companies to reduce their energy consumption and their carbon footprint, which in turn can contribute to achieving the EU's climate targets.
Definition of waste heat recovery
Waste heat recovery refers to the process by which the unused heat generated in a plant or process is recovered and used for other purposes. The aim of waste heat recovery is to make efficient use of the unused heat generated by industrial processes and thus increase energy efficiency.
Types of waste heat
The waste heat produced can have different temperatures and properties. It can be generated as process heat, exhaust air or as heat from technical systems. There are different types of waste heat, which are differentiated according to temperature level and technical possibility.
Energy agency and waste heat recovery
The Energy Agency is an important point of contact when it comes to supporting companies in the efficient use of waste heat. It offers expertise and advice on the technological possibilities of waste heat recovery and helps companies to examine and implement the potential of heat recovery.
Why is waste heat recovery important in companies?
Efficient use of waste heat
The efficient use of waste heat is important for companies as it helps to reduce energy costs and use the resources sustainably. By utilizing unused waste heat, energy consumption can be reduced and the environmental impact reduced.
Potential of heat recovery
Heat recovery has great potential for reducing energy consumption and energy costs in industrial processes. By recovering waste heat, companies can increase their energy efficiency and reduce their CO2 emissions at the same time.
Technological possibilities for waste heat recovery
Technological solutions for waste heat recovery include the use of heat pumps, heat storage systems and various heat recovery processes. These technologies offer a wide range of options for using heat energy efficiently and supplying it to your own business.
How can waste heat be used?
Use of waste heat for heating purposes
The unused waste heat can be used for heating purposes by feeding it into existing heating systems. This means that the thermal energy is used efficiently and can help to cover the company's heating requirements.
Power generation from waste heat
Waste heat can also be used to generate electricity by feeding it into ORC systems, steam turbines or other suitable systems. This allows the waste heat to be converted into electrical energy and used for the company's own operations.
Waste heat sources and their potential uses
Waste heat sources can arise in various processes and systems. It is important to identify the waste heat sources and examine their potential uses in order to make the most of the waste heat recovery potential.
Which areas benefit from waste heat recovery?
Industrial waste heat in various sectors
Industrial waste heat can be generated in various sectors, such as the manufacturing industry, the food industry or the chemical industry. By using waste heat efficiently, companies in these sectors can reduce their energy costs and increase their energy efficiency.
Waste heat recovery for cooling
Waste heat recovery for cooling offers the possibility of using waste heat to cool processes or products. By using appropriate technologies, waste heat can be used efficiently to generate cooling.
Waste heat recovery in energy-intensive companies
In energy-intensive companies, such as those in the metal or glass industry, the efficient use of waste heat can help to reduce energy costs and increase competitiveness. Waste heat recovery offers a wide range of opportunities to improve energy efficiency in such companies.
How can the efficiency of waste heat recovery be maximized?
Use of heat pumps for waste heat recovery
The use of heat pumps offers an efficient way of utilizing waste heat and raising it to a higher temperature level. By using heat pumps, waste heat can be used efficiently for a variety of purposes.
Technological solutions for recovering waste heat
Technological solutions for recovering waste heat, such as heat exchangers or steam generators, offer the possibility of recovering waste heat from processes and using it for your own heat and power supply.
Optimization of heat demand through waste heat recovery
Waste heat recovery can optimize the heat demand in your own company. The recovered waste heat can help to cover heating requirements and increase energy efficiency.
Waste heat utilization in industry: efficiently increasing the benefits
The use of waste heat is an important way to increase energy efficiency in industry and at the same time contribute to climate protection. This guide provides a comprehensive overview of the various aspects and advantages of industrial waste heat utilization.
What is waste heat recovery and why is it important?
Basics of using waste heat in industrial processes
In industrial production processes, such as the production of steel in the steel industry or metal recycling, a significant amount of energy is generated in the form of waste heat. This waste heat often escapes unused into the environment, thus representing a loss of potential energy. The efficient use of this excess heat through technologies such as heat exchangers and heat storage can significantly reduce energy costs and protect the environment.
The role of waste heat recovery for energy efficiency and climate protection
The use of waste heat contributes directly to an increase in energy efficiency by reducing the need to generate additional energy for heating systems or for the generation of process heat. Furthermore, the reduction of energy demand through the use of waste heat has a positive impact on the climate, as it significantly lowers CO2 emissions. This supports the goals of climate protection across all industries and promotes sustainable production methods.
How waste heat contributes to reducing CO2 emissions
By utilizing waste heat, companies can significantly reduce their carbon footprint. Energy that would otherwise have to be obtained from outside for heating rooms or production processes can be covered by the company's own waste heat. This not only saves energy, but also reduces greenhouse gas emissions. In many cases, the efficient use of waste heat can reduce a company's emissions by up to 30 percent.
Which technologies enable the effective utilization of waste heat?
Use of heat exchangers and heat stores
Heat exchangers and heat stores are key components for the efficient recovery and utilization of excess heat in industrial processes. Heat exchangers can transfer the waste heat directly from one process to another, while heat stores provide the option of storing energy for later use. These technologies make it possible to use the waste heat for heating operating rooms, as process heat or in thermoelectric plants.
Presentation of innovative technology for industrial waste heat utilization
Innovations such as thermoelectric generators are opening up new ways of utilizing the energy of waste heat. These devices can convert temperature differences directly into electrical energy and thus offer an efficient way of utilizing previously unused heat. Companies such as KSK GmbH advise and support companies in selecting and implementing such technologies in order to further reduce energy consumption and emissions.
Examples of how it can be used in companies and the advantages of doing so
In the chemical industry and in energy production, waste heat is already being used successfully to increase overall efficiency. Heat recovery can lower the costs of energy production and reduce dependence on fossil fuels. This not only leads to financial savings, but also to a significant reduction in environmental pollution.
How can companies improve their energy efficiency by utilizing waste heat?
Analyzing energy demand and identifying waste heat potential
The first step in improving energy efficiency through waste heat recovery is to analyze a company's existing energy needs and identify potential sources of waste heat. A detailed examination of the production processes and existing facilities can help to identify areas with high waste heat potential and develop measures for utilizing these energy sources.
Planning and implementing projects for waste heat utilization
After the sources of waste heat have been identified, careful planning of projects for waste heat utilization is essential. This includes the selection of suitable technologies, the calculation of investment costs and expected savings, and the consideration of ecological aspects. Subsidies and financial support from public authorities can help to reduce initial investment costs and facilitate the implementation of waste heat utilization projects.
Investment costs and savings through efficient use of waste heat
Although the initial investment costs for implementing waste heat recovery technologies can be a hurdle, the financial benefits often quickly become apparent in the form of reduced energy costs and lower emissions. As a rule, the investments pay for themselves within a few years, making waste heat recovery not only ecologically but also economically extremely sensible.
Which industries benefit most from waste heat utilization?
Applications in the steel industry and metal recycling
The steel industry and metal recycling are particularly energy-intensive sectors, where significant energy savings can be achieved through the effective utilization of waste heat. Reusing the waste heat generated during steel production for other industrial processes or for heating can significantly reduce energy consumption and costs.
Increased efficiency in the chemical industry through heat recovery
The use of waste heat also offers great potential for increasing efficiency in the chemical industry. Heat recovery systems make it possible to recover valuable energy that is generated during chemical reactions and use it to supply the plants with energy. This leads to a significant reduction in energy costs and, at the same time, promotes environmentally friendly operation.
Examples of successful waste heat utilization in other industrial sectors
Many other industries, including food processing, paper and pulp, and glass manufacturing, also benefit from the implementation of waste heat recovery projects. Through innovative technologies and customized solutions, efficiency can be increased and a contribution to environmental protection can be made in almost every industrial sector.
What are the challenges and solutions for utilizing industrial waste heat?
Overcoming technical and financial hurdles
The main challenges to utilizing waste heat are technical and financial hurdles. Technical challenges include integrating waste heat utilization systems into existing facilities and processes. Financial hurdles relate to the initial investment costs and ensuring the economic viability of the projects. Solutions include the use of funding, technical advice from experts and the selection of energy-efficient technologies that lead to long-term savings.
Strategies for maximizing energy savings and environmental impact
To maximize energy savings and ecological benefits, a holistic approach to waste heat recovery is necessary. This includes the continuous optimization of facilities, the training of employees in energy awareness and the integration of waste heat recovery into corporate policy. In addition, cooperation between industry, research and government institutions plays an important role in the development and implementation of innovative solutions.
Expert opinions and best practices in the field of waste heat utilization
Involving subject matter experts and studying best practices provides valuable insight into successful waste heat recovery strategies. Numerous companies have already proven that investing in waste heat recovery is worthwhile and brings both financial and environmental benefits. By sharing experiences and working with professionals, businesses can avoid potential pitfalls and optimize the adoption of waste heat recovery systems.
FAQs on waste heat utilization
Q: How can the waste heat in industrial plants be used efficiently?
IA: Industrial companies, especially energy-intensive ones, produce large amounts of excess heat every year. By using heat recovery technologies, this excess heat can be used to heat rooms, produce hot water or even be fed into the local district heating network. The German Federal Ministry for Economic Affairs and Energy supports such projects to promote energy efficiency. By using heat recovery technologies, industrial companies can not only reduce their energy costs, but also contribute to climate protection by reducing their CO2 emissions. In addition, they can generate additional income by selling surplus heat to third parties.
To facilitate the implementation of such projects, the Federal Ministry for Economic Affairs and Energy offers various funding programs. These include, among other things, grants for the planning and implementation of heat recovery measures, as well as loans and grants for investments in efficient technologies.
By promoting heat recovery in industrial plants, the Federal Ministry for Economic Affairs and Energy is helping to increase energy efficiency in Germany and achieve climate targets. Companies that invest in such measures can not only benefit from the financial advantages, but also make an important contribution to environmental protection.
Q: What economic advantages does the utilization of waste heat offer companies?
A: Using waste heat can help companies reduce their energy costs, as less energy needs to be purchased from external sources for heating or hot water. In addition, companies can benefit from subsidies and tax advantages. According to the German Energy Agency (dena), operating costs can be significantly reduced, which is particularly interesting for medium-sized companies. Furthermore, the use of waste heat also offers ecological advantages, as it contributes to the reduction of CO2 emissions. By using heat efficiently, less fossil energy is required, which in turn reduces environmental pollution. To make effective use of waste heat, companies need to use appropriate technologies such as heat recovery systems or heat pumps. However, these investments can pay off in the long term, as they can lead to a long-term reduction in energy costs and increase the company's competitiveness. Overall, the use of waste heat offers both economic and ecological advantages for companies. It is therefore worth considering appropriate energy efficiency measures and integrating them into the corporate strategy.
Q: Can waste heat also be used to generate electricity?
A: Yes, by using combined heat and power (CHP) plants, electricity can also be produced from the excess heat. The steam generated by the use of waste heat is used to drive a turbine. This process can both increase energy efficiency and reduce CO2 emissions. By using combined heat and power plants, the principle of energy efficiency can be improved because the excess heat that would normally be dissipated unused is converted into electricity. This means that less energy is wasted and, at the same time, CO2 emissions can be reduced because less fuel is needed to generate energy.
Combined heat and power plants are particularly efficient in buildings or industrial plants where heat and electricity are needed continuously. By using these plants, a significant contribution can be made to the energy transition, as they help to reduce dependence on fossil fuels and promote renewable energies.
Overall, combined heat and power plants represent a sustainable and resource-efficient way to generate energy and are therefore an important building block for a future climate-friendly energy supply.
Q: What should be considered when planning a system for waste heat utilization?
A: When planning a system to use waste heat, it is important to analyze and understand the entire energy flow of the respective operation. This includes identifying sources of waste heat, heat demand and possible heat utilization pathways. It is recommended to consult experts to implement an efficient and sustainable solution. Furthermore, it should be checked to what extent funding programs can be used. Furthermore, it is important to keep an eye on local laws and regulations in order to go through any approval procedures. This also includes taking into account environmental protection requirements and emission guidelines.
When implementing a system to use waste heat, long-term costs and possible savings should also be considered. Investment costs, operating costs and potential savings from using the waste heat are important factors to consider.
Careful planning and implementation of a system for utilizing waste heat can not only lead to cost savings, but also to a reduction in CO2 emissions and thus contribute to sustainable operations. It is therefore important to carefully analyze all aspects of the system and develop a holistic solution.
Q: What role do renewable energies play in the utilization of waste heat?
A: Renewable energies and the use of waste heat complement each other perfectly. The integration of systems that use waste heat into existing plants operated with renewable energies can improve the overall efficiency of energy consumption. This further contributes to the reduction of CO2 emissions and to achieving sustainability and climate protection goals. By utilizing waste heat from industrial processes, buildings or power plants, energy can be used more efficiently and the consumption of primary energy sources can be reduced. This not only lowers energy costs, but also the environmental impact of using fossil fuels.
In combination with renewable energies such as solar, wind or biomass, the use of waste heat can also help to balance out fluctuations in energy production. For example, heat boilers can be combined with solar thermal energy to ensure a continuous supply of hot water even when there is no sunshine.
Furthermore, waste heat systems can also help to improve the economic efficiency of renewable energies. This is because the integration of waste heat can reduce the operating costs of plants and shorten the amortization periods.
Overall, the use of waste heat in combination with renewable energies offers numerous advantages for the environment, the economy and climate protection. It is therefore important to continue promoting this approach and to implement it more in practice.
Q: To what extent does the utilization of waste heat contribute to sustainability?
A: The use of waste heat plays an important role in reducing energy consumption and CO2 emissions. By efficiently reusing heat that would otherwise escape unused into the environment, companies contribute directly to the conservation of natural resources and sustainability. This is an important step towards greener production and sustainable economic activity. Waste heat is produced in many production processes, especially in industry, but also in households or office buildings. It can be used in a variety of ways, for example for heating buildings, in heat recovery processes or for generating electricity using combined heat and power.
By using waste heat, companies can not only reduce their energy consumption and costs, but also contribute to climate protection. After all, lower energy consumption also means lower CO2 emissions, which contribute to global warming.
It is therefore important that companies recognize waste heat as a resource and use it in a targeted manner. Technical solutions such as heat exchangers or efficient heating systems can be used for this purpose. Working together with other companies or institutions in the form of heating cooperatives can also help to use waste heat efficiently and thus protect the environment.
Overall, the use of waste heat offers great potential for saving energy and reducing CO2 emissions. Companies that go down this path not only contribute to environmental protection, but can also benefit economically from it. It is therefore important that the use of waste heat is increasingly promoted and encouraged in order to support a sustainable and resource-efficient economy.
Q: Are there examples of successful waste heat utilization in Germany?
A: In Germany, there are numerous examples of the successful use of waste heat. One example is the use of waste heat from steelworks to supply neighboring residential areas via a district heating network. Another example is the use of waste heat from data centers to heat office buildings. Such projects show that the technology is not only theoretically worthwhile, but also practically feasible and beneficial. Another example is the use of waste heat from industrial plants for the generation of electricity and heat in combined heat and power plants. Here, the waste heat that arises during electricity generation is put to good use to increase energy efficiency and conserve resources.
There are also opportunities for utilizing waste heat in agriculture. For example, waste heat from biogas plants can be used to heat greenhouses. This can lower operating costs and reduce CO2 emissions.
Overall, the use of waste heat offers a wide range of opportunities for using energy more efficiently and protecting the environment. Through innovative technologies and concepts, companies and private households alike can benefit from the advantages.
