HRL was enlisted by a client to perform an Energy Audit of their expansive industrial facility, which incorporated a wide range of unit operations including boilers, dryers, mills and distillation towers. The facility operated on a large scale, consuming a substantial amount of energy in its production processes. The aim was to pinpoint opportunities for reducing energy consumption and costs while enhancing environmental sustainability. The client sought to recover waste heat and enhance the overall efficiency of their energy systems.
Energy Audits Case Study
Challenge
Solution
HRL executed a comprehensive Energy Audit adhering to the Australian Standard AS/NZS 3598.2:2014, Energy audits - Industrial and related activities. The audit incorporated site inspections, a thorough review of energy bills and plant data, and identification and evaluation of energy saving opportunities. Special attention was given to the client's condensate heat recovery system, leading to recommendations such as additional heat exchangers and optimized controls.
Results
The Energy Audit revealed numerous opportunities for energy reduction, cost savings, and environmental improvement. In total, HRL identified energy-saving opportunities equivalent to ~9% of total fuel and electricity use. This included optimising boilers, implementing wastewater heat recovery for process heating, and voltage optimisation.
A significant energy savings opportunity that was identified related to implementation of a condensate heat recovery system. HRL performed a detailed study of the opportunity and developed a report with actionable recommendations. Subsequently, HRL was engaged to design and assist with implementation of the Waste Heat Recovery Plant, projecting significant annual energy and cost savings and short payback period. The project encompassed process modelling, equipment specifications, supplier collaboration, and design verification to meet state regulations.
Process model for waste heat recovery plan
This holistic approach of the Energy Audit, coupled with the implementation of recommendations, showcased tangible benefits for the client. By addressing the condensate heat recovery system and subsequent initiatives, HRL demonstrated expertise in achieving substantial energy savings, cost reductions, and environmental improvements. This success underscores HRL's commitment to aiding clients in meeting their energy efficiency and sustainability objectives while enhancing their overall financial performance.
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