Unlocking Energy Efficiency

Unlocking Energy Efficiency: Advancing Surface Treatment Value Chains with CALORPLAST Heat Exchangers In today's dynamic industrial landscape, energy efficiency stands as the paramount objective driving innovation and sustainability across various industries. In the complex world of surface finishing, where processes demand precise temperature control, the pursuit of energy savings gains unique significance. This article explores the concept of energy recovery from aggressive exhaust air using CALORPLAST heat exchange technology, a solution with tremendous potential to revolutionize energy consumption patterns in surface finishing operations.

Overcoming Energy Barriers

The scope of surface finishing operations is as broad as the applications in which their end products are used. From electroless nickel to hard anodizing, all processes exist at the intersection of energy consumption and operational realities. Depending on the specific method employed, energy expenditures can represent a significant share of around 7-20% of total production costs. In particular, hard anodizing, characterized by relentless energy hunger, is by far the greatest outlier due to its high thermal and electrical energy demands. In recent years, we have witnessed a particularly unwelcome increase in energy costs. For manufacturers engaged in surface finishing, this translates directly to a blow to their operational profitability. The rise in energy expenditures has disrupted value chains and created waves of concern across the sector. A common sentiment echoes through the corridors of production facilities: the need to act swiftly to reduce general overhead and increase operational efficiency. However, the challenges are not limited to financial matters alone. Surface finishing operations often involve aggressive and corrosive substances. While these aggressive environments are an integral part of producing customized coatings, they also bring with them a unique set of barriers when energy recovery is at stake. The characteristics that impart effectiveness to these processes make energy recovery a complex puzzle. [caption id="attachment_157098" align="aligncenter"] Figure 1. Rising Energy Costs in Europe[/caption] Enter CALORPLAST's innovative heat exchangers. Designed with over 40 years of experience, German precision, and a keen understanding of surface coating intricacies, these heat exchangers offer a potential key to unlock energy efficiency. CALORPLAST's heat exchangers address the energy problem directly by seamlessly integrating into energy-intensive processes.

From Air to Action

Since both thermal and electrical energy are introduced into surface finishing processes via rectifiers on plating tanks or heating elements in process baths and storage tanks, a large portion will not be utilized for the process itself. [caption id="attachment_157099" align="aligncenter"] Figure 2. Energy flow in a surface treatment facility[/caption] Instead, it will be converted into waste heat energy present in the process environment, primarily the air surrounding the facility. Additionally, for many high-quality processes, the production facility's air is a tightly regulated factor for both product quality and worker safety. Since it may contain corrosive and aggressive components depending on the relevant process tanks, large quantities of facility air must be exhausted by exhaust air systems without affecting surface finishing operations or jeopardizing worker health. This, of course, means that this exhaust air needs to be replaced. Depending on external conditions, this typically means the supply air is conditioned by a fresh air system or air handling unit (AHU). Considering that outdoor air temperatures in winter can easily reach negative double-digit figures, one can estimate how high the heating costs will be for replacing waste air of up to 80,000 m³/hour for a single treatment line. [caption id="attachment_157100" align="aligncenter"] Figure 3. Shares of energy consumption in a typical surface treatment process[/caption] In the midst of these operational flows, exhaust air emerges as an element contributing significantly to overall energy expenditure. Energy-intensive surface treatment processes not only demand substantial energy input but also generate exhaust air containing a significant portion of that energy. This synergy created by factors such as continuous ventilation and voluminous air changes forms the core of the energy environment in which surface treatment processes find themselves.

Plastics, Progress, Power

As the imperative to optimize energy consumption strengthens, a significant challenge persists: how to harness energy dissipated in corrosive environments. Even with the inclusion of chemical scrubbers, the byproduct air remains laden with aggressive elements and requires a system that not only captures energy but also resists corrosion. Foreseeing this urgent need more than 30 years ago, CALORPLAST pioneered and led the development of entirely plastic air-liquid heat exchange units. Born from decades of expertise, these heat exchangers represent a powerful response to surface treatment line operators' energy recovery demands. [caption id="attachment_157101" align="aligncenter"] Figure 4. Run-around coil system schematics and CALORPLAST modularity concept[/caption] The unique architecture of CALORPLAST's heat exchangers aligns perfectly with the principles of run-around coil systems, a vital component of energy recovery installations in surface treatment facilities. Run-around coil systems facilitate energy transfer between two separate air streams without direct contact, which is critical for highly contaminated systems with high renewal rate requirements. In this context, CALORPLAST's air-liquid units stand out in their own right, channeling their corrosion-resistant properties to facilitate energy transfer even under challenging conditions. Modularity forms the foundation of every CALORPLAST heat exchanger: a unique, patented technology automatically bundles numerous polymer tubes into assemblies. Experienced engineers fine-tune each heat exchanger's design with decades of expertise, and the final product is manufactured in Germany from separate modules to achieve the highest quality at the highest performance. This, in essence, creates a heat exchanger made entirely of corrosion-free materials, cost-effective, customizable, and scalable according to the demands placed upon it. With complete corrosion resistance, CALORPLAST enables the vast potential of exhaust air energy to be harnessed while simultaneously providing cost-conscious solutions to the challenges faced by operators and manufacturers alike.

Illuminating Pathways to the Future

As the energy recovery journey progresses, measurable impacts emerge. Depending on the processes applied, energy recovery rates can range from 50% to 68% and can reduce overall heating and air conditioning costs by more than half. This shift toward energy optimization extends beyond mere financial results, aligning with the urgent need for sustainable practices. CALORPLAST's heat exchangers contribute not only to cost efficiency but also to environmental responsibility by channeling this dissipated energy back into the working cycle. The reduction in carbon emissions associated with energy production meets and often exceeds applicable sustainability regulations. This dual impact—cost reduction and carbon footprint reduction—resonates strongly in a sector highly sensitive to ecological concerns. Current economic reality demonstrates that significant reductions in overall costs are unlikely to occur without action. Continuous energy demand and rising energy costs mean that every moment of inaction results in ongoing financial losses. The fact that customers postponing energy recovery efforts are essentially forgoing monetary gains achievable through reduced energy consumption demonstrates that the opportunity cost of inaction is substantial. In conclusion, the energy challenges faced by surface treatment operations have become urgent. While energy demands remain constant, the outlook for energy costs has changed. Amid these changes, CALORPLAST's heat exchangers emerge as a practical and proven solution. By producing units designed to operate in corrosive environments and seamlessly integrate with energy recovery systems, CALORPLAST enables operators to harness exhaust air energy, enhancing operational efficiency and environmental stewardship. The current call to action is not merely a matter of reducing costs; it is an investment in a future where financial gains and environmental responsibility converge.   Bekir Türker Project Director ThermoPark Türkiye