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How Can Heat Exchangers Lower Energy Costs?

Businesses are looking for effective and sustainable solutions to preserve energy as a result of rising fuel prices and growing environmental consciousness. Industries around the world place a high priority on energy conservation.

Read to know more about how heat exchangers can lower costs & connect with our top vendors with best-in-class solution

Heat exchangers are pieces of equipment that transfer heat between two or more fluids that are in direct or indirect contact. Power plants, chemical processing systems, heating and air conditioning systems, waste heat recovery units, and food processing systems are just a few of the engineering applications for heat exchangers.
A heat exchanger uses the laws of thermodynamics to help with effective heating, cooling, and energy recovery operations. They provide several benefits, like saving 30% on energy efficiency, lowering running costs, and reducing the environmental impact of energy generation.

1. How Heat Exchangers Can Lower Energy Costs

Heat exchangers can help lower energy costs in several ways, such as:
A) Utilize waste heat
B) Improve HVAC efficiency
C) Improve process efficiency

A. Utilize waste heat

One of the primary ways heat exchangers lower energy costs is by recovering waste energy. Many industrial processes, such as steel mills, glass furnaces, and cement kilns, generate hot exhaust gases and waste streams. They harness this heat to preheat process fluids, generate steam, or produce electricity. Waste heat recovery power is largely untapped. Combined heat and power (CHP) units use a single fuel source to produce both thermal energy (i.e., heating or cooling) and electricity through the waste heat for power recovery.
According to the TechSci Research Report, the Indian CHP system is projected to reach $161 billion by the end of 2023. The majority of CHP plants in India are above 10 MW and are used in refineries, petrochemicals, and chemical plants.
According to the IEA, India had a combined heat and power system potential of around 30 GW in 2017, and it is anticipated to expand to roughly 85 GW by 2030.

B. Improved HVAC efficiency

Air conditioning systems are energy-intensive. Heat exchanger units between incoming and outgoing air can reduce the load on the heating and cooling systems and reduce power consumption.  There are two heat exchangers in HVAC systems:

  • Conventional heat exchanger coils
  • Heat pipe heat exchangers.

HVAC systems account for 40 to 60% of energy consumption in commercial buildings.
The Carbon Trust estimates that a commercial or office heat exchanger system with an efficiency of 70% could save about 38% on a company’s or organization’s gas bill.
The high efficiencies provided by heat exchangers mean that you could expect a complete return on your investment in as little as two years.

C. Improve process efficiency

Careful temperature control is required in the food and beverage and pharmaceutical industries. Heat exchangers can improve efficiency by optimizing the heat transfer between two process streams. ‘
Many process streams discharge hot and cold streams. Heat exchangers can utilize this thermal energy from the byproduct streams to heat or cool process fluids. Heat exchangers help reach required process temperatures, save energy requirements, improve product quality, and reduce costs.
For example, heat exchangers can recycle as much as 94–95% of the heat content of pasteurized milk.
Heat exchangers employ cutting-edge designs to achieve maximum efficiency when processing different goods with varied viscosities. A heat exchanger’s efficiency is a critical factor, and thermal efficiency differences of 5–10% will result in significant energy savings and lower operating costs.

2. Our top heat exchanger vendors are:

  1. HRS Process System Ltd
    Heat Exchangers Blog - vendor 1

2. Omeel Coils Private LimitedHeat Exchangers blog - vendor 2

3. Vision Engineers

Heat exchangers blog- Vendor 3

4. Thermosystems Private Limited

Heat Exchanger blogs - Vendor 4

To learn more about heat exchanger vendors, visit our website.

3. Types of heat exchangers

Types of heat exchangers

These heat exchanger categories offer advantages such as high heat transfer efficiency, compact design, flexibility, and ease of maintenance. They find applications in several industries, like power generation, chemical processing, and HVAC.
Heat exchanger manufacturing uses several metal fabrication techniques, such as:

  • Drilling
  • laser cutting or water jet cutting
  • metal forming
  • various forms of welding

4. How do heat exchangers work?

How heat exchangers work

The basic heat exchanger design is similar; there are two fluid streams (hot and cold), separated by a solid barrier.  The hot fluid transfers its heat to the cold fluid without the two fluids mixing.

  • Fluid Flow: The hot and cold fluids flow in the corresponding channels in the heat exchanger.  According to the type of heat exchanger, these channels may take the shape of tubes, plates, or coils.
  • Heat Transfer Surface: The heat transfer surface acts as the barrier between the two fluids. Designers try to maximize the heat transfer area to help in efficient heat transmission.
  • In exchangers, heat is exchanged through conduction and convection.

5. How can Venwiz help?

Venwiz can significantly contribute to helping organizations identify the best solutions when it comes to heat exchangers. Venwiz is one of the leading platforms to explore solution providers. The user-friendly platform provides integrated solutions. Here are some ways Venwiz might help:

  • Large network of vendor profiles: Venwiz has several vendors specializing in heat exchangers. You can partner with Venwiz and connect quickly with knowledgeable and reliable service providers. The vendors can provide end-to-end solutions from design, fabrication, and installation.
  • Streamline the procurement process: Venwiz can help streamline communication and collaboration between businesses and vendors. You can browse vendor profiles, and ask for and receive quotations on our platform. By ensuring a seamless and effective procurement process, Venwiz helps organizations save time and effort.
  • Expert Advice and Support: Throughout the entire engagement process, Venwiz provides expert advice and support. Our client engagement team is ready to assist. Our project management tools help track milestones and ensure the project is on track to meet deadlines and delivery goals.
  • Financing support: Financing is one of the major roadblocks in the execution of any project, and obtaining funds to execute a project can be challenging. With Venwiz, businesses and vendors can get the required funding. We have partnered with financial institutions to provide financial options for smooth project delivery and execution.

Explore Venwiz today for comprehensive support in finding the best heat exchanger solutions for your organization.

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