INTRO
Reducing greenhouse gas emissions in energy intensive industriesETEKINAThermal energy recovery
Industries account for one third of the world´s greenhouse gas emissions, of which 70% stem from heat generation. One way to reduce the environmental footprint therefore is to recover the generated heat and reuse it in other industrial processes.
An effective means to do so is:Heat pipesThey transfer heat much better than normal pipes do!
ETEKINA INTRO
ETEKINA will build and test heat pipe heat exchangers for use in an aluminium die caster, a ceramics producer and a steel factory. Their manufacturing processes require intensive heat, sometimes exceeding 1000 °C, which makes these industry sectors major energy consumers and CO2 emitters.
"These industries do want to reduce their high energy consumption. But to invest in new energy-saving technologies, they need to see success stories." "ETEKINA will provide them with three success stories."
Bakartxo Egilegor Ezenarro, Ikerlan
Coordinator of ETEKINA
Keep scrolling to find out more about the pioneering pilots installed at an aluminium die caster, at a ceramics producer and in a steel factory!
Coordinator of ETEKINA
Keep scrolling to find out more about the pioneering pilots installed at an aluminium die caster, at a ceramics producer and in a steel factory!
aluminium industry
THE CHALLENGE
The production of light-weight aluminium components with special mechanical properties requires high temperatures at several production stages. To achieve this, aluminium die casting facilities melt aluminium alloy at up to 750°C. Subsequently, the casted, solid parts undergo different heat treatments to alter their mechanical properties.
These processes dissipate a lot of excess heat into the environment, but recovering this unused thermal energy is not that easy in the harsh environment of aluminium factories.
These processes dissipate a lot of excess heat into the environment, but recovering this unused thermal energy is not that easy in the harsh environment of aluminium factories.
"Aluminium can be recycled as many times as we wish and it doesn’t lose any characteristics. However, the production of aluminium as a raw material needs a lot of energy, and the transformation of a raw material to a component is also an energy-consuming process." "It is important to recuperate all the energy possible to consume less and thus to reduce emissions."
Dr. Eva Gonzalez
Responsible of Partnership & Technological Vigilance
Edertek Technology Centre, Spain
Responsible of Partnership & Technological Vigilance
Edertek Technology Centre, Spain
Adapted to the processes and conditions on site, the ETEKINA HPHE prototype has been installed in one of the production units of Fagor Ederlan. The manufacturer of aluminium components expects to recover 43% of the heat and directly cut energy costs.
Ceramic Industry
THE CHALLENGE
Tile production requires a significant amount of thermal energy, employed mainly in the kiln and the spray dryer. With operating temperatures around 1200 °C and 600 °C, they together require 90% of the factory's total energy consumption.
Overall, energy accounts for around 25-30% of total production costs. The exact figure strongly depends on changes in fuel prices and stands in stiff competition with regions where energy prices are traditionally cheaper.
Thermal energy recovery can strengthen the ceramic industry in Europe and secure thousands of jobs while reducing its environmental impact.
Overall, energy accounts for around 25-30% of total production costs. The exact figure strongly depends on changes in fuel prices and stands in stiff competition with regions where energy prices are traditionally cheaper.
Thermal energy recovery can strengthen the ceramic industry in Europe and secure thousands of jobs while reducing its environmental impact.
The ceramic tile producer Atlas Concorde has already adopted different measures to increase their energy efficiency. The ETEKINA HPHE prototype will contribute to higher energy efficiency with a calculated heat recovery rate of 41%.
STEEL Industry
THE CHALLENGE
The steel sector requires excessive heat of sometimes 1000 °C and higher. Natural gas constitutes the key energy source to generate this heat. The global market price difference for this resource varies greatly making energy efficiency an important aspect in the sector.
Increasing the energy efficiency will boost the global competitiveness, secure local jobs and contribute to meeting the EU’s 2020 climate goals.
Increasing the energy efficiency will boost the global competitiveness, secure local jobs and contribute to meeting the EU’s 2020 climate goals.
SIJ METAL RAVNE, a leading niche market steel producer, expects to recover 47% of the excess heat with the ETEKINA HPHE prototype.
ENDING
"We always aim at a return on investment of less than three years.""When they invest and install this system, it will reduce the carbon footprint of their installation, give them back some energy otherwise wasted, and make their process much more environmentally friendly. But at the same time it will be very cost effective."
Professor Hussam Jouhara
Heat Pipe and Thermal Management Research Group
Brunel University London
Technical Coordinator of ETEKINA
Heat Pipe and Thermal Management Research Group
Brunel University London
Technical Coordinator of ETEKINA
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ETEKINA
Heat pipes
"ETEKINA will provide them with three success stories."
THE CHALLENGE
"It is important to recuperate all the energy possible to consume less and thus to reduce emissions."
THE CHALLENGE
"We always aim at a return on investment of less than three years."
