Performance Evaluation

Energy Hunter

Our structured engineering process audits existing heat transfer configurations to identify measurable savings in fuel usage, cooling tower water loss, and compressor electricity consumption.

Electricity Savings

Savings in Electricity

Chiller Condenser Isolation

Water cooled chiller compressors suffer efficiency losses when cooling tower water deposits scale in the condenser tubes. Installing an intermediate gasketed plate heat exchanger isolates the chiller circuit, maintaining design heat transfer rates and reducing compressor power draw by up to 15%.

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Static Pressure Interception

High rise building circuits generate high static heads at lower levels. Using AHRI certified plate heat exchangers as pressure breakers (up to 30 bar) isolates basement plant components, reducing the structural pressure rating requirements and capital cost of chillers and terminal automation loops.

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Cooling Tower Free Cooling Bypass

For operations where ambient wet bulb temperatures drop below process chilled water requirements, a bypass plate heat exchanger redirects the process heat directly to the cooling tower loop. This bypasses mechanical chiller compressors, reducing electrical power requirements during cold periods.

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Ammonia Chiller Optimization

Configuring semi welded plate heat exchangers as evaporators and condensers in R717 systems reduces the temperature approach difference (down to 1.0K) and lowers refrigerant charge volume requirements, decreasing mechanical compressor power demand.

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Fuel Savings

Savings in Fuel Costs

Air Compressor Heat Recovery

Industrial screw air compressors convert up to 90% of electrical energy input into heat. Installing a plate heat exchanger in the compressor lubrication oil loop recovers this thermal energy as clean hot water (up to 70°C) for boiler make up or wash down loops, reducing boiler fuel usage.

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Wastewater Heat Exchange

Process effluent discharged from wash down, dye baths, or CIP loops carries significant thermal energy. Wide gap plate heat exchangers reclaim this low grade heat to pre heat incoming clean process intake streams, directly reducing plant steam generation requirements.

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Flash Steam Condensation

Condensing waste flash steam vents using gasketed or welded plate condensers recovers latent heat while returning treated condensate back to the boiler feed water tank, saving both thermal energy and water treatment chemicals.

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Boiler Circuit Isolation

Isolating the primary boiler water loop from oxygenated and debris laden secondary heating circuits prevents scale build up inside the boiler. Maintaining a scale free boiler tube surface preserves design thermal transfer efficiency and prevents fuel consumption increases.

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Cooling Tower Loop Recovery

Reclaiming low temperature thermal energy from cooling tower water loops prior to atmospheric heat rejection. This low grade heat is transferred to fresh water feeds or elevated via heat pumps, reducing overall boiler fuel requirements.

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Efficiency

Efficiency and Uptime

Cooling Tower Interchangers

Atmospheric cooling towers collect dust and airborne debris, which clogs process exchangers downstream. An intermediate plate heat exchanger confines atmospheric fouling to a single, cleanable unit, maintaining clean process loops and extending plant uptime.

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Shell and Tube Upgrades

Upgrading legacy shell and tube exchangers to compact plate patterns improves heat transfer coefficients, reduces floor space footprints by up to 80%, and decreases fluid hold up volumes for faster process thermal response.

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Oil Cooler Replacements

Replacing standard oil coolers on rotary screw air compressors with highly turbulent plate heat exchangers prevents temperature related oil breakdown, avoiding high temperature safety shutdowns and maintaining compressor efficiency.

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Technical Performance Standards

Validate Your Heat Recovery Potential

Contact our application specialists to perform a thermal balance calculation and model your return on investment based on actual operating parameters.

Expert Consultation