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Project overview
A chemical manufacturing facility required a reliable and energy-efficient solution to meet its high-temperature hot water demand for critical polymerisation processes, while also addressing chilling requirements.
Conventional steam-based heating methods were energy-intensive and resulted in higher operational costs. Thermax evaluated the process requirements and introduced its Hybrid Heat Pump solution to deliver high-temperature hot water and simultaneous cooling in a single, integrated system.
Challenges
- Requirement for consistent hot water at 110°C for chemical processes
- High energy consumption due to steam-based heating systems
- Dependence on plate heat exchangers for hot water generation
- Need to reduce power, steam, water consumption, and carbon emissions
- Requirement for a sustainable and cost-effective heating and cooling solution
Solution
- Thermax implemented its Hybrid Heat Pump, developed in collaboration with Kehems Technologies, combining electrical and absorption technologies in one system.
- Generated hot water at 110°C without continuous steam usage
- Delivered cooling capacity equivalent to 30% of heating output
- Allowed existing plate heat exchangers to remain on standby
- Enabled continuous operation with reduced energy and resource consumption
- Ensured high efficiency, sustainability, and process reliability
Result
- Significant reduction in steam and power consumption
- Annual steam savings of over 3,300 tonnes
- Reduction in CO₂ emissions and water consumption
- Lower overall operational costs with improved energy efficiency
- Reliable delivery of high-temperature hot water and cooling for chemical processes
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