Industrial Project

Modernization of the Heating System for a Prefabricated Elements Factory

Design and implementation of a hybrid heating and cooling system for an industrial production unit, with a focus on waste heat recovery.

Technical Challenge

The client, a factory producing prefabricated concrete elements, was facing an old heating system with an efficiency below 60%, which did not meet the thermal requirements of the curing hall. Energy losses and operational costs were prohibitive. A major issue was the excessive waste heat from cement processors, which was being vented into the atmosphere.

Thermal efficiency below 60%.
Failure to reach the required temperature in the curing hall (+12°C vs. the required +18°C).
Estimated annual energy losses: over 450 MWh.
Large temperature variations between production zones.

Our Design Approach

We adopted a three-step strategy, focused on efficiency and sustainability:

1. Energy Audit and 3D Modeling

We performed a complete thermographic scan and modeled heat flows in specialized software to identify critical loss points and recovery potential.

2. Hybrid System with Heat Recovery

We designed a system centered on a high-capacity air-to-water heat pump, partially powered by heat recovered from the processors. This was integrated with the existing (refurbished) boiler, which now operates only during peak load.

3. Automation and Zonal Control

We implemented an energy management system (BMS) with IoT sensors that regulate temperature by zone and optimize the entire system's operation in real-time.

Implementation and Results

The work was executed over an 11-week period, with minimal disruption to the production process. The system was commissioned at the start of the cold season.

92%

New efficiency

-68%

Energy costs

18°C

Stable temperature

3.2 years

Estimated ROI

Project Details

Client: Prefabricated Elements Factory
Location: Industrial Platform
Sector: Industrial
Period: 11 weeks
Completion Year: 2023

Supporting Materials

Technical Conclusion

"The project demonstrated that integrating heat recovery technologies into existing industrial ecosystems is feasible and produces dramatic reductions in primary energy consumption, setting a new efficiency standard for the client."

— Thermal Engineering Team, merkeziisitmaproje.com

Our Design Process

Our rigorous methodology ensures the efficient implementation of every centralized heating system, from concept to completion.

Needs Analysis and Assessment

We receive the request and analyze in detail the building specifications, estimated energy consumption, and efficiency objectives. We conduct a preliminary technical assessment to understand the project scope.

Thermal Modeling and Simulation

We use specialized software to model the system and simulate its energy performance under various conditions. This stage is crucial for optimizing the configuration and selecting equipment.

Development of the Executive Project

We prepare the complete technical documentation: detailed plans, flow diagrams, technical specifications, and the bill of materials. The executive project serves as a precise guide for the implementation phase.

Coordination and Procurement

We coordinate the procurement of components and technical equipment from certified suppliers. We ensure all materials meet quality standards and are delivered according to schedule.

Execution Supervision

Our engineers monitor and guide the installation process directly on-site, ensuring strict adherence to the project and safety standards. We intervene to immediately resolve any discrepancies.

Testing and Final Handover

After installation, the system is fully tested under maximum load. We issue the final acceptance report and provide training to operators, concluding the project with a guarantee of optimal operation.