In the face of the growing importance of environmental issues globally, companies are increasingly called upon to review their production processes to reduce waste and environmental impact. The heat wasted during industrial production activities is a valuable resource still underutilized: its recovery represents one of the most effective strategies to improve energy efficiency, reduce operational costs, and make a tangible contribution to the reduction of greenhouse gas emissions. The starting point for any heat recovery optimization project is the accurate measurement of thermal energy, and ISOIL Industria offers a wide range of tools suitable for this purpose.
What is waste heat recovery?
In the industrial sector, a significant portion of the energy used in production cycles is dissipated as residual heat. Industrial furnaces, boilers, turbines, compressors, and other equipment generate large amounts of thermal energy, which, in the absence of recovery systems, is released into the environment without any useful application.
Heat recovery involves harnessing the residual heat generated by industrial processes and reusing it either in the same production process, in internal company processes (e.g., for space heating, hot water generation, or steam production), or for external uses, such as district heating networks.
Global transformations and the growing focus on environmental sustainability are prompting companies to substantially review their approach to energy management.
The tightening of regulatory frameworks and the commitments made at the European level to achieve climate neutrality by 2030 require concrete and timely actions. In this context, the recovery of heat generated in industrial processes emerges as a strategic lever to increase energy efficiency, reduce environmental impact, and align with decarbonization policies.
Applications and benefits of waste heat recovery
Waste heat recovery offers a particularly advantageous opportunity in energy-intensive sectors. In the food industry, for example, processes such as cooking, pasteurization, and sterilization require significant amounts of heat. Similarly, in the chemical and pharmaceutical sectors, operations like distillation, drying, and the functioning of chemical reactors demand large quantities of thermal energy.
The metallurgical industry, with its high-temperature processes such as melting and forging, is another area with intense heat production, as is the case in plastic and rubber extrusion and molding processes, or in the use of industrial furnaces in the glass and ceramics industries.
In these and other contexts, the adoption of heat recovery solutions represents a choice that offers significant benefits in economic, environmental, and operational terms.
Heat recovery technologies
The heat dissipated in production processes can be classified into high, medium, and low temperature categories. High-temperature heat, generated, for example, by industrial furnaces or metallurgical processes, is generally easier to recover due to its high energy content.
On the other hand, recovering medium-temperature (100–500°C) and low-temperature (<100°C) heat is more complex, as it is found in processes like drying, pasteurization, distillation, or in low-enthalpy thermal flows such as compressor discharges and wastewater. It is precisely in this area that most technological innovations are focused today.
Below is an overview of the main technologies used for heat recovery in industrial processes:
- Heat pumps are devices that transfer heat from a low-temperature source (such as air, water, or soil) to a higher temperature source, using electrical energy. In thermal recovery systems, they can be used to reuse residual heat from discharges or production processes, redirecting it towards heating systems, hot water production, or other processes that require thermal energy.
- At the core of every energy recovery system are heat exchangers: these devices are designed to transfer thermal energy between two vectors at different temperatures without direct contact. There are various types, such as plate, tube bundle, or compact exchangers, each suited to specific operational needs. Thanks to increasingly compact geometries and materials with high thermal conductivity, it is possible to achieve exchange efficiency close to 100%, while maintaining sustainable costs for the industry.
- A well-established technology for heat recovery, particularly effective in electricity production from low to medium-high temperature sources, is the Organic Rankine Cycle (ORC). This technology converts thermal energy into electricity using turbines and organic fluids that evaporate at lower temperatures compared to conventional Rankine cycle fluids. ORC turbines are used in various fields, such as industrial heat recovery, waste-to-energy production, and cogeneration.
- Thermal storage systems play a strategic role in the flexible management of energy, allowing recovered heat to be stored for use during peak demand periods.
- The adoption of digital technologies is revolutionizing the way heat recovery is managed in industrial processes. Thanks to advanced meters, data analysis tools, and optimization software, companies can monitor thermal flows in real time and improve overall efficiency, reducing waste. Increasingly widespread are also intelligent Energy Management Systems (EMS), which are capable of automatically monitoring and regulating heat recovery activities.
Advantages and challenges of heat recovery
Implementing heat recovery systems brings numerous benefits. First and foremost, it allows for a significant reduction in energy consumption, which in some cases can reach up to 20-30%.
This translates into substantial savings on energy costs, a reduction in CO? emissions, and thus a tangible improvement in the company’s environmental footprint. Additionally, the adoption of these solutions enhances corporate competitiveness by improving operational efficiency and, in many cases, provides the opportunity to access public incentives.
Even though there are some challenges, like the need to share more technical knowledge, this creates chances for new training programs and more experts in the field. Uncertainty about how long it takes to get back the money invested can be reduced thanks to better technology and specific financial support.
These improvements make these solutions easier to use and more beneficial in the medium to long term. The first cost, even if sometimes high, is a smart step toward a greener and more competitive future. Adding heat recovery systems to existing plants, especially older ones, is also a good chance to upgrade equipment, improve performance, and cut waste. Each challenge becomes a starting point to innovate, grow, and build a more efficient and responsible industry.
ISOIL Industria, your partner for thermal energy measurement
The measurement of thermal energy plays a crucial role in the heat recovery process. A preliminary energy analysis allows for the identification of available heat sources, the thermal needs of the plant, and the evaluation of the recovery potential in relation to the existing infrastructure. Accurate measurement of thermal variables enables real-time monitoring of heat flows, optimizing industrial processes and promoting more efficient resource use.
This study, which often involves an energy audit, is essential for selecting the most suitable technology and for the correct design and sizing of the system.
The precise measurement of thermal variables allows for real-time monitoring of heat flows, optimizing the entire production process and minimizing energy losses. Monitoring thermal flows and heat losses is crucial for ensuring optimal performance of heat exchangers anal for assessing the effectiveness of energy efficiency measures.
ISOIL Industria offers a wide range of innovative solutions for measuring energy carriers such as thermal oil, steam, air, or gas, as well as for flow regulation to achieve maximum heat exchange efficiency, thanks to the new THERMAG Valve.