Major Dairy Producer

Dairies-1
Industry

Dairies

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Location

United Kingdom

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Solution

FLU-ACE™ 

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D01 Major Dairy Producer

This customer runs a 600KW electrical output Combined Heating and Power (CHP) plant, 24 hours a day. The CHP is used to generate electricity for supply to the grid. Thermal Energy International identified that significant savings could be achieved by utilizing the waste heat from the waste gasses and the engine cooling jacket.

Project Impact

  • ~ 11,200 MMBtu/year  waste heat recovered
  • 22% reduction in gas consumption
  • £137,838 a year in fuel savings
  • Over 1325 tonnes/year of greenhouse gas reduction
  • 1.8 years payback period

Thermal Energy installed a FLU-ACE and finned tube economizer to the existing CHP flue with a modulating damper. This allowed the waste gases to be drawn off into the recovery equipment. These gases are then cooled in two stages recovering the energy stored in the gas:

  1. Firstly the finned tube economizer recovers the bulk of the sensible heat from the waste gases.
  2. The gases are then directed into the FLU-ACE where the gas temperature is reduced to below the dew point in the tower releasing the remaining sensible and latent heat from the gas in the form of hot water. 

This hot water is then directed to plant rooms to preheat existing loads, reducing the steam load on the steam boilers. The recovery water is then returned to be reheated with flue gases and topped up with waste heat from the engine jacket and the cycle repeats. The spent gases are discharged to atmosphere through a new separate stack at 95°F. Further savings have been achieved by reducing CIP times and other process impacts.

The customer’s Energy and Environment Manager said:

Our gas bills have reduced significantly and considerable process savings have been realised.

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Thermal Energy International understands the operational demands of dairy processing, from stringent quality standards to energy-intensive production and highly competitive global markets. Our proven technologies improve thermal efficiency while maintaining process integrity. By combining robust engineering with practical deployment, we enable dairy producers to lower operating costs, reduce emissions, and safeguard product quality.

Dairy and Nutrition Multinational

FLU-ACE™ delivered a payback of under two years, reduced CO₂ emissions by over 3,300 tonnes per year, cut natural gas use by approximately 1.73 million m³ annually, and recovered more than 2.4 MW of energy on average while improving CHP efficiency by over 10%.

Dairy Processing Company

Converted to GEM™ steam traps, delivering a six-month payback, over 2,500 MWh/year energy savings, and approximately 505 tonnes of CO₂e reduction annually.

Global Nutrition Provider

Implemented 2-Stage HeatSponge™ economisers, delivering annual savings of $87,900, reducing CO₂ emissions by 621 tonnes per year, and achieving a payback of under two years.

Global Nutrition Provider

Applied GEM™ steam traps sitewide for line drainage and process duty, delivering a one-year payback, 972,000 kWh annual gas savings, and approximately 180 tonnes of CO₂ reduction per year.

Global Nutrition Provider

FLU-ACE™ delivered up to 1 MW of recovered energy, reduced CO₂ emissions by approximately 1,500 tonnes per year, cut natural gas consumption by around 75%, and increased boiler efficiency by roughly 20%.

Global Nutrition Provider

FLU-ACE™ delivered over 15,000 tonnes of CO₂ savings to date, recovered more than 2.7 MW of energy across four systems, and eliminated electric cooling load while supporting net-zero objectives.

Major Dairy Producer

Installed FLU-ACE™ heat recovery and economisers to capture CHP exhaust energy, cutting gas use by 22%, reducing CO₂ by 1,325 tonnes, and saving 3.2 GWh annually with payback in under two years.

Global Nutrition Provider

FLU-ACE™ delivered 3,138 MWh per year in energy savings, reduced CO₂ emissions by 581 tonnes annually, and achieved a return on investment of under 2.5 years.
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