Manufacturing 2020
Process Heat Optimization
Applied advanced CFD modeling and combustion optimization to improve thermal efficiency at a manufacturing facility with multiple process furnaces.
Key Results
+6%
Efficiency Gain
-15%
NOx Reduction
<18 Mo
ROI Period
The Challenge
The manufacturing plant had aging process furnaces with suboptimal combustion and heat transfer. High fuel costs and NOx emissions were impacting both profitability and environmental compliance.
Our Solution
Using advanced CFD modeling, we analyzed combustion patterns and heat distribution in the furnaces. Based on simulation results, we redesigned burner configurations and optimized air-fuel ratios.
Results Achieved
The optimization project delivered efficiency improvements that significantly reduced operating costs. NOx emissions dropped substantially, and the project achieved full ROI in under 18 months.