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Low-grade waste heat recovery and repurposing to reduce the load on cooling towers
McLean, Shannon H.,Chenier, Jeff,Muinonen, Sari,Laamanen, Corey A.,Scott, John A. Techno-Press 2020 Advances in energy research Vol.7 No.2
Industrial cooling towers are often ageing infrastructure that is expensive to maintain and operate. A novel approach is introduced in which a heat pump circuit is incorporated to reduce the load upon the towers by extracting low-grade energy from the stream sent to the towers and repurposing in on-site processing operations. To demonstrate the concept, a model was constructed, which uses industrial data on cooling towers linked to a smelter's sulphuric acid plant, to allow direct economic and environmental impact comparison between different heat recovery and repurposing scenarios. The model's results showed that implementing a heat pump system would significantly decrease annual operating costs and achieve a payback period of 3 years. In addition, overall CO<sub>2</sub> emissions could be reduced by 42% (430,000 kg/year) and a 5% heat load reduction on the cooling towers achieved. The concept is significant as the outcomes introduce a new way for energy intensive industrial sectors, such as mineral processing, to reduce energy consumption and improve long-term sustainable performance.