Pinch analysis spotlights energy-saving potential

• Connecting hot water circuits for internal and external saves around 35 000 MWh pa
• Using waste heat from upstream plants saves around ~241 000 MWh pa

Wacker Chemie is an innovative global company with its origins in Germany, which produces silicone, polymers and various fine chemicals. The company applied pinch analysis aimed at minimising the energy consumption of chemical processes by optimising energy recovery and recycling. The first step was to determine the essential heat sources and heat sinks at its production plant, and to hook them up to the existing steam networks. Residual heat from the steam condensates was then reused for nearby public areas, which led to significant energy savings for the company.

Key results

The resource efficiency measures led to the following energy savings:

• Using waste heat from the high-temperature processes in upstream plants; annual savings of around 315 000 tonnes of steam (~241 000 MWh)
• Integrating suitable heat sources in the existing steam network structure; annual savings of about 220 000 tonnes of steam (~180 000 MWh)
• Connecting hot water circuits for internal and external use; annual savings of around 35 000 MWh for heating water
• Using condensate heat recovery at adjoining public institutions; annual savings of around 9 000 MWh for heating water