Manufacturing Facility

RED was appointed to undertake an audit of this soap factory in Europe. Not only did the factory use significant amounts of heat and power, it also contained a large spray tower which used heat to extract the soap powder from the base slurry. By definition, this plant was a huge source of waste heat to the atmosphere, while other parts of the factory used heat separately generated in the boiler house.

RED proposed sweeping changes to the steam generation, distribution and condensate return systems, including a CHP feasibility report, together with modifications to the process heating, compressed air and ventilation systems.

Additionally, we received an opportunity to recover waste heat of the spray tower precipitators, using compressed air to prevent the fouling of the required heat exchangers.

Key Facts

• Estimated annual savings of 16,400 MWh, resulting in operating cost savings of €682,000
• Reductions in CO₂ emissions of 3,100 tonnes per annum