Customer:
Solenis Chemicals India Pvt. Ltd., Ankleshwar
Project Category:
HVAC Products
Customer Requirement:
Client: Solenis Chemicals India Pvt. Ltd. Location: Plot 8001, Phase VI, GIDC Ankleshwar – 393002 Process Type: Continuous chemical manufacturing with 24-hour operation Water Source: Cooling-tower return water maintained between 25–31 °C. Objective: Replace partial PNG consumption for process heating with an electric heat-pump-based pre-heating solution.
Project Result:
Successful completion of Solar Water Heating Project
What we did:
The HeatRay W2W heat-pump system utilizes the cooling-tower loop as the evaporator source and transfers recovered heat into a buffer tank supplying the boiler feed line. System Flow Cooling-tower water → Heat-pump evaporator (heat source) Heat-pump condenser → 500 L buffer tank (hot-water storage) Buffer tank → Boiler feedwater circuit for pre-heating PLC-based automation regulates temperature, level, and safety interlocks BTU + energy meters record delivered thermal energy and electrical input ----------------------------------------------------------------------------------------------------------------------- Reduced PNG consumption through thermal energy recovery. Stable and automated pre-heating of boiler feedwater. Continuous operation with low maintenance and no combustion-related emissions. Enhanced energy efficiency and carbon-footprint reduction. ---------------------------------------------------------------------------------------------------------------------- Two W2W heat pumps (approx. 34 kW + 18 kW heating capacity) 500 L multi-pass buffer tank with integrated level sensor Selec PLC controller for full automation Coaxial heat exchangers for condenser and evaporator Kirloskar/Shakti hot-water pumps (rated to 80 °C) Siemens electrical protection and control components
Project Description
Solenis Chemicals required a continuous, energy-efficient method to pre-heat boiler feedwater and reduce dependence on natural gas. HeatRay Solar engineered and installed a dual-heat-pump Water-to-Water (W2W) system using the plant’s cooling-tower water as a renewable heat source. The system delivers high-temperature water up to 80 °C, operates 24×7, and integrates a 500-litre multi-pass buffer tank with full automation and performance monitoring. Recover low-grade heat from cooling-tower water to pre-heat feedwater. Improve boiler efficiency by supplying pre-heated water at 80 °C Reduce PNG fuel use and CO₂ emissions. Provide a fully automated, low-maintenance system capable of continuous operation. Establish transparent measurement and verification through BTU and energy metering.
Project Budget:
NA
Completion Date:
2024-09-23T00:00:00
