Foundry heat recovery systems
Foundry heat recovery can capture energy that leaves melting, holding, heat treatment, and related processes.
Furnace exhaust heat recovery applications
High source temperature can create a meaningful opportunity, but temperature alone does not establish value. The project also needs a compatible demand, operating overlap, safe integration, and an economic case.
Furnace exhaust heat recovery may support combustion air, makeup air, water, boiler feedwater, or another approved process requirement. Source composition, temperature range, dust loading, pressure constraints, production cycles, and existing pollution control equipment must be understood before a configuration is developed.
Demanding exhaust conditions
Foundry waste heat recovery often involves particles and harsh operating conditions. ThermStar evaluates whether Lepido® source technology and its open geometry fit the application.
Materials, access, controls, protection, and maintenance requirements must follow current approved technical information.
Waste heat recovery solutions across industries
Wherever hot exhaust and a useful thermal demand exist, there may be an opportunity to recover and reuse that energy. ThermStar™ applies the same assessment process across industries to identify the strongest opportunities. From a single exhaust source to a multi-facility network, the system can be configured around the application.
Industrial Laundry
Recover heat from lint laden dryer exhaust and cut natural gas costs. Built for the conditions that make conventional laundry heat recovery fail.
Food Manufacturing
Recover energy from oven, cooking and process exhaust in food manufacturing, including humid and particulate laden streams that foul conventional units.
Pet Food Manufacturing
Extrusion, drying and rendering exhaust carries recoverable energy along with moisture and particulate. See how ThermStar handles these conditions.
Foundries
Recover useful thermal energy from furnace and process exhaust in foundry operations, in conditions where conventional recovery is hard to maintain.
Manufacturing
Turn exhausted thermal energy into lower operating costs and reduced emissions across manufacturing operations and multiple facility networks.
Restaurants & Commercial Kitchens
Grease laden kitchen exhaust carries energy worth recovering. The technology behind ThermStar was developed for exactly these conditions.
Plant efficiency
Foundry energy efficiency improves when recovered energy displaces energy the operation would otherwise purchase. ThermStar compares available source heat with the practical load and models the expected overlap. Installed cost, energy value, operating effect, maintenance, and available incentives shape the decision.
Support broader manufacturing goals
Metal casting energy efficiency can contribute to cost reduction and emissions goals while retaining the thermal processes required for production. Any emissions claim depends on actual measured energy displacement and an accepted calculation method. Monitoring can provide the operating evidence needed for internal reporting or eligible programs.
Evaluate the opportunity safely
ThermStar works with the customer and qualified project professionals. ThermStar does not replace engineering, installation, safety, environmental, or permitting responsibilities. Request an Assessment to identify the data needed for a preliminary review.
What happens next
A first conversation helps ThermStar understand the operating goal, the facility context, and the people involved in the decision.
From there, the team can identify the smallest useful information request and determine whether a screen, technical review, partner discussion, or document request is appropriate.
This approach keeps the process proportionate to the opportunity while giving operations, finance, engineering, health and safety, and sustainability stakeholders clear information for the next decision.
What makes a foundry heat recovery project viable
The strongest candidates have a consistent thermal source, a productive receiving load, useful temperature alignment, overlapping operating hours, workable integration, and enough displaced energy value to support the project. A high exhaust temperature by itself is not sufficient.
What can recovered furnace exhaust heat be used for
Possible uses include approved process air, makeup air, process water, domestic hot water, boiler feedwater, and other thermal demands. The selected use must be compatible with the available temperature, capacity, schedule, location, controls, and facility requirements.
Can several foundry operations be evaluated together
Yes. An organization can begin with a portfolio screen using consistent information from multiple sites. ThermStar can help identify which locations deserve deeper review. Findings from one project may inform later work, but each facility still requires confirmation.
How are foundry energy savings confirmed
Savings are based on useful recovered energy and the energy it displaces. A project specific method may use temperature, fluid flow, operating time, equipment status, baseline efficiency, and approved conversion factors. Actual reporting depends on the installed monitoring and any utility or internal requirements.