WHY HEAT RECOVERY?
Heat recovery is one of the most effective and economic levers to improve the energy efficiency of industrial processes.
Often more than half of the total energy consumption is used for heating and cooling. Recovering this energy directly within the process reduces operating costs, lowers CO₂ emissions and improves overall sustainability performance.
At the same time, regulatory requirements and reporting obligations are increasing, making a structured and economically sound heat recovery concept more important than ever.
Our heat recovery (Pinch) analysis approach is a systematic method to identify the technically and economically optimal heat recovery and utility concept for industrial processes, typically reducing thermal energy demand by 10–40%, often resulting in significant energy cost savings attractive payback times of 1–4 years.
A structured heat recovery pinch analysis provides:
- Clear heat recovery targets (minimum heating and cooling demand)
- Optimal heat recovery and heat pump integration
- Prioritisation of technically feasible measures
- An investment-optimized concept considering CAPEX, OPEX and payback time
- A sound basis for decarbonisation and utility system optimization
Unlike isolated measures, pinch analysis evaluates the entire process energy system to avoid sub-optimal or conflicting solutions.
How does a heat recovery pinch analysis work – in simple terms?
- Collect the process streams: We list all process steps that need heating (cold streams) and those that release waste heat / need cooling (hot streams), including inlet/outlet temperature and heat load. During this step we also challenge requirements (e.g., “do we really need this temperature?”), which often reveals quick wins.
- Create the composite curves: All hot streams are combined into the Hot Composite Curve, and all cold streams into the Cold Composite Curve. The curves are a condensed “energy picture” of the whole plant across temperature levels.
- Identify the theoretical heat recovery potential: The overlap between both curves shows how much heat could be recovered internally in theory (HR Pot.). From the same diagram we also derive the minimum remaining Hot Utility (HU) and Cold Utility (CU) needed from external supply.
- Find the best ΔTmin (CAPEX vs. OPEX): Heat recovery depends on the minimum temperature difference ΔTmin: a smaller ΔTmin increases the heat recovery and reduces energy cost, but requires larger heat exchanger area (higher investment). We evaluate this trade-off to select an economically reasonable ΔTmin.
- Turn theory into a practical concept: The potential heat recovery HR Pot. provides the benchmark; next we translate it into a realistic concept considering layout, operability and economics. The result is a prioritised set of measures, including heat exchanger network improvements and—where useful—heat pumps or CHP to upgrade low-temperature waste heat.
Management-Summary: a Pinch Analysis…
- Maps where heat is used and where it is wasted
- Shows how much heat can optimally be recovered
- Balances investment cost vs. energy savings
- Defines minimum heating and cooling needs
- Turns theory into practical, implementable solution
Our Offer
The key question is not whether heat recovery is possible, but how much economic potential exists and which level of analysis is needed to identify the optimal integration. A structured approach is essential: implementing local heat recovery measures without understanding the overall system or cross-process heat recovery opportunities leads to sub-optimal results and missed potential.
Our offered heat recovery analysis and implementation services (see below sections for details):
- Rough Heat Recovery Screening
Fast, structured overview to identify heat recovery potential and define the right next steps. - Full Heat Recovery (Pinch) Analysis
Detailed, investment-optimized, site-wide and cross-process heat recovery and utility concept. - Adaptation and Multi-Site Rollout of Heat Recovery Concepts
Adaptation of existing studies and scaling of proven heat recovery measures across multiple sites. - Implementation Support
Independent expert support during engineering, procurement and implementation.
Based on our experience, we usually recommend starting with the Rough Heat Recovery Screening, where these essential questions are answered: Does the process have relevant heat recovery potential? How large is it approximately? And is the system complexity high enough to justify a full pinch analysis—or is the situation already clear enough to directly design selected heat recovery solutions?
Starting with a Rough Heat Recovery Screening, the level of analysis is defined step by step: starting simple and increasing depth only where it creates value.
Rough or Full – Which level of analysis is right for your site?
In some cases, the heat recovery potential and site complexity are clear enough to start directly with a Full Heat Recovery (Pinch) Analysis. This can slightly reduce overall project duration. In most cases, however, starting with a Rough Heat Recovery Screening does not materially increase total time or cost—while keeping the initial effort and budget low.
Start with a Rough Heat Recovery Screening if:
- you want a fast, structured overview of where heat is used and wasted
- you need an order-of-magnitude estimate of heat recovery and CO₂ reduction potential
- you want a clear recommendation for next steps: full pinch analysis vs. direct design of selected measures
- you want to align internal stakeholders before going into a detailed study
A Full Heat Recovery (Pinch) Analysis is recommended if:
- you want an investment-optimized site-wide concept (CAPEX vs. OPEX trade-off)
- the site has several heating and cooling tasks across different temperature levels
- you are interested in potential heat pump / CHP / utility integration as part of the concept
- you need a prioritised measure package with economic evaluation for implementation planning
Typical outcome:
Go / No-Go decision for a full pinch analysis or direct concept design of selected heat recovery measures.
Typical cost range:
EUR / USD / CHF: 5’000 – 20’000+
Typical outcome:
A detailed, prioritized heat recovery and utility concept with economic evaluation and an implementation roadmap.
Typical cost range:
EUR / USD / CHF: 30’000 – 100’000+
Important note:
The actual effort depends on site complexity, number of relevant process streams, data availability and batch vs. continuous operation. An initial Rough Heat Recovery Screening often helps to define the optimal level of analysis with minimal upfront effort. The consulting work performed during the screening is not lost when proceeding with a Full Heat Recovery (Pinch) Analysis. In most cases, the screening findings provide a strong foundation for the detailed study and typically help to reduce the effort and cost of the full analysis.
1. Rough Heat Recovery Screening
A Rough Heat Recovery Screening is a fast and pragmatic way to identify major energy consumers, waste heat sources and the overall heat recovery potential of a plant.
During the screening, we identify the main energy consumers, map relevant waste heat sources and estimate the order of magnitude of achievable energy and CO₂ savings. Based on these findings, we recommend the most effective next step: a detailed Full Heat Recovery (Pinch) Analysis or direct concept design of selected heat recovery measures.
MAIN FEATURES
- Get to know the overall system/processes
- Rough estimation of energy saving potential
- Approaches to increasing energy efficiency
- Next steps defined:
- More detailed Pinch analysis needed?
- Or go on in implementing the heat recovery systems
WHEN DOES A (ROUGH) PINCH ANALYSIS MAKE SENSE?
- Production plants with thermal processes (continuous or batch)
- Planning of new plants or retrofit heat recovery integration
- Heating and cooling tasks at different temperature levels
- Annual costs for thermal energy typically above 200’000 EUR
WHICH QUESTIONS WILL BE ANSWERED
- What is the site’s approximate thermal energy demand?
- What savings are achievable (order of magnitude)?
- Is a Full Heat Recovery (Pinch) Analysis justified?
PROVIDED RESULTS
- Energy efficiency improvement and CO₂ reduction potential
- Heat recovery opportunities with rough quantification of measures
- Optional: Sankey energy flow diagram to visualise key consumers, losses and opportunities
- Enables early consideration of potential public funding (energy and/or CO₂ reduction)
2. Full Heat Recovery (Pinch) Analysis
A Full Heat Recovery (Pinch) Analysis provides a technically sound and economically optimised, site-wide and cross-process heat recovery and utility concept for industrial plants.
MAIN FEATURES
- Typical energy savings of 10-40% (of whole thermal demand)
- Significant CO2 reduction (and basis for Net Zero Roadmap)
- Typical payback of 1-4 years (equipment and implementation)
- Strong ROI, positive NPV (and long lifetime)
Exemplary hot and cold composite curves. Shifting the cold CC to the left reduces the dTmin, increases the heat recovery potential (HR Pot.) and reduces the need for cold and hot utility (CU resp. HU)
TYPICAL SCOPE
- Complete analysis of process, plant and energy supply
- Evaluation of heating and cooling tasks at different temperature levels
- Optimal integration of heat recovery
- Integration of utilities (steam, hot water, heat pumps, CHP, etc.)
WHEN DOES A PINCH ANALYSIS MAKE SENSE?
- Production plants with thermal processes (continuous or batch)
- Planning of new plants and retrofit
- Heating and cooling tasks at different temperature levels
- Annual costs for thermal energy over about 200’000 EUR
Interested in a structured heat recovery or pinch analysis for your site? Contact our experts to discuss scope, effort and expected benefits:
KEY QUESTIONS ANSWERED
- What would the minimum energy demand be for a fully energy-optimised process?
- Where is the economic optimum regarding investment and operating costs?
- How can this optimal condition be achieved?
- Which energy supply is optimal for the entire system (steam boiler, heat pump, combined heat and power unit, etc.)?
- Is the existing energy supply optimally integrated into the system?
PROVIDED RESULTS
- Information on the absolute energy and CO2 saving potential
- Optimal and “realistic” measures for optimized heat recovery and energy supply
- “Correct” integration of HP, CHP etc. into industrial processes
- Catalogue of measures with technical/economic assessment (costs, benefits, payback)
- Strategic planning of the implementation of measures
HOW DOES THE PROCESS OF A PINCH ANALYSIS WORK
1) Data Preparation -> understand and challenge the current energy situation
- Data extraction; process review and balances
- Stream table of relevant heat sources/sinks
- Energy flow diagram and selected P&IDs
2) Analysis and Modelling -> determine the max. heat recovery potential as a benchmark
- Challenge process conditions and define requirements
- Define perimeter; pinch modelling in software
- Composite curves, targeting, heat exchanger network, utilities/HP/CHP options
- List of measures with economic indicators
3) Practical Adaptation -> turns theoretical potential into practical measures
- Technical and economic feasibility verification
- Iterative adaptation of the heat exchanger network and measures
- Packages of measures recommended for implementation incl. prioritisation
3. Adaption and Multi Site Rollout of Heat Recovery Concepts
Many companies have already performed heat recovery or pinch studies in the past—or operate multiple sites with similar processes. We support both the adaptation of existing studies and the rollout of proven concepts to additional sites.
A) Adaptation of existing studies (review & update)
- Review and challenge existing pinch/heat recovery studies and recommended measures
- Update key assumptions and boundary conditions (production, utilities, energy prices, operating modes)
- Adapt measures to the current process conditions and constraints
- Re-check technical feasibility and implementability
- Update savings (energy, CO₂) and economic indicators (payback, NPV, ROI)
B) Multi-site rollout (replication & prioritisation across sites)
- Standardized approach and templates for site data collection
- Re-validation of heat recovery potential and utility integration per site
- Portfolio view across sites: savings, CAPEX, payback and project prioritisation
- Structured rollout roadmap with recommended next steps
4. Implementation Support and Heat Recovery Engineering
Anytherm supports customers from concept to implementation—as a solution-independent heat recovery expert and, where suitable, also as a heat recuperator product partner for selected applications.
Anytherm provides solution- and product-independent consulting. For specific applications—especially exhaust air and flue gas heat recovery—we can also contribute in-depth practical know-how based on our own technical solutions. For other applications (e.g. liquid/liquid heat recovery), we typically support technology selection and supplier evaluation. In all cases, our consulting remains strictly solution- and product-neutral and focuses on the technically and economically optimal solution.
For implementation in existing or new plants, customers often work with EPC (Engineering, Procurement and Construction) contractors. We support by ensuring that the findings of the heat recovery analysis are translated into a feasible, operable design and correctly implemented.
- Implementation Support
- Expert support during engineering and detailed design
- Joint workshops with engineering / EPC (Engineering, Procurement and Construction) contractors
- Ensuring correct translation of Pinch concepts into detailed design
- Support during supplier selection and evaluation
- Engineering of the heat recovery system for selected applications
Conclusions – Get in Touch!
“The target is to operate a process at required throughput and product quality with minimum energy, resource requirements and emissions.”
Heat recovery is one of the most effective levers to reduce thermal energy demand and CO₂ emissions in industrial plants. Anytherm’s systematic heat recovery approach (Pinch-based) looks at the entire system: whole-site, cross-process, utilities and energy supply—to avoid sub-optimal local measures and to define an economically optimized overall concept.
Typical outcomes:
- Clear targets for minimum heating and cooling demand
- Prioritized heat recovery opportunities with economic evaluation
- A practical roadmap from concept to implementation
Do you want to quantify the heat recovery potential at an existing site or are you planning a new plant or a major retrofit?
Anytherm’s systematic heat recovery analysis helps to get the energy concept right from the start!
Advising in a solution-oriented, competent and neutral manner