Aluminum Hot Combustion Air
Capture waste heat to preheat combustion air and reduce fuel consumption
Overview
Storing Waste Heat for Hot Combustion Air in Aluminum Processing
In aluminum processing, significant amounts of waste heat are generated during smelting and casting operations. IsoTES® captures this waste heat and stores it for later use in preheating combustion air for furnaces. By delivering hot air at consistent temperatures, this solution reduces natural gas consumption by up to 30% while improving overall energy efficiency and reducing carbon emissions.
Background & Challenges
Background
Aluminum demand is rapidly increasing due to lightweighting trends
- Aluminum is heavily used for battery packs and car skeletons
- EV manufacturers are driving unprecedented demand for lightweight materials
Large amounts of waste heat are currently being wasted
- Significant thermal energy is vented to atmosphere during processing
- This represents both energy loss and environmental impact
Challenges
EU CBAM (Carbon Border Adjustment Mechanism) poses significant challenges
- EU imposes carbon tax on imported aluminum based on CO2 content
- Korean aluminum products contain approximately 2x more CO2 than EU-produced aluminum
- This creates significant competitive disadvantage for Korean EV and aluminum exports
Solution and Values delivered by IsoTES®
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IsoTES® stores waste heat from aluminum processing that would otherwise be vented
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Stored heat can be used to generate hot combustion air for furnaces
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Additional applications include cold energy generation via absorption refrigerators
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Steam can be generated for neighboring facilities or processes
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This multi-purpose approach significantly contributes to CO2 emission reduction
How It Works
IsoTES® waste heat storage system for aluminum processing with multiple output applications
Key Values
Features and benefits of this solution
Key Features
- Waste heat capture from aluminum processing
- Constant-temperature hot air delivery
- Integration with existing furnace systems
- Multi-purpose output: hot air, cold energy, steam
Benefits
- 30% reduction in fuel costs
- 30% reduction in CO2 emissions
- Additional CO2 reduction possible with renewable energy sources
- Lower CBAM-related carbon tax burden
Technical Highlights
Engineering details and specifications
High-temperature molten salt TESM
Heat exchanger optimized for air heating
Continuous operation capability
Status & Plan
This application is part of the Multi-Purpose Demonstration Facility Project
Demonstration facility will validate waste heat recovery and multi-output capabilities
Successful demonstration will pave the way for commercial-scale deployment in Korean aluminum industry
Related Technology
Learn more about the IsoTES® systems used in this application
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Ready to Get Started?
Let us help you implement Aluminum Hot Combustion Air with IsoTES® technology.