AI Waste Heat Recovery Optimization

Identifies and optimizes waste heat recovery opportunities and control strategies to maximize recovered energy and ROI.

The Problem

“Unlock Waste Heat Value Across Complex Assets”

Organizations face these key challenges:

Waste heat quantity and quality fluctuate with load, ambient temperature, and process upsets, making WHR sizing and day-to-day operation difficult to optimize manually

Steam, hot water, and power networks have tight constraints (header pressures, turbine limits, condenser backpressure, emissions, grid export/import rules) that create complex trade-offs and frequent suboptimal bypass/venting

Performance losses from fouling, scaling, leaks, and sensor drift are hard to detect early, leading to sustained efficiency losses and unplanned downtime

Impact When Solved

1–4% site fuel reduction and 5–15% higher recovered heat utilization through continuous setpoint optimization2,000–25,000 tCO2e/year emissions reduction per large site via displaced fuel/power and reduced venting$0.5M–$5M/year net savings with faster payback (often <12–24 months) by improving WHR dispatch, reliability, and maintenance timing