Kohler Pottery Heat Recovery

Kohler Company was looking for a way to recover the heat emitted from their production in their Pottery facility.  They were particularly concerned about the 18,000 gallons of 120°F hot water used domestically and in production per day. The firing process in the shuttle kiln creates waste heat at a maximum temperature of 700°F at 65,000 pounds per hour. With a simple modification to the kiln exhaust stacks that allows for bypass when heat recovery is not required and a high pressure hot water system, we are able to recover more than enough heat/energy. Covering the load required for hot water, process load in the pottery dryers as well as future possibilities in heating plant make-up air saving over $200,000 in natural gas costs per year. Key points from this project: 

• A custom designed pump skid.
• Heavy Duty heat recovery coils and exhaust fans.
• All equipment motors operate on a VFD for maximum efficiency.
• Integration of hot water heating system controls with remote monitoring and data collection system.
• Hot water storage allows for future expansion.