Integrated Cogeneration and Heat Recovery System for Industrial Process Optimization

This thesis presents the design and analysis of a cogeneration system integrated with heat recovery for an industrial plant. The study focuses on optimizing the production of hot water, steam, and electricity by exploiting the energy content of natural gas and waste heat streams from existing processes. The main objectives were to enhance energy efficiency, reduce fuel consumption, and lower operational costs. To achieve this, a steam generator with flue gas heat recovery was modeled and dimensioned, coupled with a cogeneration unit supplying heat for preheating, process steam, and electrical power to the plant. The design process accounted for thermodynamic performance, operational constraints, and integration with existing infrastructure. An economic analysis was conducted to evaluate the feasibility of the intervention. This included calculation of fuel savings, return on investment, and payback period, demonstrating the potential benefits of the proposed system in terms of energy efficiency and cost reduction. The results show that the integrated heat recovery and cogeneration system can significantly improve overall energy performance, providing both environmental and economic advantages. This study highlights the practical application of cogeneration and waste heat recovery in the industrial sector and serves as a reference for future energy efficiency projects.