The Troisdorf-based manufacturer of hot-rolled special profiles will in future use the waste heat from its production facilities to feed it into its own heat supply network. Through the optimization measures identified in collaboration with E.ON, the company reduced its energy requirements for internal heat supply by almost 40 percent and reduced its annual CO2 emissions by more than 1,800 tons
Mannstaedt GmbH will be focusing on a sustainable energy concept in the coming years. The company, which is part of the GMH Group, has launched an extensive energy efficiency program that significantly reduces CO2 emissions. Overall, the Troisdorf-based manufacturer plans to save more than 1,800 tons of CO2 emissions per year with its package of measures. According to a calculation by the North Rhine-Westphalia Consumer Center, this corresponds to the annual emissions of 450 to 500 gas-heated single-family homes of older construction.
“The planning and implementation of this project is also a particular challenge for us due to its target values and the dimensions of the heat exchanger system. We are proud to be able to make an important contribution to Mannstaedt’s sustainable energy concept,” explains Alexander Fenzl, Chief Sales Officer at E.ON Energy Infrastructure Solutions Germany
Saved energy requirements
This is accompanied by savings of more than eight percent of the site’s annual natural gas consumption. The heart of the program is a heat exchanger system provided by E.ON. Hot exhaust gases from a production plant are passed through this new system and heat up heating water, which is then fed into the heat supply circuit at the location. Until now, this valuable energy escaped unused as exhaust gas via the chimney into the environment.
Through this measure alone, the company plans to save almost 30 percent of its thermal energy requirements in the future. As part of the collaboration with E.ON Energy Infrastructure Solutions, Mannstaedt has also initiated various optimizations of its production facilities. This results in further thermal energy savings potential of up to ten percent.
“In intensive discussions with E.ON, we examined various options for a sustainable energy concept,” says Sebastian Ahrens, Commercial Director and project manager at Mannstaedt, describing the course of the collaboration with E.ON Energy Infrastructure Solutions. “We came to the collective conclusion that the use of waste heat offers the greatest leverage for saving CO2 emissions, also due to the performance of our production facilities. And on a scale that is not an everyday occurrence even for E.ON.”
The investment volume for the main system delivered by E.ON is around three million euros. The project is to be supported with public funds amounting to around 900,000 euros. Corresponding funding applications have already been submitted to the responsible authorities.
Mannstaedt uses the facility as part of a lease and operator agreement. Construction work is scheduled to begin in the middle of next year. The particular challenge here is that the installation of the system and all other structural measures must be prepared so precisely that they can be carried out during the factory holidays without affecting ongoing production. The plant is scheduled to begin operations at the end of 2024. The groundbreaking project is one of many transformation measures that the GMH Group is currently implementing with the aim of achieving climate-neutral production by 2039.