- Waste heat recovery and thermal storage help make use of energy that would otherwise be lost.
- Thermal storage systems increase time-based flexibility and improve energy efficiency in production.
- Power-to-heat and waste heat recovery complement each other to support a stable and climate-friendly heat supply.
In energy-intensive industries, heat accounts for the majority of energy demand. Globally, around 75 percent of industrial energy consumption is used to generate process heat. A significant share of this energy escapes unused into the environment. Yet this loss carries untapped potential. Companies that manage to recover and store waste heat and feed it back into their operations when needed can reduce costs, cut emissions and strengthen their energy supply. The challenge lies in integrating such solutions into existing systems without disrupting production.
Bringing waste heat recovery into industrial practice
The basic idea is simple: capture heat where it was previously lost. In practice, this means tapping into sources like kilns, dryers, compressors or combustion chambers. The technical details, however, depend heavily on the temperature level and the origin of the waste heat. Not every type of heat is directly reusable. Different recovery and storage systems are needed depending on the case.
A typical setup includes a heat exchanger that extracts excess energy from exhaust gases or surfaces, paired with a thermal storage unit that holds the energy with minimal losses. This stored heat can then be used as process steam or for preheating. The approach is especially useful when heat generation is irregular, for instance in batch processes or during maintenance periods.
Thermal storage as a key technology
Once a thermal storage unit is integrated into the system, it adds a new level of flexibility. This is particularly relevant when the timing of heat supply and demand does not align. A common case: high-temperature waste heat is generated during production, but steam is only needed later for drying or cleaning processes.
Thermal storage bridges this gap. It absorbs the available energy, stores it efficiently and releases it when needed. This makes it possible to start a new production cycle without relying on additional fossil fuel input.
At the same time, storage improves planning reliability. Peaks in heat demand can be absorbed, equipment usage becomes more balanced, and load profiles are easier to manage. The result is a more stable system that no longer depends on real-time heat generation.
There is an added benefit when thermal storage is combined with power-to-heat systems. Waste heat recovery reduces energy losses, while excess electricity from renewable sources can also be used to produce heat. The stored energy becomes a flexible asset that helps decarbonize process heat in industry.
Solutions from ENERGYNEST: integrating heat intelligently
One company combining industrial waste heat recovery with storage is ENERGYNEST. At the core of its power-to-heat solution is the ThermalBattery™, a modular high-temperature storage unit developed specifically for energy-intensive applications.
Working with a heat exchanger and a recovery module, the system captures excess heat from exhaust or radiant sources at temperatures above 350 degrees Celsius and stores it with low thermal losses. The energy is then available on demand. But the system offers more than just heat: acting as a buffer, it smooths out fluctuations, reduces peak loads and enhances process control. This also cuts fuel use, especially natural gas, and helps lower operating costs. Electricity demand in energy-intensive steps can also drop.
Why now is the time to act
The pressure to increase energy efficiency, reduce emissions and ensure supply stability is growing. At the same time, technical solutions like thermal storage are becoming more accessible. For companies, waste heat recovery is no longer just a question of environmental responsibility. Competitiveness and resilience are also on the line.
Firms that take a closer look at their processes, identify waste heat sources and integrate storage systems can achieve significant results with manageable effort. The combination of waste heat recovery, thermal storage and power-to-heat creates synergies that improve the energy balance and bring the goal of climate-neutral process heat within reach.
