In today’s industrial landscape, energy efficiency is no longer just a preference—it’s a necessity. At Bacon Engineering, we specialize in delivering advanced boiler control and heat recovery solutions that help industrial clients reduce energy consumption, lower emissions, and optimize operational performance. One of the most impactful technologies we support is boiler heat recovery systems.

What Is a Boiler Heat Recovery System?

Boiler heat recovery systems are engineered to capture excess heat from a boiler’s exhaust stream or blowdown process and repurpose it for productive use. Rather than allowing thermal energy to be lost through flue gases or discharged water, these systems reclaim it to preheat incoming boiler feedwater or support other thermal processes. The result is a significant improvement in overall system efficiency.

Types of Heat Recovery Solutions

At Bacon Engineering, we offer a range of heat recovery systems tailored to the needs of various industrial operations. These include:

Economizers

Economizers are heat exchangers that recover energy from hot flue gases and use it to preheat boiler feedwater. This simple yet highly effective solution reduces the fuel required to generate steam, resulting in immediate energy savings.

Condensing Heat Exchangers

Condensing heat exchangers go a step further by capturing latent heat from the water vapor present in flue gases. These systems are particularly effective in facilities where return water temperatures are low enough to support condensation, delivering even greater efficiency gains.

Blowdown Heat Recovery Units

During the boiler blowdown process, high-temperature water is expelled to remove dissolved solids and impurities. Blowdown heat recovery units reclaim this heat and use it to preheat makeup water, enhancing overall energy utilization.

Flash Steam Recovery

Flash steam systems recover steam generated during blowdown by exploiting pressure drops. This recovered steam can be redirected into process heating or space heating systems, reducing the need for additional steam generation.

Combined Heat and Power (CHP) Systems

CHP systems generate electricity while simultaneously capturing waste heat for thermal use. These cogeneration systems are ideal for operations requiring both power and heat, and they provide superior efficiency over traditional methods.

Why Choose Bacon Engineering?

Bacon Engineering brings decades of expertise in boiler control and energy optimization to every project. We work closely with our clients to evaluate their existing systems, identify opportunities for heat recovery, and implement solutions that deliver measurable returns. Our heat recovery systems are designed not only to enhance efficiency but also to support regulatory compliance and sustainability goals.

Key Benefits

• Reduced Fuel Costs: By reclaiming waste heat, facilities can significantly cut their fuel usage.
• Lower Emissions: Improved energy efficiency directly contributes to reduced greenhouse gas emissions.
• Extended Equipment Life: Preheated feedwater and optimized boiler loads reduce wear and tear on equipment.
• Regulatory Compliance: Meeting environmental standards becomes easier with reduced energy footprints.
• Faster ROI: Many heat recovery systems pay for themselves within a few years through energy savings.

Serving a Wide Range of Industries

Our solutions are applicable across a broad spectrum of industries, including manufacturing, food processing, healthcare, and energy production. Whether you operate a single boiler or a large-scale boiler plant, Bacon Engineering can design and implement a custom heat recovery system to meet your operational needs.

Partner with Bacon Engineering

At Bacon Engineering, our goal is to help you operate smarter, cleaner, and more efficiently. With our advanced boiler heat recovery systems, you can take a significant step toward sustainable operations and reduced energy costs.

Contact us today to learn more about how we can support your facility with tailored boiler heat recovery solutions.