Once waste heat opportunities are identified, the next step is transforming those findings into a technically robust network design.
This is where nPro, our partner software company based in Germany, proves instrumental. With its advanced design and simulation platform—purpose-built for district heating networks—we transition seamlessly from opportunity identification to detailed engineering, accelerating project delivery without compromising precision.
From data to decisive action
By integrating real operational data with geospatial layouts, this tool allows us to:
- Map optimal pipeline routes across complex industrial sites
- Simulate heat flows under varying loads and seasons
- Size equipment and pipe diameters for efficiency and reliability
- Calculate heat losses and pumping requirements
- Test multiple connection scenarios and future expansion paths
This modeling process ensures that every network we design is technically feasible, cost-optimized, and ready for funding applications.
A Real Case: industrial heat recovery
In a recent confidential project for a major European industrial site, we evaluated the reuse potential of condensate water recovered from a high-temperature process. The facility included diverse buildings—warehouses, offices, control rooms, and specialized production plants—collectively consuming hundreds of thousands of megawatt-hours annually for space heating and high-temperature processes (>1000°C).
Our analysis identified a consistent source of 80°C waste heat from process steam condensation. While previously vented or underutilized, this heat could be repurposed to meet a significant portion of on-site demand through a district heating network.
Using nPro, we developed a preliminary heating network design that:
- Linked the main waste heat source to multiple heat consumers via ~4 km of buried distribution piping.
- Distributed energy to process water preheating, space heating, and domestic hot water systems
- Integrated space heating for warehouses, control rooms, and office buildings
- Provided a temperature map showing expected supply levels for each consumer
- Included pipe sizing, flow rates, and hydraulic balancing to ensure operational stability
The design was further optimized to minimize CAPEX, reduce thermal losses, and allow for future extensions — including the possibility of connecting to nearby facilities.
The Value for decision-makers
This approach takes a project from “we may have recoverable heat” to “we know exactly how much we can deliver, to whom, and how”.
For decision-makers, that means:
- Clear technical scope for CAPEX and OPEX estimation
- A network plan aligned with decarbonization and compliance targets
- A foundation for securing funding from national or EU low-carbon programs
- Reduced risk thanks to data-driven simulation and expert validation
From concept to funding-ready proposal
By combining detection with network design, we deliver a package that bridges early-stage opportunity assessment and detailed engineering.
The result: investment-grade proposals that can move straight into permitting, funding, and procurement.
How We Support Your Project
• Pre-Development Site Analysis
We assess potential sites for new developments, evaluating environmental impact, technical feasibility, and energy demand potential.
• Site and Master Planning
We design comprehensive decarbonization and energy transition plans for large-scale developments, campuses, or districts.
• Regulatory & Funding Alignment
We create actionable plans that align with compliance requirements, capital planning needs, and available funding mechanisms.
• Advanced Modeling & Simulation
We apply cutting-edge modeling tools to quickly simulate scenarios and identify high-impact, cost-effective solutions.
Our Approach in Action
In the case study above, our modeling showed that the proposed thermal network could deliver:
- A linear heat density of ~98 MWh/m, far above the typical economic viability threshold.
- Stable operation with constant base load from process heat, supplemented by seasonal heating demand.
- Significant emissions reduction by replacing gas-fired heating with recovered industrial heat.
This type of analysis doesn’t just confirm technical feasibility—it demonstrates economic viability, enabling stakeholders to make confident investment decisions.
The Bigger Picture
Waste heat recovery is one of the most underutilized levers in industrial decarbonization. In heavy industry, where processes often release consistent low- to medium-grade heat, a well-designed district heating network can:
- Cut CO₂ emissions by displacing fossil-fuel-based heating.
- Reduce energy costs through fuel savings and improved process efficiency.
- Create infrastructure value that serves both current operations and future expansions.
Get in touch if you want to turn waste heat potential into a fully engineered, fundable solution.