Energy Integration and Optimization From efficient processes to climate-neutral industry

Present State Analysis with Field Measurements
A reliable analysis begins with a thorough understanding of the existing processes. We establish mass and energy balances and characterize the process and utility systems using operating data, process documentation and, where necessary, targeted field measurements. This provides the basis for the subsequent analysis and can already reveal opportunities for operational improvement.

Pinch Analysis with PinCH Software
Before technical solutions are considered, the underlying process requirements, temperature levels and operating constraints are critically reviewed. Using the PinCH software and tools developed at HSLU, we determine heating and cooling targets, quantify the potential for heat recovery, and evaluate the economically viable integration of utilities and energy conversion technologies.

From Analysis to Integrated Solutions
Based on the results, we develop implementation concepts for heat recovery, heat-exchanger networks, heat pumps, thermal storage, renewable heat and connections to thermal networks. We also support the energy-efficient integration of processes such as CO2 capture.

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Process Modeling and Simulation
We develop models that represent the mass and energy flows and relevant thermodynamic behavior of processes and components. Depending on the application, we use established simulation tools or develop customized models. Where possible, the models are calibrated and validated using operating or experimental data. 

Dynamic Simulation and Optimization
Industrial processes and energy systems are influenced by changing production schedules, energy demand, ambient conditions and energy prices. We use dynamic models to investigate part-load and transient operation, interactions between system components and thermal storage, and to optimize system design, control strategies and flexibility.

Thermal Networks and Regional Energy Systems
We model and analyze thermal networks, from systems serving individual sites or groups of companies to district heating and cooling networks. We assess how available thermal energy sources, particularly excess heat, can meet heating and cooling demands and how these systems can be designed and operated efficiently.

CO2 Capture and System Integration
We simulate CO2 capture and conditioning processes and their integration with industrial energy systems, transport, utilization, and storage. Through techno-economic analysis, we compare centralized, decentralized and cluster-based concepts at site and regional levels.

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Heat Pumps, Chillers and Refrigeration Systems
We investigate and develop system configurations for industrial and high-temperature heat pumps, chillers, refrigeration systems and steam-producing technologies such as mechanical vapor recompression. Our work evaluates and integrates components, refrigerants and cycle configurations based on their efficiency, capacity, operating limits and part-load behavior to identify the most suitable solution for each application.

Integration into Processes, Products and Thermal Networks
System performance depends on the appropriate matching of heat sources and sinks. We analyze temperature levels, load profiles and opportunities for simultaneous heating and cooling, heat recovery and storage. The results guide integration into industrial processes, products, industrial thermal networks, and district heating or cooling systems.

Experimental Investigation and Validation
Using HSLU’s laboratory infrastructure, heating and cooling systems with capacities of up to 600 kW can be investigated under representative operating conditions. We measure characteristics such as heating and cooling capacity, efficiency, operating range and part-load performance. Where required, we also conduct measurements at partner sites. The resulting data are used to validate models, evaluate system performance and derive measures for further optimization.

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Analysis of Processes and Products
The development process begins with a systematic analysis of the existing process, product or comparable solutions on the market. We determine the relevant material and energy flows, operating conditions, component interactions and technical requirements using documentation, operating data and targeted measurements. Based on these findings, we identify improvement potential and define measurable development objectives.

Concept Development and System Integration
We develop and compare concepts that may involve redesigned process steps, heat recovery, heating and cooling systems, or new component configurations. Simulation and techno-economic analysis guide the design and help identify solutions that combine technical feasibility, energy efficiency and economic viability.

Prototyping and Experimental Validation
We translate promising concepts into functional models, prototypes or experimental installations. Purpose-designed experiments and test rigs are used to evaluate performance, efficiency, operating behavior and control strategies. The results inform design refinement, model validation and decisions on scale-up or industrial implementation.

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