Innovation Exchange challenge: Heat recovery and process efficiency optimisation in advanced plasma coating manufacturing

Background

Zircotec Ltd is a UK-based leader in high-performance ceramic thermal barrier coatings and fabricated heatshield systems, serving automotive, motorsport, aerospace, and industrial sectors.

Our manufacturing processes use energy-intensive plasma spraying and fabrication equipment, which involves the use of multiple water chiller systems for process cooling, and compressed air systems for a range of activities. Heat generated in compressors and chillers is currently dumped to the environment and not utilised even during winter months, while chilled water provision is fragmented across multiple units. This creates inefficiencies, increases costs, and misses opportunities to use recovered energy. Furthermore, the chillers are being used to take heat away from process water flows that are initially relatively warm, and where heat could potentially be shed more efficiently and potentially reused via a water/air heat exchanger.

Zircotec is ideally looking for a solution that combines these different needs to improve overall energy efficiency of their operations.

The Challenge

Zircotec is seeking a practical, scalable solution to optimise energy efficiency by better use and management of heat in its operations. This includes:

• Capture hot air from compressor heat recovery systems.
• Recover heat from chiller radiators for secondary use.
• Consolidate chiller capacity into a single chilled water reservoir.
• Reduce chiller usage through the use of water/air heat exchangers.
• Utilise low grade heat from the above for space heating within our factory and/or offices.

Solutions are preferred that address most, if not all of these aspects ideally by combining requirements into a single solution.

The proposed solution must integrate with existing facilities, operate reliably in an industrial environment, and maintain the required cooling and coating performance to allow throughput and quality to be maintained.

This iX is in the Foundation Industries and supply chain challenges group, therefore, the solution provider will be eligible to apply for £25,000 to develop the proposed solution towards meeting this challenge. The funding will cover a 3-month project, the details of which will need to be refined with Zircotec. It is envisaged that this 3-month project should deliver a complete system design, energy modelling to quantify potential savings and implementation roadmap to show how the solution will be integrated into live operations.

Eligibility

This iX is in the Foundation Industries and supply chains challenges. Due to the nature of this challenge and the funding support available, there are the following eligibility criteria:

• Entrants to this competition must be a UK registered business.
• Entrants can only apply to one of the Foundation Industries and supply chains challenges.

Rewards and market opportunity

Successful applicants will be given the opportunity to pitch their solution to Zircotec Ltd. The winning applicant, as selected by the company, will then be eligible to apply for £25,000 grant funding to kickstart the development of the proposed solution through a 3-month project. The selected solution may be piloted in Zircotec’s live manufacturing environment, with potential for commercial adoption and R&D collaboration.

Successful applicants will:

• Pilot their solution in Zircotec’s live production environment.
• Receive technical support, process data, and performance benchmarking.
• Be considered for commercial adoption and future collaborations.
• Access wider markets in automotive, aerospace, and industrial thermal management.

The benefits package for a successful applicant may also include:

• Support from Innovate UK Business Connect
• Support in the development of a prototype or pilot
• Technical support
• Invitation to attend or present at Innovate UK Business Connect events
• A potential business collaboration
• Investor introductions (if investment is required)
• Support if any Innovate or similar competitions are relevant.

For full technical and operational requirements, assessment criteria, and further details, visit the Innovation Exchange site at the link below.