{"id":27459,"date":"2026-03-19T16:03:27","date_gmt":"2026-03-19T15:03:27","guid":{"rendered":"https:\/\/www.kma-filter.de\/exhaust-air-filtration-and-heat-recovery-for-melting-furnaces\/"},"modified":"2026-11-04T16:35:18","modified_gmt":"2026-11-04T15:35:18","slug":"exhaust-air-filtration-and-heat-recovery-for-melting-furnaces","status":"publish","type":"page","link":"https:\/\/www.kma-filter.de\/en\/industries-applications\/exhaust-air-filtration-and-heat-recovery-for-melting-furnaces\/","title":{"rendered":"Exhaust air filtration and heat recovery for melting furnaces"},"content":{"rendered":"\t\t
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HEAT RECOVERY and
EXHAUST AIR FILTRATION <\/b>
for melting furnaces<\/h1>\t\t\t\t<\/div>\n\t\t\t\t
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Make cost-effective use of process waste heat from melting-furnace exhaust air, keep emissions safely under control, and sustainably reduce energy costs.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tSolution & technology<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tFor megacasting<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tFor retrofit<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\t\tYour potential at the melting furnace<\/span>\t\t\t\t<\/div>\n\t\t\t\t
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Heat recovery pays off at the melting furnace<\/h2>\t\t\t\t<\/div>\n\t\t
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The hot exhaust air from every melting furnace contains valuable energy. KMA recovers this process heat and makes it usable where your operation needs it\u2014either as a retrofit on a single furnace or as an energy source for the entire production site. <\/p>

In most cases, we return the heat as hot water: for production hall heating, for washing systems and phosphating, for hot water, or for feeding into an existing heating network. Where the furnace technology allows, returning it as hot air is also possible\u2014for example to preheat the burner supply air at the melting furnace, which reduces fuel consumption directly at the furnace. Which route pays off fastest depends on the heat demand at your site. <\/p>

The second advantage: exhaust air filtration can be integrated directly. KMA systems reliably comply with the strict dust limit values of the new EU BAT conclusions for foundries. This way, you combine emissions protection and energy efficiency in one system\u2014on a small scale as well as in megacasting. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\"KMA<\/figure>

Retrofit on an existing melting furnace<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Even a small foundry saves noticeably. <\/strong><\/p>

Example:<\/strong>propane-fired furnace with 1.5 t capacity in a foundry in Germany.<\/p>

The furnace exhaust air at around 345\u00b0C heats 22.8 m\u00b3\/h of water from 65 to 80\u00b0C, delivering just under 400 kW of heating output for the hall.<\/p>

Result: <\/strong>1.6 GWh of recovered heat per heating period and up to 9% less propane consumption \u2014as a compact retrofit on the existing furnace.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\"Heat<\/figure>

Greenfield megacasting project<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Here, the energy balance of the entire site is what counts.<\/strong><\/p>

Example:<\/strong> natural-gas-fired shaft furnace with 4.5 t capacity at a European OEM.<\/p>

The hot shaft-furnace exhaust air provides warm water for phosphating in the paint shop\u2014cleaned by an integrated electrostatic precipitator, cheaper to operate than a bag filter.<\/p>

Result:<\/strong> up to 2.8 GWh of usable heat per year, lower energy demand across the entire site \u2014while reliably meeting emission limit values.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\"Icon-Heat-Exchanger-Eco-accent-light\"<\/figure>

1.6 GWh of heat per heating period<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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9% less propane<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"Icon-Solution-modular-system_circle-blue\"<\/figure>

Simple retrofit
on the existing furnace<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"Icon-Payback-accent-light-circle-blue\"<\/figure>

Make full use of funding opportunities<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\"Icon-Heat-Exchanger-Eco-accent-light\"<\/figure>

2.8 GWh of heat as an energy source<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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Meet emission limit values<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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- 0.5 GWh energy consumption vs. bag filters<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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Low maintenance costs thanks to CIP<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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clean air.
save energy.<\/b><\/h2>\t\t\t\t<\/div>\n\t\t
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2.8 GWh or more energy yield per year <\/p><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t

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\n\t\t\t\t\t\t\t\t\tContext: example project\nAn example for a natural-gas-fired shaft melting furnace with 3.5 t melting capacity and 7 t holding capacity describes an annual energy yield of around 2.8 GWh.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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9% less propane consumption <\/p><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t

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\n\t\t\t\t\t\t\t\t\tContext: example project\nFor a retrofit example on a propane-fired melting furnace, preheating the burner air is stated to reduce propane consumption by 9% year-round.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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1.6 GWh usable heating energy <\/p><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t

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\n\t\t\t\t\t\t\t\t\tContext: example project\nIn the same retrofit example, integrating into the building\u2019s hot-water system makes around 1.6 GWh of heating energy usable over the heating period.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Up to 0.5 GWh savings compared to bag filters <\/p><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t

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\n\t\t\t\t\t\t\t\t\tContext: application-specific benchmark\nFor ULTRAVENT\u00ae, savings of up to 0.5 GWh or more are cited compared to conventional bag filters, due to lower pressure drop and reduced fan power demand.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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We put our trust in KMA<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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\"DGS
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\"GF
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\"Harting
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\"BMW
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\"IDRA
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\"Volvo
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\"DAIHATSU
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\"VW
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\"Magna
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\"Nemak
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\"B\u00fchler
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\"DAIMLER
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\"Renault
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\"VOIT
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\u201cWith the KMA solution, we have taken the energy efficiency of the entire production site to a new level\u2014this solution turns furnace exhaust air into an energy source for the foundry of the future.\u201d<\/p><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Klaus Hansen, foundry architect, Odin Ltd.
(Photo from left to right: Dr Holger Wagner, KMA, Klaus Hansen, Odin Ltd.)<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Improved energy efficiency in the foundry<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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70% of your energy costs are in process heat. We recover it. <\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Holistic solutions in the foundry combine exhaust air filtration, heat recovery, supply air provision and energy utilisation into a coordinated overall system.<\/a> Instead of merely discharging exhaust air safely, the process waste heat it contains is made technically usable for an energy-efficient production site.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t<\/path><\/svg>\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\tHere\u2019s the dena guide for foundries<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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OUR SOLUTION for the melting furnace in large casting<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Green megacasting with improved energy efficiency<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Large casting needs high-capacity melting furnaces\u2014and anyone investing in a megacasting casting cell will usually build a new furnace as well. That\u2019s exactly when it pays to plan the evironmental technology in from the start: capture, filtration and heat recovery can be integrated into the production hall layout instead of being added later. <\/p>

Up to 2.8 GWh of usable heat per year, emissions reliably below the limits, and around 0.5 GWh less energy consumption than with bag filters.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t

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ULTRAVENT\u00ae H with horizontal airflow with a capacity of 30,000 m\u00b3\/h per unit. <\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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ULTRAVENT\u00ae H combined with a decentralised aluminium melting furnace and giga casting casting cell<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Recover
heat<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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\"Icon-CO2-cloud-accent-light-1000px\"<\/figure>

Meet the strictest EU emission limit values<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Save 0.5 GWh energy consumption compared to bag filters <\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Reduce maintenance costs
with CIP system<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tLearn more about ULTRAVENT\u00ae H<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Here\u2019s where it gets specific:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Results from the customer example <\/p><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t

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