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Case Study: Energy Optimisation for ANV Greece with Bronx Hot Water Economiser System

Read this case study to discover how ANV Steel in Greece slashed gas consumption by 20 %, saved over €130 000 annually, and cut emissions through a bespoke Hot Water Economiser System from Bronx Thermal Solutions — transforming their continuous coil-coating line into a leaner, greener operation.

Client:

ANV Steel, Greece — A leading metal processor operating a Continuous Coil Coating Line.

Bronx Hot Water Economiser System at ANV Greece

Stage HEXs That Distribute

Heat to Stage Tanks

Project Overview

Bronx successfully retrofitted a Hot Water Economiser System at ANV’s Continuous Coil Coating Line to improve energy efficiency in the heating of pretreatment sections, replacing a high gas-consumption system.

Challenge

ANV’s production line previously used gas-fired immersion tubes to heat the pretreatment section. This setup led to elevated gas consumption and energy loss, with exhaust gases from the Thermal Oxidiser being discharged directly into the atmosphere without heat recovery.

Solution

Bronx designed and installed a tailored Hot Water Economiser System, which included:

High-efficiency Hot Water Economiser
Plate-type heat exchangers
Closed-loop water circulation system

This system captures waste heat from the oxidiser’s exhaust and redirects it to the pretreatment section. The original gas heaters were retained as a backup, and Bronx modified the control system to monitor and regulate water temperature and flow, maintaining consistent process heating.

Implementation

Bronx’s specialist engineers installed and commissioned the system on-site, ensuring smooth integration and minimal disruption to ongoing operations.

Results and Benefits

20% reduction in gas consumption – Immediate improvement in energy efficiency.
Over €130,000 in annual savings – Based on a gas price of €46/MWh.
Dual-heating configuration – Flexibility to switch between hot water and gas-fired heating.
Automated control system – Accurate temperature regulation without manual intervention.
Lower emissions – Reusing waste heat reduces the environmental footprint.

Conclusion

The Bronx Hot Water Economiser System has proven to be a cost-effective and sustainable solution for modern coil coating lines. ANV’s investment has delivered considerable operational savings, improved energy use, and enhanced environmental performance.

Contact The Bronx Group

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