Electrification of Hot Water Preparation | Apparel Impact Institute

Pozzi
Electrification of Hot Water Preparation

This solution reduces GHG emitted from generating heat and electricity by electrifying the preparation of hot water. Pozzi has developed a cutting-edge system that integrates a passive heat recovery unit known as RHeX with an active electric heat pump to remarkably reduce fossil energy demand in hot water preparation, thanks to a ratio of 6 to 12 between the total thermal energy generated and the electrical energy consumed. Notably, this system facilitates the transition from fossil fuels to electricity and can amplify its environmental benefits when powered by renewable electricity sources, potentially even self-generated ones.

Solution maturity level

Pre-seed

Definition:

Solutions that are at a concept level and in the process of evaluating and establishing their impact potential.

Pilot

Definition:

Solutions that are in the process of testing their solution in order to demonstrate a proof of concept.

Model

Definition:

Solutions that are working towards de-risking and reducing known barriers to scale.

Goal:

Develop feasibility study to reach a wider solution scale up in more emission intensive facilities.

Scale

Definition:

Solutions that are commercially viable with a proven go-to-market strategy.

Model

Current Level

Pre-seed

Pilot

Scale

Model DEFINITION

Solutions that are working towards de-risking and reducing known barriers to scale.

LEARN MORE ABOUT OUR MATURITY LEVELS

Goal Of This Model Solution

Develop feasibility study to reach a wider solution scale up in more emission intensive facilities.

Current Level

Pre-seed DEFINITION

Solutions that are at a concept level and in the process of evaluating and establishing their impact potential.

LEARN MORE ABOUT OUR MATURITY LEVELS

Pilot DEFINITION

Solutions that are in the process of testing their solution in order to demonstrate a proof of concept.

LEARN MORE ABOUT OUR MATURITY LEVELS

Scale DEFINITION

Solutions that are commercially viable with a proven go-to-market strategy.

LEARN MORE ABOUT OUR MATURITY LEVELS

Financial breakdown

The initial investment is for the installation of the heat exchangers, heat pumps and any other ancillary works. Once deployed the facility starts saving energy costs. Savings are maximized for facilities with high flow rate, big temperature delta of in-outlet water, big delta of electricity VS fossil fuel price.

Site Investment

Implementation cost

Payback period

Months average payback period

tCO₂e =

$18.1

$67 industry average

Payback period

Average actual total investment cost per tCO₂e reduction

Invested COST PER tCO₂e REDUCTION

DISCLAIMER: These are average projected values, average cost and impact ratios will depend on site specific implementation.

What are the different saving types?

Implementation Plan

Once a facility is enrolled, Pozzi performs a feasibility study to collect basic data and assess the factory layout of the manufacturing process. After scenarios are simulated and decisions are made, the equipment is installed - typically during a holiday period to avoid disrupting production.

1 - 8 months

Projected average length for feasibility study and plant installation

Implementation milestones

Projected project length

Data gathering

Equipment selection

Commercial offer

Installation

Example projects

Electrification of hot water preparation of yarn dye-house (Italy)
Electrification of hot water preparation of fabric processing (Belgium)

Vago Case Study

1 Region

1 Site

1 Year

Impact

GHG saved

806

tCO2e

Energy saved

10,689

The Challenge

The solution has the best performance to heat (or preheat) water up to around 60°C which is a common need in textile mill and in leather tanning. The Italian facility that has implemented the technology, is a representative case study for the industry. the facility has a wastewater discharge of 14m3/h at 52°C and a requirement of 14m3/h of water at 50-55°C. The global Coefficient of Performance is 13 (49 KW of electricity is used to deliver 668 K of thermal energy).The plant cut its GHG emissions by 90% specifically in water heating, thanks to the reduction of fossil fuel (methane) consumption. The energy cost saving for this facility totals $237,300 per year, and the payback period was less than a year.

Solution program growth

Since 2022, Electrification of hot water preparation has been deployed in 2 sites.

2

Total Sites

2022-2023

Solution providers

Pozzi Profile

Founded in 1885, Pozzi is an Italian manufacturing and engineering entity that services the wet processing textile industry and holds a strong dedication to energy efficiency. Pozzi patented a self-cleaning heat exchanger that had been implemented in 6000 facilities worldwide.

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