Heat recovery from the process – savings of 106 GWh in a wood-based panel plant

Heat recovery from the production process – OSB drying line modernization

At the OSB board plant, DB Energy implemented a heat recovery system from the formalin cooling process. The waste energy was used for the belt pre-dryer, reducing energy consumption by over 106,000 MWh and generating savings of around 9.6 million PLN. It also reduced CO₂ emissions by 40,000 tons. The simple payback period of the investment is 4 years.

The challenge

OSB board production is highly energy-intensive, generating both high electricity and heat consumption. In the analyzed plant, a large amount of energy was irreversibly lost during formalin cooling and released to cooling towers. At the same time, the drying process required significant heat input, resulting in high operating costs and CO₂ emissions. The key challenge was therefore to utilize waste energy effectively during the OSB pre-drying stage without compromising the final product quality.

Our approach

DB Energy experts conducted an audit of the thermal components of the OSB production line — analyzing the formalin cooling process, heat exchanger operation, and losses in cooling towers. Based on this, it was proposed to use the waste heat — instead of disposing of it irreversibly — to power a new low-temperature belt pre-dryer. A technical concept was prepared, including integration of plate heat exchangers with the existing system, an economic feasibility assessment, and an analysis of the impact on CO₂ emissions.

Solution

DB Energy engineers designed a system for heat recovery from the formalin cooling process and its reuse in OSB board pre-drying. The energy that was previously released to cooling towers was redirected to the technological installation, supporting the drying process.

Implementation included the installation of:

heat exchangers,
pipeline system,
automation system controlling energy flow according to demand.

Effects

The modernization brought benefits including:

reduction of final energy consumption by over 106,000 MWh annually,
financial savings of approximately 9.6 million PLN annually,
a 4-year payback period on the investment, with capital costs of 39 million PLN,
reduction of CO₂ emissions by around 40,000 tons annually.

Conclusions

The completed project is a clear example of effective use of waste energy as an alternative to costly fuel. Heat recovery in the OSB process brought operational and environmental savings. The key success factor was precise identification and analysis of heat losses and designing the integration of recovery with the existing process. The implementation confirms that industrial energy efficiency measures generate real investment returns, lower emissions, and easy adaptation in existing plants.

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