Valorizing waste flows

Many industrial production processes generate gaseous or liquid waste flows that still hold significant energy value. By putting these flows back to work as a fuel, you can lower your primary energy consumption, reduce your CO2 emissions and get more out of your production process.

The Callens Group develops installations that integrate waste flows into your energy supply safely and efficiently. Thanks to our expertise in combustion technology, fuel systems and industrial heat generation, we turn waste flows into a reliable energy source.

Discuss your valorization project

When is valorizing waste flows worthwhile?

Many industrial companies have waste flows that are discharged unused — think of wastewater, syngas or hydrocarbons. Unfortunately, valuable energy is sometimes lost this way.

The Callens Group investigates which waste flows are technically and economically valuable. To do so, we take account of your fuel properties, heat demand, your existing installations and operational reliability. The result is a solution that gives you maximum return from the available energy.

Stoom vloeibare reststromen
Callens stoom vloeibare reststromen mixed fatty acids 2

Why choose to valorize waste flows?

  • To reuse valuable energy streams within the production process.
  • To reduce natural gas or heating oil consumption.
  • To structurally lower CO2 emissions.
  • To deploy waste flows as a full-fledged energy source.
  • To increase the energy efficiency of the entire site.

Your challenge

Most suitable solution

Biogas is being released during the production process.

Biogas-fired boiler installation

Your production generates syngas as a side stream.

Syngas-fired heating installation

You have hydrogen-rich waste gases.

Hydrogen or hydrogen-ready boiler installation

You have liquid waste flows as an alternative fuel.

Installation for liquid waste flows

The availability of alternative fuels varies throughout the production process.

Dual-fuel or multi-fuel system

Which waste flows are valuable?

Every waste flow behaves differently. That is why we examine your waste flow for composition, calorific value and availability to determine whether it is valuable to your production process.

After an additional analysis of your site’s entire energy balance, we know which waste flow will deliver the most:

  • Biogas as a sustainable fuel for steam, hot water or thermal oil installations.
  • Syngas as an alternative energy source for industrial heat processes.
  • Hydrogen-rich waste gases as a low-carbon fuel, where technically feasible.
  • Liquid waste flows as an alternative fuel for adapted heating installations.
  • Dual-fuel systems that flexibly switch between conventional and alternative fuels, depending on their availability.

This creates an energy supply that makes maximum use of the available waste flows, lowers fossil fuel consumption and is tailored to your heat demand and sustainability goals.

BENEFITS

Benefits of valorizing waste flows

Waste flows often still contain a considerable amount of usable energy. By putting them back to work, you increase the efficiency of your production process.

Lower CO2 emissions

Putting waste flows to good use lowers the climate impact of your heat production.

Higher energy efficiency

More available energy is effectively deployed within the production process.

Less dependence on fossil fuels

Alternative fuels (partly) replace natural gas and/or other conventional energy carriers.

Smart use of waste flows

Available waste flows are redeployed as a valuable energy source.

Fully tailor-made

Every installation is designed based on available waste flows, heat demand and business objectives.

Flexible fuel choice

Installations can be tailored to one or more alternative fuels.

“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your specific environment and goals.”

Projects for valorizing waste flows

Callens Vynova stoomketel waterstof 1
Thermal technology Hydrogen-fired Valorizing waste flows +2

Hydrogen fires 60 tons of sustainable steam per hour

Capacity2 x 30 ton/h
Design pressure16 barg
Fuelhydrogen, natural gas, combination
CO2-reduction10.000 ton/year
Beschikbare hoeveelheid H2> 1.200 kg/h
Brouwerij De Brabandere Bavikhove ST biogas 25 T PRJ12427 1
Thermal technology Valorizing waste flows Biogas-fired +2

Steam boiler utilizes brewery’s biogas maximally

Capacity2.5 tons/h
Operating pressure13 barg
Working pressure8 barg
FAQ

Questions? We have the answers.

That will depend on your production process and the properties of the available waste flows. Industrial companies can deploy flows like biogas, syngas and certain liquid waste flows as an alternative fuel for heat production. The Callens Group analyzes the energy value, composition and availability of these flows and determines how they can be integrated into your energy supply safely and efficiently. Discuss the options with our specialists.

In many cases, existing heating installations can be adapted to use alternative fuels in part or in full. Depending on the technical situation, you can opt for a retrofit, a dual-fuel solution to make maximum use of the existing infrastructure, or a completely new installation. Have your installation analyzed by our specialists.

Every waste flow has different properties in terms of composition, calorific value and availability. That’s why the Callens Group always starts with an analysis of your production process, energy demand and existing installations. On that basis, we recommend the technique that combines the highest return with reliable, safe operation.

Yes. The Callens Group carries out waste-flow valorization projects from A to Z. We analyze the available energy streams, design the most suitable installation, handle the engineering, delivery, assembly and commissioning, and also take care of service and maintenance after delivery. That gives you a single partner throughout the entire process and assures you of a solution that is tailored to your production environment — technically, economically and operationally. You can find more information on the various steps in our workflow here.

For a Belgian brewery, the Callens Group installed a new 2.5 t/h steam boiler that uses the biogas from its own water treatment plant as fuel. When the available amount of biogas is insufficient, the installation automatically switches to a combination of biogas and natural gas.
More info: https://www.callens.eu/en/thermal-technology/steam-boilers/steam-boiler-utilizes-brewerys-biogas-maximally

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