19NOVEMBER 2025Alexander Pavlov, General Manager - Compressor Technique at Atlas Copco, in an interaction with Thiruamuthan, Correspondent at Industry Outlook, shares how compressor heat recovery and advanced thermal solutions are shaping sustainable manufacturing and driving India's journey toward net-zero industrial zones. Alexander Pavlov, a seasoned business leader with over 25 years of global experience, specializes in compressor systems, industrial automation, and customer-centric service operations. He brings deep expertise in strategic leadership, operational efficiency, and sustainable technology integration across diverse international markets.INDUSTRY INSIGHTSHOW COMPRESSOR HEAT RECOVERY DRIVES PLANT-WIDE ENERGY EFFICIENCYWith Indian manufacturers under pressure to meet energy efficiency targets, how are heat recovery-enabled compressors being integrated into existing plant infrastructures to reduce system-level losses?As Indian manufacturers face stringent energy efficiency mandates, heat recovery-enabled compressors are becoming crucial for reducing system-level losses. The optimal configuration places steam boilers adjacent to compressor rooms, enabling direct hot water recovery from compressor waste heat. Oil-free screw compressor technology excels in this application, generating high-grade heat up to 90°C. This recovered hot water can be directly fed to boiler systems, creating immediate energy savings. A key efficiency principle applies: every 6°C increase in boiler feed water temperature yields 1 percent efficiency improvement, making compressor waste heat recovery highly valuable.Beyond steam generation, numerous industrial processes require hot water, making compressors dual-purpose assets--air suppliers and heat sources. Without heat recovery, this thermal energy is entirely wasted, representing a significant efficiency loss. While heat recovery technology is readily available as off-the-shelf solutions, integration challenges persist. Long-distance piping requires proper insulation to prevent heat loss during transport. Engineering complexity and installation requirements can be substantial, demanding careful planning and investment.However, the benefits far outweigh these challenges. Manufacturers should prioritize heat recovery projects, recognizing that compressors represent untapped thermal resources. Strategic integration of these systems not only meets regulatory requirements but delivers substantial operational cost savings through improved overall plant efficiency.As legacy infrastructure limits thermal integration, what are the main barriers to implementing compressor heat recovery in India's older steel and cement plants?A major barrier to the implementation of compressor heat recovery in India in old plants of the steel and cement industry is related to both technical constraints and operational factors regarding legacy infrastructure. The oil-injected, air-cooled compressor systems that are mainly used in these facilities have limited heat recovery capabilities than oil-free screw compressors, which produce a greater recovery of temperatures as high as Alexander Pavlov, General Manager - Compressor Technique, Atlas CopcoAlexander Pavlov, General Manager - Compressor Technique
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