Regulatory pressures are rising: Is your thermal processing system future-ready?
Why plate-type heat exchangers are well suited to address rising challenges
Author: Jamie Zachary
In today’s industrial landscape, the intersection of operational excellence and environmental responsibility is a reality that manufacturers across all sectors must address.
Regulators worldwide are implementing more stringent environmental regulations covering energy efficiency, emissions control and heat recovery. This is driving operators to rethink how they invest and innovate to stay compliant and competitive.
Whether it’s fertilizer production, chemicals manufacturing, food processing or minerals refinement, the question is becoming clear: Is your equipment built to meet the future?
The regulatory shift: What you need to know
New and emerging regulations are putting industrial process equipment under the microscope. The European Union’s Industrial Emissions Directive, Canada's Clean Fuel Regulations, and the U.S. EPA’s focus on industrial decarbonization are have their sights set on reducing greenhouse gas emissions, improving air quality and encouraging the adoption of energy-efficient technologies. Every stage of the industrial process is facing increased scrutiny.
The heat and cooling stages are no exception. Both are essential in transforming raw materials into high-quality finished product, yet they have traditionally been associated with high energy use and particulate emissions. For many manufacturers, especially those still relying on direct-contact systems such as rotary drums or fluid beds, this raises serious compliance concerns.
Why legacy systems may be falling behind
Older thermal systems are often centered around combustion-based heat sources and direct-contact methods, which can:
- · Require high energy inputs to reach desired product temperatures.
- · Generate higher emissions of nitrogen oxide, carbon dioxide and particulate matter.
- · Create uneven temperature distribution that can compromise product quality.
These systems were designed for an era when energy costs were lower and environmental regulations less stringent. Today, their limitations are now more pronounced, both in terms of performance and compliance risk.
“When evaluating existing thermal equipment, the question shouldn’t just be, ‘Is it still working?’ but, ‘Is it working efficiently, cleanly and in line with where the industry is headed?’” says Warren Chung, Regional Director, Asia-Pacific for Solex Thermal Science.
“The gap between functional and future-ready is where many facilities find themselves today. It’s also where innovation in heat exchange technology can make a real difference.”
A smarter path forward with indirect heat exchange
Plate-type moving bed heat exchangers (MBHEs) address both regulatory and operational challenges in one efficient system. Unlike conventional technologies, plate-type MBHEs employ indirect contact heat transfer principles to heat or cool bulk solids materials without direct exposure to air or combustion gases.
This approach results in:
- · Reduced emissions: The absence of direct contact between the bulk solid and heat transfer medium mitigates opportunities for dust or particulates to escape into the environment.
- · Improved energy efficiency: Plate-type MBHEs can reduce energy inputs by up to 90%. They also support low-grade heat recovery and can be easily integrated into waste heat utilization systems.
- · Greater product integrity: Uniform temperature profiles prevent hotspots and preserve product quality.
At Solex Thermal Science, our indirect heat exchange solutions are engineered for free-flowing granular materials such as fertilizers, sugar, sand and oilseeds. The vertical, gravity-fed design of our plate-type MBHEs maximizes heat transfer efficiency while minimizing the equipment’s carbon footprint — making compliance easier to attain without sacrificing throughput.
Future-proofing your operations
The transition to a future-ready system is not simply a matter of regulatory compliance. It is also an issue of operational resilience. With the world transitioning toward decarbonization and circular economies, industrial plants must remain agile in the face of evolving requirements and stakeholder expectations.
“Our customers are changing how they value the thermal energy wasted in their product processing,” says Scott Harris, Regional Director, Americas, for Solex Thermal Science.
“It’s no longer just about delivering a quality product. It’s about consciously considering how to recover waste energy –which aligns with their desire for sustainability and being ready for tomorrow’s regulatory demands and ever-changing energy costs.”
Curious about how a Solex moving bed heat exchanger can help bring your operations into compliance with existing and upcoming regulations? Visit our Industries Page to find out how we're helping companies like yours in a wide range of applications — from chemicals and fertilizer to food products and minerals.
Or, contact us today to speak with one of our heat exchange experts. We’ll help you find solutions that not only solve today’s challenges, but are also ready for tomorrow’s.
This entry was tagged Energy, Heating, Cooling, and last updated on 2025-6-3