Reducing enegy, materials use and waste

DSF Refractories operates a large refractory manufacturing site at Friden in Derbyshire. The company was keen to reduce energy use, generate renewable energy, and reduce materials use and waste. 

About DSF Refractories

DSF Refractories operates a large refractory manufacturing site at Friden in Derbyshire. The business has extremely high electricity, natural gas, and gas oil consumption, resulting in carbon emissions of almost 10,000 tonnes per year (2020).

Why did they engage with DE-Carbonise

The company was keen to reduce energy use, generate renewable energy, and reduce materials use and waste.

During a review, it was established that two old and inefficient fixed speed compressors from the 1960s were being used (one in use and one as a spare). The business operates oil-fired furnaces and is keen to move either to gas (cleaner fuel) or alternative cleaner fuel sources. Fuel use could be reduced by recovering waste heat from the furnaces to use to either generate electricity or heat which could be used in other process areas.

What has been the impact of working with DE-Carbonise?

Monitoring of the compressors indicated that a minimum of 15kW could be saved per hour and, as the compressors are used 24 hours, 7 days per week, this would mean substantial savings for the SME. The business was supported with a DE-Carbonise grant to replace the 90kW compressor with a better-sized 75kW variable speed version. The £20,000 grant also supported a heat recovery system that takes waste heat from the compressor to provide heating in one of the office areas in the factory.

The compressor replacement and heat recovery save at least 100 tonnes of carbon per year and will give the company a better-regulated supply of compressed air and reduce energy costs. Recovered heat from the compressor system is also being used to heat office space, resulting in reduced heating costs and associated carbon emissions.

Impact data

About DE-Carbonise

DE-Carbonise is a three year collaboration between the University of Derby, Derby City Council and Derbyshire County Council, which started in November 2019. The collaboration is funded by the European Regional Development Fund (ERDF) and follows on from the successful D2 Energy Efficiency/Low Carbon project.

Logo's for European Union Regional Development Fun, Derby City Council, Derbyshire County Council and Midlands Engine.

Get in contact with us

To find out about current support available for your business in reducing your environmental impact, or your journey to net-zero. Please get in contact with our business gateway team.

Call usEmail usMake an enquiry