Thermocline technology revolutionises energy recovery
At the heart of this project is an advanced thermocline storage system - a breakthrough in waste heat recovery. Unlike conventional systems that require separate tanks for hot and cold water, the thermocline tank allows to store both heat and cold energy efficiently

The energy storage tank operates by stratifying hot and cold water within a single reservoir:

• During cooling cycles, heat from industrial processes is absorbed by water, which then returns to the tank’s upper part, increasing stored thermal energy.
• During heating cycles, the stored heat is extracted from the upper part and transferred to the next batch, while cooler water settles at the bottom, ready to absorb new waste heat in the next cycle.

This closed-loop system enables continuous energy recovery, reducing reliance on external heating or cooling sources and significantly cutting energy costs. The entire process is monitored and optimised using Track Advance®, Boccard’s digital supervision tool, which allows real-time tracking of energy efficiency and system performance.

Heat exchangers central to success
Boccard has built a pilot plant to demonstrate this innovative solution. To ensure efficient heat transfer within the pilot plant, Kelvion supplied two brazed plate heat exchangers from its GBS range – the GBS 240H-20 and GBS 240H-10 models. These exchangers were chosen for their compact design, robust stainless-steel construction, and exceptional thermal performance.

They operate effectively over a wide temperature range, making them ideal for water-to-water applications in energy recovery systems. 

Challenges and solutions
One of the key challenges was to meet Boccard's tight delivery schedule. Drawing on a partnership spanning more than two decades, Kelvion's plate heat exchanger team in Wilchwitz ensured timely delivery without compromising on quality. 

"Working with Kelvion on this project was a remarkable experience,” says Marine Pasco, process engineer at Boccard Life Solutions. “Their commitment to quality and timely delivery played a pivotal role in the successful realisation of our energy recovery system".

A scalable future
The initial phase of this project has proven the effectiveness of thermocline-based heat recovery, reducing energy consumption and supporting industrial decarbonisation. Boccard’s next step is to scale up with an industrial partner to implement this solution on a larger scale.

Boccard's process engineering expertise and Kelvion's cutting-edge thermal solutions are paving the way for a more sustainable and low-carbon industrial future.