Waste Heat Recovery (WHR) Systems

Waste Heat Recovery (WHR) Systems – From Lost Heat to Clean Value

Many industrial processes discharge high-temperature exhaust gases or hot flue streams that simply vanish into the atmosphere. Our WHR systems capture that waste heat and convert it into useful thermal energy or power—reducing fuel costs, improving plant efficiency, and lowering emissions. Through cleverly engineered solutions across furnaces, ovens, DG exhausts, thermic fluid heaters and more, we enable rapid paybacks and sustainable operations.

Key benefit summary

Flexible WHR Solutions for Your Heat Source

 Choose the system tailored to your exhaust temperature, flow, and thermal load.
Example lineup (replace placeholders with your actual model names/specs):

  • WHR-Furnace Series – For furnace/oven exhausts (500-750 °C).
  • WHR-DG Exhaust Series – For diesel generator sets & engine exhausts (350-500 °C).
  • WHR-Thermic Fluid / Boiler Pre-heater Series – Captures lower‐temperature streams (120-350 °C).
  • WHR-ORC Ready Series – Integrated ORC (Organic Rankine Cycle) ready units for power generation from waste heat.
  • WHR-Low-Grade Series – For adsorption/low-grade recovery (<120 °C).

How Our WHR Systems Work

The system is engineered to capture the otherwise wasted thermal energy from exhaust gases, transfer it via a heat exchanger or recuperator to a usable medium (water, steam, thermic fluid, ORC working fluid), then route the recovered heat for reuse (pre-heating, hot water generation, auxiliary steam) or convert into electricity via an ORC. Opel Energy’s scope covers design, fabrication, installation and commissioning of the full system.

 Key steps (list):

  • Exhaust flue gas passes through heat-recovery unit (e.g., plate/fin heat exchanger, shell-and-tube, recuperator).
  • Heat is transferred to working medium (thermic fluid, water/steam, ORC fluid) and elevated to useful temperature.
  • The recovered heat is then supplied to the process (pre-heating feed, generate hot water, drive adsorption or ORC for electricity).
  • Exhaust gas exits at lower temperature, reducing thermal losses and fuel demand of upstream process.

 Why this matters:

  • Lowered fuel input or reduced electrical load → immediate cost savings.
  • Reduced emissions (CO₂, NOₓ) via lesser fuel burn.
  • Quick ROI via unlocking existing waste energy streams.

Industrial Sectors & Applications

Our WHR solutions are engineered for industrial facilities with sizeable thermal exhausts—from automobile paint ovens, stainless steel melting furnaces, DG set exhausts, thermic fluid heaters to RTO/TT equipment.

  • Automotive & auto components – paint shop oven exhausts, annealing furnaces.
  • Metal & foundry – melting furnaces, heat treatment, annealing lines.
  • Power & utilities – DG exhausts, steam boiler flue gas, process heaters.
  • Chemical & petrochem – ovens, incinerators, RTO exhausts.
  • Large commercial/utility campuses – captive DG sets, central boiler systems.

Typical Use-Cases

  • Boiler/thermic fluid heater pre-heating via furnace/oven exhausts.
  • Steam/hot-water generation from DG exhaust heat. Eg: for 2 × 750 kVA DG sets, 450 °C exhaust, heat recovery ~470,000 kcal/hr, annual savings ~ ₹44 lakh.
  • ORC power generation from high-temperature waste streams.
  • Low-grade heat recovery for adsorption/chiller systems.
  • Conversion of electrical heating to waste‐heat‐based thermal systems.

Why Our WHR Solutions Stand Out

Proven Execution / Rapid ROI / Turnkey Capabilities

  • Proven track record: Over 225 projects executed by Opel Energy, reputed across national & international clients.
  • Turnkey delivery: From free walk‐through audits, detailed engineering, manufacturing, installation, commissioning—and service support.
  • Wide temperature & capacity range: Handles 120 °C to 750 °C and capacities 0.3 million kcal/hr to 30 million kcal/hr.
  • Quick payback and low risk: Simple, implementable solutions with lowest pay-back periods.
  • Strong client base & recognition: Corporate clients include Tata, Honda, Volkswagen, RAK Ceramics, etc.

Unlock Your Heat Recovery Potential Today

Want to turn your wasted heat into savings or revenue? Contact us for a free on-site audit and customised WHR proposal—with estimated savings, payback and footprint assessment.