ENERPOWER
Waste Heat Recovery Boiler
The ENERPOWER series is a revolutionary heating solution designed to capture and repurpose high-temperature exhaust gases from Diesel Generator (DG) sets and industrial engines. By converting waste heat into high-pressure steam or hot water, ENERPOWER allows industries to generate process energy virtually for free, significantly reducing fuel costs and carbon emissions.
Engineered for seamless integration, each ENERPOWER boiler is custom-sized to match specific engine outputs, providing a reliable, user-friendly, and low-maintenance path to industrial energy efficiency.
Operating Range
- Capacity – 500 KG to 3000 KG
- Fuel- Waste gas from DG
- Pressure- 10.54 Kg/cm² to 21 Kg/cm²
High-Efficiency Energy Recovery
The ENERPOWER system acts as a high-performance heat exchanger between your engine exhaust and your process line:
- Engine-Specific Engineering: Every unit is factory-insulated and designed to match the specific back-pressure requirements of your engine, ensuring no loss in engine performance.
- Multi-Engine Integration: Our sophisticated design allows multiple engine exhausts to be connected to a single ENERPOWER unit, centralizing your energy recovery.
- Virtually Free Energy: By utilizing heat that would otherwise be vented into the atmosphere, you can generate steam or hot water without consuming additional fossil fuels.
- Rapid ROI: Due to the massive savings on primary fuel (Coal, Oil, or Gas), most ENERPOWER installations offer an exceptionally fast return on investment.
Key Features
- Modular Design: Tailored to fit various DG set sizes and space constraints.
- Heavy-Duty Insulation: Factory-applied high-density insulation minimizes radiant heat loss.
- Automated Safety: Equipped with bypass dampers and safety valves to protect both the boiler and the engine during fluctuating loads.
- Ease of Maintenance: Features accessible inspection manholes and cleaning ports to ensure the heat transfer surfaces remain efficient.
Industry Applications
The ENERPOWER system is ideal for facilities that operate DG sets for primary or backup power and require constant process heat:
- Textile & Process Houses: For fabric dyeing and finishing using recovered steam.
- Pharmaceuticals: For sterilization and climate control systems.
- Chemical Plants: To maintain temperatures in reaction vessels and storage tanks.
- Food & Beverages: For pasteurization and cleaning-in-place (CIP) cycles.
- Hotels & Hospitals: To provide consistent hot water for laundry and sanitation.
| Specification | Unit | EP-05 | EP-10 | EP-15 | EP-20 | EP-30 | ||||
|---|---|---|---|---|---|---|---|---|---|---|
| General | ||||||||||
| Steam Output From & at 100°C | Kg/hr | 500 | 1000 | 1500 | 2000 | 3000 | ||||
| Working Pressure | Kg/CM² | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | ||||
| Steam Temoerature | °C | 183 | 183 | 183 | 183 | 183 | ||||
| No's Passes | No's | Single Pass | ||||||||
| Steam Outlet | MM | 40 | 50 | 80 | 80 | 100 | ||||
| Type of Fuel: Waste gas from DG | ||||||||||
| Boiler efficiency with HRU | ||||||||||
| On Waste Gas | % | 70 +/-2 | 70 +/-2 | 70 +/-2 | 70 +/-2 | 70 +/-2 | ||||
| Flue gas | ||||||||||
| Inlet Gas Temprature | °C | 450 | 450 | 450 | 450 | 450 | ||||
| Outlet Gas Temprature | °C | 150 | 150 | 150 | 150 | 150 | ||||
| Gas flow | Kg/hr | 2700 | 5400 | 8100 | 10800 | 16200 | ||||
| Electrical Load | ||||||||||
| Feed Water Pump | H.P. | 2.00 | 2.00 | 3.00 | 3.00 | 4.00 | ||||
| 3 Way Divertor Damper | H.P. | 1.00 | 1.00 | 2.00 | 2.00 | 3.00 | ||||
| Total Electric Load | H.P. | 3.00 | 3.00 | 5.00 | 5.00 | 7.00 | ||||
| NOTE: In view of constant endeavors to improve our products, we reserve the right to alter or change above specifications without prior notice. | ||||||||||
Frequently Asked Questions (FAQ) about Waste Heat Recovery Boiler
Depending on the exhaust temperature and mass flow of your engine, an ENERPOWER unit can often fulfill 100% of your low-to-medium steam requirements during engine operation, effectively reducing your primary boiler's fuel consumption to zero during those hours.
No. Our engineers design the ENERPOWER specifically to match the allowable back-pressure limits of your engine manufacturer. This ensures that the engine operates at peak efficiency while the boiler captures the waste heat.
Yes. We offer custom designs that allow the exhaust from multiple DG sets to be manifolded into a single waste heat recovery unit, maximizing energy collection in a compact space.
The system is equipped with an automated bypass damper. If the steam demand is met or the boiler reaches its set pressure, the exhaust gases are safely diverted away from the boiler directly to the stack.
Not at all. Since the "fuel" is clean exhaust gas, there is no soot or ash buildup like in coal or oil boilers. Occasional inspection of the heat transfer tubes is all that is typically required to maintain high efficiency.