Turn Lost Energy into Measurable Operational Value
Industrial processes can lose up to 20–50% of their energy input through exhaust gases and hot process streams. AURA Waste Heat Recovery Systems capture this untapped energy and convert it into usable process heat, improving overall efficiency and reducing operating costs.
Waste Heat Recovery Unit
Waste Heat Thermal Fluid Heating System
Waste Heat Hot Water Heating System
Why Choose AURA?
Waste Heat Recovery Technologies
Three Technologies. One Objective.
Waste heat recovery captures and reuses thermal energy that would otherwise be released to the atmosphere, improving process efficiency and reducing fuel consumption without additional energy input.
Typical heat sources include:
- Flue gas from burners or boilers
- Gas turbine exhaust
- Furnaces and kilns
- Dryers and ovens
- Process exhaust air
Instead of releasing this energy into the environment, waste heat recovery (WHR) systems convert it into usable heat for:
- Process heating
- Thermal fluid systems
- Steam or hot water generation
- Air preheating
Waste Heat Recovery Unit (WHRU)
High-capacity recovery system for turbine exhaust, flue gas, or large industrial waste–heat streams.
Heat source: flue gas / exhaust gas
Possible output medium: thermal fluid, steam, hot water, or air, depending on design
Temperature range: based on exhaust source and target medium
Output range: up to 20,000 kW, if internally approved
Best Fit When:
- Large exhaust volumes
- Gas turbines
- High-value heat recovery
- Multi-use heat integration
Waste Heat Thermal Fluid Heating System
Flue-gas–heated thermal-fluid system for high-temperature process heat.
Heat source: flue gas / exhaust gas
Possible output medium: thermal fluid
Thermal fluid temperature: up to 400°C / 752°F, if final approved
Output range: up to 15,000 kW
Best Fit When:
- Existing thermal-fluid loops
- High-temperature process heat
- Fuel-consumption reduction
Waste Heat Hot Water Heating System
Flue-gas-heated hot-water system for process or facility heating.
Heat source: flue gas / exhaust gas
Possible output medium: hot water
Water temperature: 40°C–230°C / 104°F–446°F, if final approved
Output range: up to 3,000 kW, if using the brochure value
Best Fit When:
- Hot water demand
- Process preheating
- Facility heat
- Moderate-temperature applications
When you require?
I have a large, valuable exhaust stream and need a high-capacity, engineered recovery unit
I want to recover exhaust heat into a thermal-oil loop for high-temperature process heat.
I have hot-water or pressurized-hot water demand and want to use exhaust energy for process, utility, or facility heat.
How It Works?
AURA waste heat recovery systems are engineered to capture unused thermal energy and convert it into valuable process heat. By reintegrating recovered energy into existing operations, they improve efficiency, reduce fuel consumption, and support long-term sustainability goals.
- Heat Source Identification
Recoverable energy is captured from exhaust gas, flue gas, turbine exhaust, furnace exhaust, engine exhaust, or hot process air streams. - Source Characterization
Key parameters such as temperature profile, flow rate, pressure, gas composition, contaminants, operating hours, and allowable pressure drop are evaluated to determine recovery potential. - Heat Sink Definition
A suitable application for the recovered energy is established, including thermal fluid, hot water, steam generation, air heating, preheating, drying, or other process requirements. - Engineered Heat Transfer
Heat is transferred through a custom-designed heat exchanger selected based on gas conditions, target medium, fouling characteristics, material requirements, and maintenance accessibility. - Process Heat Reintegration
Recovered energy is reintegrated into the plant to supplement process heating, reduce primary fuel consumption, or support additional thermal loads. - Control and Monitoring
Temperature, flow, bypass control, pressure drop, and safety functions are continuously monitored and managed to ensure stable, efficient, and reliable system operation.
Technical Benefits & Lifecycle Value
The business case for waste heat recovery is influenced by exhaust temperature, gas flow rate, operating hours, fuel costs, process heat demand, retrofit complexity, maintenance requirements, and payback objectives. AURA conducts a detailed evaluation of these factors to recommend the most technically and economically viable waste heat recovery solution.
- Utilizes existing exhaust gas energy
- Improves energy efficiency
- Reduces fuel consumption
- Lowers operating costs
- Reduces CO₂ emissions
- Supports sustainability goals
- Generates value from waste heat
- Attractive payback potential
- Enhances plant performance
- Improves ROI
- Reduces energy dependency
- Supports environmental compliance
Applications
- Turbine & Engine Exhaust Recovery
Recover heat from gas turbines, engines, and power generation systems. - Furnace & Combustion Exhaust Recovery
Capture waste heat from furnaces, kilns, ovens, dryers, and combustion processes. - Thermal-fluid Process Heating
Use recovered energy to support thermal-fluid heating systems. - Hot Water Generation
Produce hot water for process, utility, and facility heating applications. - Dryer & Oven Heat Support
Improve efficiency in drying and curing operations across multiple industries. - Chemical & Process Plant Integration
Recover heat for reactors, process vessels, refineries, and chemical plants. - Crude fluid Processing & Offshore Applications
Utilize turbine exhaust heat for thermal-fluid heating in offshore and energy facilities.
Key Features
- Custom-engineered systems tailored to process conditions
- High-efficiency heat exchangers for optimal energy transfer
- Integration with existing heating systems (electric or fired)
- Designed for continuous industrial operation
- Compatible with thermal oil, steam, and hot water systems
- Robust construction for long-term durability
- Engineered for minimal energy loss and maximum recovery
Applications
- Chemicals
- Plastics
- Nonwovens
- Pulp & Paper
- Food Industry
- Energy Transition