Waste Heat Recovery Units for High-Capacity Exhaust Energy Recovery
Industrial processes and energy generation systems release large amounts of thermal energy through exhaust and flue gases. In many facilities, this heat is discharged unused into the atmosphere, resulting in energy loss and increased operating costs.
AURA Waste Heat Recovery Units (WHRU) are designed to capture this unused thermal energy and convert it into usable process heat, improving overall plant efficiency and supporting more sustainable industrial operations.
By recovering and reusing waste heat, industries can significantly reduce fuel consumption, lower CO2 emissions, and optimize energy utilization across processes.
System Properties
- Heat source: Flue gas / exhaust gas / turbine exhaust
- Typical source conditions: Project-specific; high-temperature exhaust streams, up to final approved value
- Output medium: Thermal fluid, steam, hot water, or air depending on system design
- Thermal-fluid temperature:Up to final approved value, e.g. 752°F if confirmed
- Output Range:Up to 20,000 kW if internally approved, otherwise use 15,000 kW consistently
Best Fit When:
- Gas turbines,
- Large exhaust volumes,
- Offshore/process-Energy applications,
- Multi-use heat recovery
Operating Principle of Waste Heat Recovery Units
Industrial turbines and process systems generate exhaust gases with temperatures often ranging between 400°C and 600°C or higher. AURA WHRU systems recover this thermal energy through a controlled heat transfer process.
The process includes:
- Hot exhaust gases are directed into the Waste
- Heat Recovery Unit
- Heat exchangers transfer thermal energy to a secondary medium such as thermal fluid, steam, or water
- The heated medium is supplied back into the industrial process
- Exhaust gas temperatures are reduced in a controlled and energy-efficient manner
Each system is precisely engineered based on:
- Exhaust gas temperature
- Volume flow rate
- Pressure conditions
- Process heating requirements
Your Advantages at a Glance
Significant reduction in operating costs
Lower fuel consumption
Improved overall energy efficiency
Reduced CO2 emissions
Reliable continuous industrial operation
Seamless integration into existing systems
Suitable for large-scale industrial applications
Key Features
- Custom-engineered waste heat recovery solutions
- High-efficiency heat transfer systems
- Integration with existing industrial infrastructure
- Compatible with thermal oil, steam, and hot water systems
- Robust design for continuous operation
- Optimized for maximum energy recovery and efficiency
Applications
- Crude oil processing
- Offshore platforms
- Power generation systems
- Refineries
- Chemical production facilities
A Waste Heat Recovery Units is the right fit when:
- A large, stable exhaust or flue-gas stream is available for heat recovery.
- The heat source originates from gas turbines, combustion systems, industrial furnaces, reciprocating engines, or other high-temperature process exhaust streams.
- The recovered thermal energy must support one or more output media, depending on process requirements.
- Thermal fluid, steam, hot water, or heated air are being evaluated as the preferred heat-transfer medium.
- The project offers significant energy recovery potential, justifying a fully engineered waste heat recovery solution rather than a standard off-the-shelf approach.
- Pressure drop limitations, exhaust gas composition, bypass requirements, control strategy, and plant integration constraints require detailed thermal and mechanical engineering to ensure optimal system performance.
Applications
- Gas Turbine Exhaust Recovery
Recover high-temperature exhaust energy from gas turbines used in power generation, offshore platforms, refineries, and other energy-intensive industrial facilities. - Crude Fluid & Offshore Process Heating
Utilize recovered turbine exhaust heat to generate thermal fluid for crude processing, offshore production facilities, and other indirect process heating applications. - Refinery & Petrochemical Exhaust Recovery
Capture valuable waste heat from large combustion systems, process heaters, furnaces, and high-temperature exhaust streams to improve energy efficiency and reduce operating costs. - Power Generation & Industrial Energy Systems
Recover continuous waste heat from power generation equipment and industrial processes with high operating hours, supporting improved plant efficiency, lower fuel consumption, and reduced emissions.
Why Choose AURA?
40+ years of engineering experience
5,000+ installations worldwide
German engineering precision with global service capability
ASME & National Board certified systems
Tailor-made instead of modular commodity systems
Fully customized systems (no standard products)
In-house manufacturing and quality control
End-to-end support: design, production, commissioning, and service
Responsive engineering support
400+ systems delivered to the US
Frequently Asked Questions
A Waste Heat Recovery Unit captures unused thermal energy from industrial exhaust gases and converts it into usable process heat.
Waste heat recovery is highly effective in continuous industrial operations with stable exhaust gas temperatures and sufficient exhaust gas flow.
Waste heat can be transferred to thermal fluid, steam, or hot water systems depending on process requirements.
Yes. AURA systems can be integrated into many existing industrial heating and energy systems.
By reducing fuel consumption and improving energy utilization, waste heat recovery systems can significantly lower overall emissions.
The recovery potential depends on exhaust gas conditions and process demand. AURA systems are engineered to maximize usable energy recovery.
Yes. Waste heat recovery systems can be combined with thermal energy storage solutions for improved energy management and operational flexibility.