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Waste Heat Recovery Units
Heatxforce provides expert specification, installation, commissioning, repair and maintenance services for Waste Heat Recovery Units (WHRUs) across commercial buildings, manufacturing facilities, energy centres and industrial process plants.
Waste heat recovery is one of the most effective ways to improve energy efficiency, reduce operating costs and lower carbon emissions. By capturing heat that would otherwise be discharged to atmosphere and reusing it elsewhere within the process, Waste Heat Recovery Units significantly improve overall system performance while supporting sustainability and net-zero objectives.
Whether recovering heat from boilers, CHP systems, compressors, furnaces, refrigeration plant or industrial exhaust processes, Heatxforce delivers complete engineering support throughout the lifecycle of every waste heat recovery installation.
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Waste Heat Recovery Units Explained
What is a Waste Heat Recovery Unit?
A Waste Heat Recovery Unit (WHRU) is a heat exchanger system designed to capture thermal energy that would normally be wasted through exhaust gases, process cooling water or other industrial heat sources.
Instead of allowing valuable energy to escape into the atmosphere, a WHRU transfers that heat into another process where it can be reused for heating water, generating steam, pre-heating combustion air or supporting industrial manufacturing processes.
Recovering this otherwise wasted energy reduces fuel consumption, lowers operating costs and improves the overall efficiency of mechanical plant.
Waste Heat Recovery Units are widely used across manufacturing, power generation, food processing, pharmaceutical production, district heating networks and commercial buildings where large quantities of recoverable heat are available.
What is a Waste Heat Recovery Unit Used For?
Waste Heat Recovery Units are installed wherever surplus heat can be captured and reused.
Typical applications include:
- Boiler flue gas heat recovery
- CHP engine exhaust recovery
- Industrial furnace exhaust systems
- Compressor heat recovery
- Refrigeration heat recovery
- Process cooling systems
- Kilns and ovens
- Chemical manufacturing
- Food processing
- Pharmaceutical production
- District heating schemes
- Renewable energy systems
By recovering waste heat, organisations can reduce fuel consumption while increasing overall plant efficiency.
Why Choose Our Waste Heat Recovery Technology?
Heatxforce supplies and supports high-efficiency waste heat recovery systems engineered to maximise energy savings while integrating seamlessly with existing plant.
Reduced Energy Costs
Recovering thermal energy that would otherwise be wasted significantly reduces fuel consumption and lowers operating expenditure.
Lower Carbon Emissions
Reducing fuel demand directly lowers greenhouse gas emissions, helping organisations achieve sustainability targets and comply with environmental legislation.
Improved Plant Efficiency
Waste Heat Recovery Units increase the overall efficiency of heating and cooling systems by making better use of the energy already being generated.
Flexible Integration
Heatxforce designs WHRUs for integration with:
- Industrial boilers
- CHP systems
- Steam generators
- Air compressors
- Refrigeration systems
- Heat pumps
- Industrial ovens
- Process exhaust systems
Every system is engineered to suit the available heat source and the required heat demand.
Reliable Long-Term Performance
Robust construction, intelligent controls and carefully selected materials provide dependable operation while minimising maintenance requirements.
Where can waste heat be recovered from?
Common sources include boiler flue gases, CHP engines, compressors, furnaces, ovens, refrigeration condensers and industrial process exhausts.
How much energy can be recovered?
The amount depends on the heat source and operating conditions, but well-designed systems can recover a significant proportion of energy that would otherwise be lost, delivering substantial fuel savings.
Is waste heat recovery suitable for existing buildings?
Yes. Many existing boiler houses, plant rooms and manufacturing facilities can be retrofitted with waste heat recovery systems, often without major disruption.
Can Heatxforce integrate waste heat recovery with existing plant?
Yes. Our engineers specialise in designing and integrating Waste Heat Recovery Units with existing boilers, CHP systems, refrigeration plant and process equipment.
Inside the Waste Heat Recovery Unit
How It Works
Every industrial process generates waste heat. Traditionally, much of this heat is lost through exhaust gases, cooling systems or process discharge.
A Waste Heat Recovery Unit captures this thermal energy by passing the hot exhaust stream through a heat exchanger.
As the hot gases flow across the heat transfer surfaces, energy is transferred into a secondary fluid such as water, glycol or process air.
The recovered heat can then be reused to:
- Heat buildings
- Produce domestic hot water
- Generate steam
- Pre-heat boiler feedwater
- Warm combustion air
- Support industrial manufacturing processes
- Feed district heating systems
Recovering energy in this way significantly improves overall plant efficiency while reducing operational costs.
Common Waste Heat Sources
Heatxforce designs recovery systems for:
- Industrial Boilers - Recovering heat from boiler flue gases before discharge.
- Combined Heat & Power (CHP) - Capturing engine jacket water and exhaust heat for building heating or hot water production.
- Air Compressors - Recovering waste heat generated during compression to provide free hot water or space heating.
- Refrigeration Systems - Recovering condenser heat for water heating or process applications.
- Manufacturing Processes - Capturing heat from ovens, kilns, dryers and furnaces to improve process efficiency.
Types of Waste Heat Recovery Units
Depending on the application, Heatxforce supplies:
- Plate Heat Exchanger
- Recovery Systems
- Shell & Tube Recovery Units
- Economisers
- Air-to-Air Heat Recovery Systems
- Air-to-Water Heat Recovery Systems
- Thermal Oil Recovery Units
- Condensing Flue Gas Heat Recovery Systems
Each system is selected according to operating temperatures, available heat source, pressure losses and required energy recovery.
Construction and Materials
The performance and longevity of a Waste Heat Recovery Unit depend on selecting materials that can withstand elevated temperatures, thermal cycling and the characteristics of the waste gas or process fluid. Heatxforce specifies every unit to suit the operating environment, ensuring reliable heat recovery and long service life.
Heat Transfer Surfaces
Waste Heat Recovery Units may incorporate:
- Stainless Steel 304
- Stainless Steel 316L
- Carbon Steel
- Duplex Stainless Steel
- Titanium (for highly corrosive environments)
- Copper and Copper Alloys (specialist applications)
Material selection is based on operating temperatures, corrosion potential, exhaust gas composition and process fluid compatibility.
Heat Exchanger Technologies
Depending on the application, Waste Heat Recovery Units may utilise:
- Plate Heat Exchangers
- Brazed Plate Heat Exchangers
- Gasketed Plate Heat Exchangers
- Shell & Tube Heat Exchangers
- Finned Tube Heat Exchangers
- Economiser Coils
- Air-to-Air Heat Exchangers
Each technology is selected to maximise heat recovery while minimising pressure drop and maintenance requirements.
Structural Construction
Frame assemblies are manufactured using heavy-duty steel sections with corrosion-resistant coatings suitable for indoor and outdoor installations.
Options include:
- Hot-dip galvanised steel
- Powder-coated carbon steel
- Stainless steel construction
- High-temperature industrial coatings
All units are designed for easy access to facilitate inspection, cleaning and maintenance.
Control Systems
Modern Waste Heat Recovery Units incorporate intelligent controls that continuously monitor:
- Exhaust gas temperature
- Flow rates
- Water temperatures
- Pressure differentials
- Pump operation
- Fan speeds (where applicable)
- Heat recovery efficiency
Integration with Building Management Systems (BMS) enables real-time performance monitoring, alarm reporting and energy optimisation.
Technical Specifications
| Operating Temperature | Up to 650°C* |
| Operating Pressure | Up to 25 bar |
| Heat Recovery Capacity | 20 kW – 20 MW+ |
| Heat Transfer Media | Water, Glycol, Thermal Oil, Air |
| Construction | Plate, Shell & Tube, Finned Tube |
| Construction | Plate, Shell & Tube, Brazed, Welded |
| Installation | Indoor & Outdoor |
*Higher temperatures are available for specialist industrial applications.
Typical Heat Sources
Suitable for recovering heat from:
- Boiler flue gases
- CHP engine exhausts
- Air compressors
- Industrial ovens
- Kilns
- Furnaces
- Refrigeration condensers
- Process cooling systems
- Dryers
- Gas turbines
Key Benefits
Lower Fuel Consumption
Recovering otherwise wasted heat reduces the energy required from primary heating equipment, lowering fuel usage and operating costs.
Reduced Carbon Emissions
Improved energy efficiency helps organisations reduce CO₂ emissions and support environmental compliance and sustainability objectives.
Improved Plant Efficiency
Waste Heat Recovery Units increase the overall efficiency of heating and cooling systems by making productive use of energy that would otherwise be lost.
Rapid Return on Investment
Many installations achieve attractive payback periods through reduced fuel bills and lower energy consumption, particularly in continuous-process industries.
Future-Proof Energy Infrastructure
Waste heat recovery supports wider decarbonisation strategies and can be integrated with heat pumps, district heating schemes and renewable energy systems to improve overall system performance.
Trusted Across Critical Heating & Cooling Infrastructure
Manufacturing
- Food processing
- Beverage production
- Plastics manufacturing
- Metal processing
- Paper mills
Energy & Utilities
- CHP plants
- District heating networks
- Boiler houses
- Energy centres
- Power generation
Commercial Buildings
- Hotels
- Hospitals
- Universities
- Leisure centres
- Large office developments
Pharmaceutical & Chemical
- Process heating
- Steam generation
- Reactor cooling
- Laboratory facilities
Marine & Offshore
- Engine exhaust heat recovery
- Accommodation heating
- Hot water production
- Process systems
Data Centres
- Heat recovery for office heating
- Domestic hot water generation
- Heat network integration
- Energy reuse systems
Waste Heat Recovery Unit Services
Specification & Design
Effective waste heat recovery begins with understanding where energy is being lost and how it can be reused.
Heatxforce carries out comprehensive thermal surveys and engineering assessments, evaluating:
- Waste heat source temperatures
- Exhaust gas flow rates
- Process operating profiles
- Available heat demand
- Pressure losses
- Existing plant integration
- Energy savings potential
- Future expansion requirements
Using detailed thermal calculations, our engineers design bespoke recovery systems that maximise energy capture while maintaining reliable plant operation.
Installation & Commissioning
Heatxforce delivers complete installation and commissioning services including:
- Mechanical installation
- Pipework integration
- Heat exchanger installation
- Pump installation
- Electrical connections
- Control system programming
- Pressure testing
- Functional testing
- Performance verification
- Operator training
Every installation is commissioned to ensure optimum thermal performance, safety and long-term reliability.
Overhaul & Repair
Over time, heat recovery equipment can experience fouling, corrosion, scaling or reduced heat transfer performance.
Our refurbishment services include:
- Heat exchanger cleaning
- Tube and plate replacement
- Gasket replacement
- Leak detection and repair
- Corrosion treatment
- Pump refurbishment
- Valve replacement
- Control system upgrades
- Performance testing
Where appropriate, Heatxforce can refurbish existing Waste Heat Recovery Units to restore efficiency and extend equipment life without the cost of full replacement.
Maintenance & Service
Routine preventative maintenance is essential to maximise heat recovery efficiency and ensure reliable long-term operation.
Our maintenance programmes include:
- Heat exchanger inspection
- Cleaning of heat transfer surfaces
- Pump and valve testing
- Water quality monitoring
- Pressure and temperature checks
- Control system calibration
- Thermal imaging surveys
- Performance monitoring
- Planned component replacement
- Annual efficiency reviews
Regular servicing helps reduce operating costs, improve reliability and maximise energy savings throughout the equipment lifecycle.
Why Choose Heatxforce?
Heatxforce provides complete lifecycle support for Waste Heat Recovery Units, from feasibility studies and thermal modelling through to installation, commissioning, refurbishment and long-term maintenance.
Our experienced engineers understand the challenges of improving energy efficiency without compromising operational reliability. By combining practical engineering expertise with innovative heat recovery technologies, we help customers reduce fuel costs, lower carbon emissions and maximise the value of existing plant.
Whether you're looking to improve the efficiency of a boiler house, recover heat from industrial processes or support a wider decarbonisation strategy, Heatxforce has the expertise to design and deliver a solution tailored to your operational requirements.
Speak to Heatxforce About Waste Heat Recovery
Recovering wasted energy is one of the most effective ways to reduce operating costs and improve environmental performance. Whether you're planning a new installation, upgrading existing equipment or looking to optimise your current system, Heatxforce can help.
Our specialists provide expert advice on specification, design, installation and ongoing maintenance, ensuring your Waste Heat Recovery Unit delivers maximum efficiency, long-term reliability and measurable energy savings.
Contact Heatxforce today to discuss your waste heat recovery requirements and discover how we can help you improve the performance of your heating and cooling infrastructure.
Codes, Standards & Certifications
Heatxforce build pressure equipment in accordance with PD5500 and ASME VIII Pressure vessel codes whilst conforming to the European Pressure Equipment Directive (PED) and UKCA Pressure Equipment Safety Regulations (PESR), which are mandatory inspection requirements applicable to pressure vessels and systems.
Our welding procedures are in accordance with ISO 15614-1 and ASME IX.
Welder qualifications are in accordance with ISO 9606-1 and ASME IX.
All of our welding related qualifications are certified by TUV Nord.
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