Waste Heat Recovery
Recover exhaust heat and convert wasted energy into usable process value.
Capture lost exhaust heat and convert it into usable process value.
Waste heat is easy to overlook because the furnace still reaches temperature.
The flue gases exit hot. The stack temperature is high. Combustion air enters cold. The recuperator installed years ago is now underperforming or bypassed entirely. And every hour the plant operates, a portion of the fuel cost goes straight to atmosphere.
In many fuel-fired systems, between 35 and 42% of the heat input to the furnace leaves through the flue gases. That heat has already been paid for.
Fuel & Energy
High stack temperature
High fuel consumption with no obvious single cause
High emissions linked to avoidable fuel use
Poor overall thermal efficiency
Recovery Equipment
Combustion air entering cold — no preheating in place
Existing recuperator underperforming or no longer functional
Ageing heat recovery equipment that has not been assessed in years
No waste heat reuse strategy
Encon identifies where heat is leaving the process and whether it can be recovered economically.
The assessment looks at flue gas temperature, exhaust volume, operating cycle, fuel type, process temperature and the existing heat recovery equipment — or the absence of it. From that picture, Encon engineers the right recovery solution for the application.
Depending on what the plant needs, the solution may involve recuperators, regenerative burners, self-recuperative burners, hot air generators, flue gas routing changes or a combination of these.
Recuperators
Encon recuperators preheat combustion air from escaping flue gases to temperatures of around 400°C, recovering heat from flue gases that typically exit at 600–950°C. This results in fuel savings of around 12–15%, with a payback period of approximately 5–7 months.
REGEN® Regenerative Burners
Recover furnace exhaust heat and preheat combustion air to temperatures close to the process temperature, reducing energy consumption by up to 50% where recuperators are not present and up to 35% where recuperators are already installed.
Self Recuperative Burners
Burners with a built-in recuperator that use flue gas heat to preheat combustion air, reducing fuel consumption and greenhouse gas emissions by up to 30%.
Hot Air Generators
Convert waste heat from flue gases into usable hot air for process heating, drying or preheating applications.
System redesign
Where existing heat recovery equipment has degraded or where flue gas routing does not allow effective recovery, Encon can redesign the system around the actual operating conditions.
Built around the exhaust conditions, process temperature and available space.
Encon's waste heat recovery solutions run from recuperators on existing furnaces to fully integrated recovery systems on new installations.
Recovery Equipment
Recuperators
Waste Heat Recovery Systems
Hot Air Generators
Recovery Burners
REGEN® Burners
Self Recuperative Burners
Combustion & Controls
Combustion Equipment
Automation & Controls
Heat recovery turns a loss into a saving.
Every degree of exhaust heat captured and returned to the process reduces the fuel required to maintain it.
Fuel & Energy
Lower fuel consumption
Heat recovered from the flue is heat the burner no longer has to produce.
Reduced flue gas losses
In many fuel-fired systems 35–42% of heat input leaves through the flue; recovery reclaims part of it.
Preheated combustion air
Air entering the burner already hot, instead of cold from the shop floor.
Improved furnace and oven thermal efficiency
More of the fuel's energy reaches the load rather than the stack.
Reduced CO₂ emissions
Lower fuel input means proportionally lower carbon output.
Lower operating cost
The saving appears in the fuel bill every hour the plant runs.
Return on Investment
Fast payback on heat recovery investment
Encon recuperators typically pay back in approximately 5–7 months.
Better return from every unit of fuel spent
The same purchased fuel does more work in the process.
Measured on real plants.
Each story below comes from Encon's combustion, furnace and process-heating work.
Reduce energy use by up to 50%.
Recover More.
REGEN® Burners
Regenerative burners that capture furnace exhaust heat and put it back to work, preheating combustion air to cut fuel consumption in high-temperature furnace operations.
Explore REGEN® Impact
Reduce fuel use by up to 73%.
Burn Cleaner.
Jupiter–Encon Oxy-Fuel Technology
Patented Jupiter–Encon oxy-fuel combustion that uses oxygen for a hotter, cleaner flame, delivering more efficient high-temperature heat with lower emissions.
Explore the Technology
Reduce operating costs by up to 50%.
Dry Smarter.
Industrial Gas Ovens
Gas-fired industrial ovens engineered for uniform temperature distribution and lower heat loss, improving drying, curing and heating performance for process industries.
See Oven Efficiency
From 42 to 32.6 ltr/ton.
22% Less Fuel.
Furnace Retrofit — Tata Steel Subsidiary
Specific fuel consumption cut by 22% after Encon's furnace and combustion retrofit at a Tata Steel subsidiary, delivering measurable savings without disrupting production.
See How We Did It
36 → 42–45 tons/hr.
25% More Output.
Furnace Revamp — TATA SSL, Boisar
A complete furnace revamp at TATA SSL, Boisar lifted production throughput while reducing both fuel and power consumption — more output from the same furnace footprint.
View the Impact
Save 20–60% fuel.
Preheat Smarter.
Ladle Heating System
Recuperative ladle preheating systems that recover flue gas heat for faster ladle readiness, better heat utilisation and significant fuel savings in steel melt shops.
Explore Ladle HeatingReduce energy use by up to 50%.
Recover More.
REGEN® Burners
Regenerative burners that capture furnace exhaust heat and put it back to work, preheating combustion air to cut fuel consumption in high-temperature furnace operations.
Explore REGEN® ImpactReduce fuel use by up to 73%.
Burn Cleaner.
Jupiter–Encon Oxy-Fuel Technology
Patented Jupiter–Encon oxy-fuel combustion that uses oxygen for a hotter, cleaner flame, delivering more efficient high-temperature heat with lower emissions.
Explore the TechnologyReduce operating costs by up to 50%.
Dry Smarter.
Industrial Gas Ovens
Gas-fired industrial ovens engineered for uniform temperature distribution and lower heat loss, improving drying, curing and heating performance for process industries.
See Oven EfficiencyFrom 42 to 32.6 ltr/ton.
22% Less Fuel.
Furnace Retrofit — Tata Steel Subsidiary
Specific fuel consumption cut by 22% after Encon's furnace and combustion retrofit at a Tata Steel subsidiary, delivering measurable savings without disrupting production.
See How We Did It36 → 42–45 tons/hr.
25% More Output.
Furnace Revamp — TATA SSL, Boisar
A complete furnace revamp at TATA SSL, Boisar lifted production throughput while reducing both fuel and power consumption — more output from the same furnace footprint.
View the ImpactSave 20–60% fuel.
Preheat Smarter.
Ladle Heating System
Recuperative ladle preheating systems that recover flue gas heat for faster ladle readiness, better heat utilisation and significant fuel savings in steel melt shops.
Explore Ladle HeatingReduce energy use by up to 50%.
Recover More.
REGEN® Burners
Regenerative burners that capture furnace exhaust heat and put it back to work, preheating combustion air to cut fuel consumption in high-temperature furnace operations.
Explore REGEN® ImpactReduce fuel use by up to 73%.
Burn Cleaner.
Jupiter–Encon Oxy-Fuel Technology
Patented Jupiter–Encon oxy-fuel combustion that uses oxygen for a hotter, cleaner flame, delivering more efficient high-temperature heat with lower emissions.
Explore the TechnologyReduce operating costs by up to 50%.
Dry Smarter.
Industrial Gas Ovens
Gas-fired industrial ovens engineered for uniform temperature distribution and lower heat loss, improving drying, curing and heating performance for process industries.
See Oven EfficiencyFrom 42 to 32.6 ltr/ton.
22% Less Fuel.
Furnace Retrofit — Tata Steel Subsidiary
Specific fuel consumption cut by 22% after Encon's furnace and combustion retrofit at a Tata Steel subsidiary, delivering measurable savings without disrupting production.
See How We Did It36 → 42–45 tons/hr.
25% More Output.
Furnace Revamp — TATA SSL, Boisar
A complete furnace revamp at TATA SSL, Boisar lifted production throughput while reducing both fuel and power consumption — more output from the same furnace footprint.
View the ImpactSave 20–60% fuel.
Preheat Smarter.
Ladle Heating System
Recuperative ladle preheating systems that recover flue gas heat for faster ladle readiness, better heat utilisation and significant fuel savings in steel melt shops.
Explore Ladle HeatingReduce energy use by up to 50%.
Recover More.
REGEN® Burners
Regenerative burners that capture furnace exhaust heat and put it back to work, preheating combustion air to cut fuel consumption in high-temperature furnace operations.
Explore REGEN® ImpactReduce fuel use by up to 73%.
Burn Cleaner.
Jupiter–Encon Oxy-Fuel Technology
Patented Jupiter–Encon oxy-fuel combustion that uses oxygen for a hotter, cleaner flame, delivering more efficient high-temperature heat with lower emissions.
Explore the TechnologyReduce operating costs by up to 50%.
Dry Smarter.
Industrial Gas Ovens
Gas-fired industrial ovens engineered for uniform temperature distribution and lower heat loss, improving drying, curing and heating performance for process industries.
See Oven EfficiencyFrom 42 to 32.6 ltr/ton.
22% Less Fuel.
Furnace Retrofit — Tata Steel Subsidiary
Specific fuel consumption cut by 22% after Encon's furnace and combustion retrofit at a Tata Steel subsidiary, delivering measurable savings without disrupting production.
See How We Did It36 → 42–45 tons/hr.
25% More Output.
Furnace Revamp — TATA SSL, Boisar
A complete furnace revamp at TATA SSL, Boisar lifted production throughput while reducing both fuel and power consumption — more output from the same furnace footprint.
View the ImpactSave 20–60% fuel.
Preheat Smarter.
Ladle Heating System
Recuperative ladle preheating systems that recover flue gas heat for faster ladle readiness, better heat utilisation and significant fuel savings in steel melt shops.
Explore Ladle Heating
Heat that has already been paid for should not go to atmosphere.
Encon can assess your current heat recovery setup, identify what is being lost and engineer the right solution to put that heat back into the process.