200kw Industrial Exhaust Gas Generator

What Is an Industrial Exhaust Gas Generator

• An “industrial exhaust gas generator” utilizes waste flue gas / exhaust gas (from furnaces, boilers, kilns, industrial processes, etc.) as fuel to generate electricity, rather than relying on fresh natural gas or diesel. This allows factories and plants to “turn waste into energy,” improving resource utilization and cutting waste disposal costs. 

• The generator is designed with specialized gas intake, turbocharging, and in-cylinder mixing technologies to safely and efficiently combust exhaust gases, even when their composition (CO, H₂, CO₂, etc.) fluctuates. 

• Such systems help industries reduce emissions and environmental footprint, while converting what would be a waste stream (exhaust / flue gas) into useful electricity — a win for both economy and sustainability.

Key Advantages of the 200 kW Industrial Exhaust Gas Generator

• Waste-to-energy / Cost savings: Since the fuel is exhaust gas (which otherwise might require treatment, flaring or emission control), using it for power generation lowers fuel costs and reduces waste-gas handling/disposal costs.

• High fuel flexibility & adaptability: The unit’s dual-intake, turbo-charging and closed-loop combustion control allow it to adapt to variable exhaust-gas compositions and pressures — ideal for industrial sites where gas composition may fluctuate. 

• Decent Electrical Efficiency: According to the manufacturer spec for similar units, comparable exhaust-gas generator sets achieve electrical efficiencies around 34%–40%, and total energy conversion efficiency (electric + thermal) up to ~77%–84%. 

• Scalable & Modular Design: The generator is part of a modular product line (from 200 kW up to 1200 kW+), which allows clients to scale or combine units based on their waste-gas volume and power demand. 

• Lower Environmental Impact: By using waste exhaust gas rather than fresh fossil fuels, the generator helps reduce overall emissions and resource consumption — contributing to a more sustainable manufacturing or industrial operation.

Introduction to Technical Features:

Turbocharging and shunt Intake technology：

    Avoiding the generation of mixed gas, the gas and air enters the cylinder isolated with no contact. At the same time, the exhaust enery from the generator will be used for turbocharing the gas and air respectively. It realizes the improvement of intake and the synchronous improvement of operation power and volume power and ensures safety operation at the same time.

    From 2018 till now, the safe stayale running time is more than 30000 hours. The measured electric efficiency is more than 40% in practice - 1m3 exhaust gas generates one kilowatt-hour of electricity.

    There is no carbon monoxide leakage, no backfire and flash explosion, and the genset runs smoothly. Self consumption rate is less than 2%. The operation control of the genset is automatically adjusted with the change of gas.

Technical parameters:

Typical Use Cases / Applications

• Industrial Plants & Factories — especially those producing exhaust or flue gases (e.g. furnaces, boilers, kilns, coal-fired plants, waste-gas burners), using the exhaust as fuel to generate electricity.

• Refineries / Chemical Plants / Smelting Plants — where exhaust gases often contain combustible components (CO, H₂, hydrocarbon residuals), turning waste into on-site power supply.

• Energy-Recovery & Waste-Gas Utilization Projects — suitable for projects aiming to reduce emissions, improve energy efficiency, and make use of by-product gases.

• Supplemental Power / Base Load Power Supply — as a consistent power source if exhaust gas supply is stable, reducing reliance on grid power or external fuel supply.

• Distributed / On-site Power Generation — for remote or isolated industrial sites where transporting fuel is costly; using on-site exhaust gas improves energy self-sufficiency.

Technical & Operational Highlights

• Dual-Intake + Turbocharging + In-Cylinder Mixing: Design ensures stable combustion even when exhaust-gas composition fluctuates; minimizes risk of backfire or flash explosion. 

• Automatic Combustion / Control System: The genset features closed-loop combustion control that adapts to real-time changes in gas composition and pressure, ensuring safe, stable operation with minimal manual intervention. 

• Reliable Historical Performance: According to the manufacturer, similar gensets have achieved stable operation over 30,000 hours in field conditions — showing good durability and reliability. 

• Efficiency Data (for reference): For example, for the 200 kW unit: electrical efficiency ~34%, thermal efficiency ~43%, overall energy utilization ~77%. 

• Compact & Simplified Installation: Modular and integrated design helps reduce installation complexity and maintenance workload, improving total cost of ownership. 

Why Choose This Exhaust Gas Generator Instead of Conventional Fuel Generators