What Is Industrial Exhaust Gas Power Generation
Industrial exhaust gas often contains combustible components (CO, H₂, CH₄, volatile organic compounds, residual hydrocarbons) that, if unutilized, are vented or flared — wasting energy and increasing emissions. An industrial exhaust gas generator captures this exhaust, filters and stabilizes it, then mixes it with air and uses a specially adapted engine to combust the gas safely, converting its chemical energy into mechanical energy and finally electricity.
Compared to conventional natural-gas or diesel gensets, exhaust-gas gensets offer:
- Utilization of waste / by-product gas — turning waste into value.
- Lower fuel procurement costs for industrial users.
- Reduced greenhouse gas emissions and less environmental pollution than uncontrolled exhaust discharge or flaring.
Key Features & Advantages of the 700 kW Unit
Robust Combustion System: Special-engine design adapted to handle mixed flue gases containing CO, H₂, CH₄, and other combustible components, even if calorific value fluctuates.
Turbocharged & Dual-Intake Gas-Air Mixing: Ensures stable and efficient combustion, avoids backfire or flash explosion — critical for exhaust-gas applications. (This design approach has been successfully used in 500 kW units with over 30,000 safe running hours.)
Automatic Combustion Control & Gas Composition Adaptive System: Monitoring and adjusting in real time according to gas pressure and quality — ensures safety, performance, and reliability.
High Efficiency: Electrical efficiency around **38%**; combined electrical + thermal (when installed with heat recovery) can reach **≈ 83% total efficiency** under optimal conditions.
Compact & Modular Design: Facilitates easier installation, maintenance, and integration with existing industrial infrastructure.
Fuel Cost Reduction & Waste Utilization: By using on-site exhaust gas, users save on fuel purchase and avoid waste gas treatment or flaring costs.
Environmental and Sustainability Benefits: Reduces emissions, cuts greenhouse gas output, and supports waste-to-energy initiatives — aligning with global “green manufacturing” trends.
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
| Model | CP22 | CP21 | CP11 | CP14 |
| CP1200GFJ22 | CP900GFJ21 | CP700GFJ11 | CP600GFJ11 | CP500GFJ11 | CP250GFJ14 | CP200GFJ14 |
| Electrical Output(kw) | 1200 | 900 | 700 | 600 | 500 | 250 | 200 |
| Electrical Efficiency(%) | 40 | 38 | 38 | 36 | 36 | 35 | 34 |
| Thermal Efficiency(%) | 44 | 45 | 45 | 44 | 43 | 44 | 43 |
| Total Efficiency(%) | 84 | 83 | 83 | 80 | 79 | 79 | 77 |
| Cylinder Number | 16 | 12 | 12 | 12 | 12 | 6 | 6 |
| Discharge(L) | 104.34 | 78.25 | 71.45 | 71.45 | 71.45 | 35.7 | 35.7 |
| Speed(r/min) | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 |
| Frequency(Hz) | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 |
| Length(mm) | 7409 | 6400 | 6300 | 6300 | 6300 | 4500 | 4500 |
| Width(mm) | 1822 | 1950 | 1950 | 1950 | 1950 | 1300 | 1300 |
| Height(mm) | 2325 | 2175 | 2175 | 2175 | 2175 | 2365 | 2365 |
| Weight(kg) | 19000 | 15000 | 14000 | 13500 | 13500 | 8400 | 7000 |
Technical & Operational Details
| Parameter | Specification / Notes |
|---|
| Rated Electrical Output | 700 kW |
| Engine Type | Industrial dual-intake lean-burn gas engine |
| Fuel / Gas Source | Industrial exhaust / flue gas / off-gas (CO, H₂, CH₄, mixed gas) |
| Electric Efficiency (typical) | ≈ 38% |
| Total Efficiency (with heat recovery) | ≈ 83% |
| Gas Supply Pressure | Low to medium pressure (after pretreatment, adjusted per site) |
| Combustion Control | Automatic adaptive control; knock detection; gas-quality compensation |
| Start/Stop Mode | Continuous rated-load operation / Base-load mode |
| Optional Extras | Heat recovery (hot water / steam), remote monitoring, silent container, parallel operation, grid connection package |
Suitable Gas Types & Pretreatment Recommendations
This genset is compatible with a variety of industrial off-gases, including but not limited to:
– CO-rich furnace exhaust gas
– Kiln flue gas
– Chemical process off-gas
– Mixed synthesis exhaust gas
– Low-to-medium calorific industrial exhaust
Pretreatment is strongly recommended: filtration (to remove dust/particles), tar and VOC removal (if present), moisture separation, H₂S / corrosive gas neutralization (if required) — ensures stable and safe combustion.
Typical Application Scenarios
Metallurgical plants & furnaces (steel, ferroalloy, non-ferrous) — using furnace exhaust gas to generate electricity and heat.
Cement, lime & kiln industries — recovering kiln flue gas energy.
Chemical plants and refineries — using off-gas or by-product gases for self-generated power.
Waste heat / waste gas power generation projects — converting waste emissions into value, reducing environmental impact.
Distributed industrial power & cogeneration (CHP) — supplying electricity and process heat / hot water / steam for on-site use.
Business Value & Environmental Impact
By installing the 700 kW Exhaust Gas Generator, enterprises can achieve:
- Significant energy cost reductions: using waste gas instead of purchasing fresh fuel.
- Reduced emissions & environmental compliance: cuts down CO, CO₂, unburned hydrocarbons, minimizes flaring or venting.
- Resource efficiency & sustainability: transforms "waste" into usable electricity and heat — contributing to circular economy efforts.
- Improved ESG / green manufacturing credentials: aligns with global environmental regulations and corporate social responsibility goals.
Maintenance & Operational Considerations
Regular gas pretreatment maintenance (dust filter, moisture separator, tar scrubbers) — to avoid engine fouling and ensure stable combustion.
Periodic inspection of ignition and knock-control system, especially if gas quality fluctuates significantly.
Routine check of exhaust and safety systems, ensuring safe emissions and preventing backfire risks.
If equipped with heat recovery system — periodic maintenance of heat exchanger, steam/water circuit, and corrosion prevention.
FAQ
Q: What types of industrial exhaust gases are suitable for this generator?
A: Furnace exhaust gas, kiln flue gas, CO-rich off-gas, mixed synthesis gases, low-to-medium calorific industrial exhaust. As long as the gas has combustible components (CO, H₂, CH₄ or similar) and is pretreated to remove dust/particles, it can be used.
Q: Is pretreatment of exhaust gas required?
A: Yes. Dust, tar, moisture, and corrosive components (H₂S, VOCs, etc.) should be removed or neutralized to protect the engine and ensure stable combustion.
Q: Can the system operate 24/7 under full load?
A: Yes. The engine and genset are designed for continuous heavy-load operation. Many installations have run reliably for over 30,000 hours under similar conditions. :contentReference[oaicite:8]{index=8}
Q: Can I recover heat as well as electricity?
A: Yes — with an optional heat-recovery module (steam or hot water), you can utilize waste heat, increasing total energy utilization efficiency. This makes the system ideal for Combined Heat and Power (CHP) applications.
Q: What if the gas calorific value fluctuates?
A: The genset’s adaptive combustion control system and turbocharged intake ensure stable combustion and power output even with gas quality variations — provided the gas meets minimum combustible thresholds after pretreatment.
Contact Us for Custom Solutions
We offer full turn-key exhaust-gas power generation solutions: from gas analysis & pretreatment, genset supply, heat recovery integration, to installation, commissioning and after-sales support.
Contact us to design a customized 700 kW solution based on your exact waste-gas composition and site conditions.
