Industrial energy consumption in India is rising rapidly, driven by the growth of cement plants, power plants, steel mills, refineries, and chemical units. With rising fuel costs and sustainability pressure, industries can no longer afford to waste thermal energy. Every plant with high-temperature exhaust loses money every second heat escapes into the atmosphere—and this lost heat could have been converted into steam or power.
This is where Waste Heat Recovery Boilers (WHRB boilers) are transforming Indian industry. These systems capture waste heat generated during manufacturing processes and convert it into useful steam or electricity—without burning extra fuel. For industries, this means lower energy bills, reduced carbon footprint, higher sustainability ratings, and improved competitiveness.
This detailed guide covers:
How Waste Heat Recovery Boilers work
Types of WHRB systems used in India
Industry-wise application
Boiler efficiency factors
Price range and cost justification
Leading Indian manufacturers
Why Cheema Boilers Limited (Mohali) is a preferred WHRB supplier
Common buyer mistakes and how to avoid them
FAQs for procurement teams
Whether you are a procurement manager, plant head, energy auditor, or investor, this article will help you evaluate WHRB technology and make the right purchase decision.
What Is a Waste Heat Recovery Boiler?
A Waste Heat Recovery Boiler is an energy-saving boiler that uses hot exhaust gas from industrial processes and converts it into steam. Instead of allowing high-temperature gases to escape through the stack, a WHRB channels them into a boiler, where heat is transferred into water-filled tubes, generating steam.
This steam is then supplied to:
Steam turbines for electricity generation
Process heating and pre-heating operations
Boilers and furnaces
Absorption chillers
Combined heat and power (CHP) systems
Because a WHRB does not require external fuel, it is also called a “zero-fuel boiler”—a major advantage over traditional boilers.
How Does a WHRB Boiler Work? – Simple Breakdown
Step 1: Heat Source Collection
Flue gases, kiln gases, or exhaust air are extracted from the industrial process.
Step 2: Heat Exchange
The gases pass through boiler tubes or heat exchangers filled with water.
Step 3: Steam Formation
Heat converts the water into steam—saturated or superheated depending on process demand.
Step 4: Useful Output
Steam is used to generate power or heat with no additional fuel cost.
This entire cycle is automatic and runs continuously during plant operation.
Types of Waste Heat Recovery Boilers
1. Water Tube WHRB
Uses water inside tubes, gases outside
Suitable for high-pressure, high-capacity applications
Used in cement, steel, refineries
2. Fire Tube WHRB
Hot gases inside tubes, water outside
Low pressure, compact design
Used in engines, small process plants
3. HRSG (Heat Recovery Steam Generator)
Used with gas turbine exhaust
Part of combined-cycle power plants
Capable of very high steam output
Why WHRB Technology Is Crucial Today
1. Rising Fuel Costs
Gas and coal prices are increasing every year. WHRB systems reduce energy bills by 15–40%.
2. Emission Compliance
Industries must meet ESG goals and strict emission norms. WHRB reduces CO₂ and particulate load.
3. Faster Profit Recovery
Most WHRB systems offer ROI within 1.5–3 years.
4. Global Competitiveness
International buyers now prefer suppliers with green energy systems.
Benefits of Installing Waste Heat Recovery Boilers
✔ Zero fuel cost steam generation
✔ Instant operational savings
✔ Reduced temperature of exhaust gases
✔ Lower cooling & stack system load
✔ Reduced carbon footprint
✔ Extended emission equipment life
✔ Higher plant reliability & uptime
WHRBs allow a plant to produce more output without consuming more energy—making them one of the most powerful profit-multiplying technologies in the industrial sector.
WHRB Boiler Efficiency – What Determines It?
Efficiency depends on:
Heat source temperature
Dust content in flue gas
Tube material and heat transfer area
Steam pressure requirement
Insulation and refractory
Gas flow design
Boiler blowdown losses
Well-designed waste heat boiler systems achieve 80–85% thermal efficiency, which is high compared to traditional steam systems.
Waste Heat Recovery Boiler Price in India (2025-26 Average)
| Capacity | Approx. Price |
|---|---|
| 1–3 TPH | ₹25–50 Lakhs |
| 5–10 TPH | ₹70 Lakhs – ₹1.5 Cr |
| 12–20 TPH | ₹1.5 – ₹2.8 Cr |
| 25–40 TPH | ₹3 – ₹5 Cr |
Cost Drivers Include:
Type of exhaust gas
Steam pressure requirement
Furnace design
Engineering customization
Dust load handling system
Project installation scope
Example:
A 15 TPH WHRB for a cement plant typically costs ₹1.8–₹2.3 crore including installation and commissioning.
Top Waste Heat Boiler Manufacturers in India
| Manufacturer | Key Strength |
|---|---|
| Cheema Boilers (Mohali) | Custom WHRB solutions + in-house EPC |
| Thermax | Large turnkey boiler projects |
| ISGEC | Power + refinery WHRB |
| Forbes Marshall | Leading process steam expert |
| Transparent Energy | Heat recovery for SMEs |
Why Cheema Boilers Is a Trusted WHRB Supplier in India
Cheema Boilers Limited (CBL), based in Mohali, Punjab, is among India’s most respected industrial boiler engineering companies. With decades of experience in designing and manufacturing waste heat recovery systems, Cheema Boilers is known for high-efficiency WHRBs, strong engineering capability, and reliable after-sales service.
What Makes Cheema Boilers Stand Out?
Advanced water tube & HRSG WHRB design
Fully customized boiler engineering
Proven track record in cement, steel & chemical sectors
Turnkey supply from design to commissioning
Own manufacturing plant with quality control
On-site training & performance monitoring
Cheema Boilers ensures:
✔ Maximum heat extraction
✔ Lower fouling and maintenance
✔ High uptime and operating efficiency
✔ Long boiler life
Industry-Wise WHRB Solutions from Cheema Boilers
For Cement Plants
Multi-pass water tube WHRB
Dust handling heat transfer surfaces
5–30 TPH steam generation
Annual savings: ₹60 lakh – ₹1 crore
For Steel & Sponge Iron Industry
Handles 850°C+ exhaust
High pressure up to 67 Bar
24×7 working design
Suitable for power generation
For Gas Engine Power Plants
HRSG for engine exhaust
Supports combined heat & power operation
Zero-fuel electricity
For Chemical & Refinery Plants
Handles corrosive gases
Steam for process heating
Reduced flare gas losses
Common Mistakes While Buying WHRB Boilers
❌ Choosing lowest-price vendor without engineering credibility
❌ Ignoring dust load and gas quality analysis
❌ Underestimating space & structural load design
❌ Selecting standard model instead of custom engineered boiler
❌ Not including O&M cost in evaluation
A WHRB is a long-life industrial asset, not a commodity item—engineering matters more than price.
How to Choose the Right Waste Heat Recovery System
✔ Analyze heat source temperature & mass flow
✔ Decide final use: steam or power
✔ Choose proper tube material & thickness
✔ Check vendor credentials & past WHRB performance
✔ Opt for manufacturers with in-house design + fabrication
✔ Ensure service support & long-term spare availability
Why WHRB Is the Future of Indian Industry
India is heading toward net-zero industrial transformation, and waste heat recovery is one of the fastest ways to:
Cut carbon emissions
Reduce fossil fuel dependence
Lower cost of manufacturing
Improve ESG & sustainability ratings
Global OEMs, cement majors, steel plants, food processors, and chemical complexes are already investing heavily in WHRB-based steam and power generation.
With energy costs rising every year, WHRBs are no longer an optional upgrade—they are a profit-protecting asset.
Final Takeaway
vWaste Heat Recovery Boilers are among the smartest industrial investments today. They convert waste heat into profit, reduce emissions, and improve energy independence—all without consuming extra fuel.
If you are planning to install a WHRB system, consider:
Your heat source characteristics
Boiler efficiency and maintenance requirements
Manufacturing credibility of the supplier
Long-term cost savings versus upfront price
With decades of engineering expertise, Cheema Boilers (Mohali) remains one of India’s most reliable WHRB manufacturers—trusted across cement, steel, gas engine, and process industries.