Waste Heat Recovery Chillers: How to Calculate ROI for Your Generator Exhaust

Quick Links: The Opportunity | ROI Calculation | Real Examples | Get Analysis

Your generator is throwing money into the atmosphere. Exhaust gases at 400-550°C contain enough energy to power substantial cooling. Waste heat recovery chillers (Exhaust-Fired VAMs) capture this "free" energy. Here is the financial case for why capturing exhaust makes sense.

Understanding the Opportunity

A 1,000 kW generator produces ~1.5 MW of thermal exhaust energy. BROAD's exhaust-fired VAMs can convert this into 350-450 TR of cooling without burning a drop of extra fuel.

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The ROI Calculation Framework

Real-World ROI Examples

• Pharma (Bangalore): 600 TR VAM on 2x1250 kVA gensets. Payback: 2.1 Years.
• Food Processing (Gujarat): 400 TR VAM on 1500 kVA genset. Payback: 1.8 Years.
• Textile (Tirupur): 350 TR VAM on 1000 kVA genset. Payback: 1.6 Years.

Key Variables Affecting ROI

• Operating Hours: 5,000+ hours/year yields ideal 2-year payback.
• Electricity Rates: Rates above ₹10/kWh accelerate payback to <18 months.
• Carbon Credits: Can add ₹15-30 lakhs/year in value.

Lifecycle Value (20 Years)

While electric chillers cost ~₹38.8 Crores over 20 years (due to power costs), a Waste Heat Recovery Chiller costs only ~₹20.9 Crores total. Total Lifecycle Savings: ₹17.9 Crores.

Optimizing Your Investment

• Right-Sizing: Match VAM capacity to actual generator load profiles.
• Hybrid Setup: Use VAM for base load and electric chillers for peak tips.
• Performance Guarantees: BROAD offers contractual COP guarantees tied to exhaust conditions.