Maxwatt offers an extensive range of energy recovery and waste pressure recovery turbines that come equipped with host of features making them arguably one of the best solutions available worldwide for these applications. These time tested features make these turbines robust, efficient, and reliable, demanding minimal maintenance.

Why Energy Recovery Makes Sense?

As distributed micro power generation technologies gain more attention, the recovery of energy from waste pressure has become increasingly significant. While the conventional approach of using a single stage turbine driving a generator or turbine bladed disc directly mounted on the generator shaft is popular, its efficiency is limited by the low speed of rotation. To address this, a more efficient approach using a gearbox was introduced. However, this introduces complexities such as the need for a lube oil system and a more intricate rotating train.

At Maxwatt, our team of Turbine experts with several decades of experience have invested considerable effort into development of a range of energy recovery turbines that offer the highest possible efficiency while minimizing the need for complex components.

Typical Schematic

Existing system – operated only in Emergency

Add on - Energeny Recovery system Normally operating

Small is beautiful again

Minimalistic, Efficient & Rugged – this is how new range of Energy Recovery and waste pressure recovery Turbines from Maxwatt can be described. These machines use Novel & well established & proven Thermodynamic design & simulation tools to minimize no. of components resulting in a machine with no gearbox and a simple lubricating oil system.

Our objective was to provide Industry a machine that offers high efficiency, ease of operation & lower maintenance requirements.

Unique features of Energy Recovery Turbines

Double Pedestal Construction

Maxwatt ERS turbines utilize a double pedestal construction with bearing support on both ends, ensuring extended operational reliability and availability, particularly for applications utilizing dry and saturated steam. Conventional approach of using an overhung design with rotor disc mounted on Generator shaft or Gear Box shaft have several problems like frequent shutdown and maintenance due to steam glands & bearing failures

Direct Drive – No Gear Box

Direct integration of the turbine and generator results in a more compact footprint and low speed simplified rotating train.. This gives several advantages like over conventional design like –

  • Elimination of a sophisticated forced-feed lubrication system as major oil consumer Gear Box is not present.
  • Lower maintenance – No need to maintain stock of expensive Gear Box Bearings, Oil baffle, Large Oil Pumps etc.
  • Compact and simple package requiring lower maintenance.

Tailored Multi-stage Design for High Efficiency

These turbines employ a multistage design customized to suit specific steam conditions, offering unrivalled efficiency that outperforms any single-stage turbine. The benefit of this design is a faster payback period.

This feature paired with double-bearing construction, results in a heavier rotor that effectively manages frequency fluctuations caused by fluctuating steam demand of the process.

Rivet-less Bladed Design

Rotor Blades are constructed with integral shroud which are machined to provide a seamless shroud surface. This help to achieve –

  • Improved Blade life as there is no blade stress which is caused in a riveted bladed design.
  • Reduced Disc clearances leading to better efficiency.

Multi-Control valve option for more efficient Part Load operation

The inlet steam flow control features 2 or 3 control valves with sequential operation, ensuring superior efficiency during part-load operation., common in several Industrial processes

Common Base frame

ER turbine and generator are factory fitted on a single base frame, creating a streamlined and simple package that is easy to install without the need for extensive foundation or civil work

Unique features of Maxwatt ERS / Micro Turbines

Installation using Anti Vibration Mounts - No requirement of specially designed Civil Foundation

  ERS Turbine Generator Package can be supplied along with suitably selected Anti Vibration mounts that can save time and high cost of civil foundation. Besides these Mounts also facilitate the installation of ERS Turbine Generator Package on upper floors without necessitating the need for extensive civil foundation.

Induction Generator for simplified plant connectivity & parallel operation with Grid

  ERS Turbine Generator Package uses an Induction Generator to provide a simple interface and parallel operation with Grid. The system provides a simplified power import reduction based on power generated by the package. Whats more the Grid synchronisation is handled by a pre-programmed start and process flow control function.

Fully Automatic control system

  The control system uses a PLC based control system offering a fully automatic control system that provides ;

  • Push Button automated start sequence.
  • Push Button or Automated shut down control
  • Monitoring of all important functions, parameters with fault

Remote Monitoring through IOT App

ERS turbine package parameters can be monitored remotely using our specially developed IOT mobile app. This can instantly provide information on key Mechanical & Electrical parameters like Turbine speed, Turbine vibration, steam parameters, Turbine Bearing Temperatures, Power generation, Generator Winding & Bearing temperatures etc.

Double Pedestal Construction

The turbines utilize a double pedestal construction with bearing support on both ends, ensuring extended operational reliability and availability, particularly for applications utilizing dry and saturated steam.

Tailored, Multi-stage Design

The turbines employ a multistage design customized to suit specific steam conditions, offering unrivalled efficiency that outperforms any single-stage turbine. The benefit of this design is a faster payback period.

Heavier rotating train that provides enhanced control of Frequency fluctuation

The turbine's double-bearing construction, paired with a multistage rotor, results in a heavier rotor that effectively manages frequency fluctuations caused by fluctuating steam demand from the process. As a result, frequency is maintained well within the operational range, without any sharp fluctuations, ensuring smooth and reliable operation.

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No. 18, 5th Main, Peenya 3rd Phase,
Bangalore Karnataka, India. PIN 560058

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