Payback vs. Fuel Savings

Case studies of Cain Industries’ exhaust heat recovery equipment showing: initial cost, BTU recovered, payback period, return on investment, annual and life expectancy savings.

Exhaust Steam Generator - ESG1

Gas & Diesel Cogeneration Market
DATA without a Cain SystemPERFORMANCE with a Cain System
Engine GeneratorESG1
Heat SinkSteam DemandOperating Steam Pressure10 PSI
Waste Exhaust Temp.1,150°FFinal Exhaust Temp.301°F
Water Temp. InletN/ABoiler Horsepower51 BHP
SCFM1,598Equivalent Evaporation1,743 lb/hr
Fuel TypeNatural GasExhaust Pressure Drop1.44" WC
O2 ContentN/ABTU/hr Recovered1,691,000
Excess AirN/ATotal Cost$70,674
Fuel Cost Per Therm$0.60
Annual Operating Hours8,700Payback:9.6 mo.
Annual ROI:125%
Annual Savings:$88,277
Life Expectancy Savings: $1,765,540 (20 years)
Equipment Payback = $70,674 vs. Lifetime Fuel Savings = $1,694,866
Fuel Savings ESG1
Each cell represents one month of operation over equipment lifetime (240 months = 20 years).

Heat Recovery Silencer Radial - HRSR x7

Gas & Diesel Cogeneration Market
DATA without a Cain SystemPERFORMANCE with a Cain System
Engine GeneratorHRSR
Heat SinkGlycol/Water LoopCirculating Liquid Flow300 GPM
Waste Exhaust Temp.922°FFinal Exhaust Temp.387°F
Water Temp. Inlet180°FWater Temp. Outlet194.1°F
SCFM2,766Water Pressure Drop0.49 PSIG
Fuel TypeLandfill GasExhaust Pressure Drop0.73" WC
O2 ContentN/ABTU/hr Recovered1,845,000
Excess AirN/ATotal Cost$47,431
Fuel Cost Per Therm$0.60
Annual Operating Hours6,000Payback:6.9 mo.
Annual ROI:175%
Annual Savings:$83,006
Life Expectancy Savings: $1,660,120 (20 years)
Equipment Payback = $47,431 vs. Lifetime Fuel Savings = $1,612,689
Fuel Savings HRSR
Each cell represents one month of operation over equipment lifetime (240 months = 20 years).

U-Tube Recovery - UTR1

Gas & Diesel Cogeneration Market
DATA without a Cain SystemPERFORMANCE with a Cain System
Engine GeneratorUTR1
Heat SinkGlycol/Water LoopCirculating Liquid Flow400 GPM
Waste Exhaust Temp.645°FFinal Exhaust Temp.357°F
Water Temp. Inlet250°FWater Temp. Outlet263.3°F
SCFM6,739Water Pressure Drop0.04 PSIG
Fuel TypeNatural GasExhaust Pressure Drop2.00" WC
O2 ContentN/ABTU/hr Recovered2,341,000
Excess AirN/ATotal Cost$22,455
Fuel Cost Per Therm$0.60
Annual Operating Hours6,000Payback:4.8 mo.
Annual ROI:250%
Annual Savings:$56,176
Life Expectancy Savings: $1,123,520 (20 years)
Equipment Payback = $22,455 vs. Lifetime Fuel Savings = $1,101,065
Fuel Savings UTR1
Each cell represents one month of operation over equipment lifetime (240 months = 20 years).

Rectangular Tube Recovery - RTR

Boiler Economizer Market
DATA without a Cain SystemPERFORMANCE with a Cain System
55,000 PPH Steam BoilerRTR
Heat SinkBoiler FeedwaterBoiler Feedwater Flow118 GPM
Waste Exhaust Temp.509°FFinal Exhaust Temp.343°F
Water Temp. Inlet227°FWater Temp. Outlet276°F
BTU/hr Burner Input70,000 MBTUWater Pressure Drop0.87 PSIG
Fuel TypeKeroseneExhaust Pressure Drop0.68" WC
O2 Content2.95%BTU/hr Recovered2,781,000
Excess Air15%Total Cost$45,009
Fuel Cost Per Therm$0.70
Annual Operating Hours4,000Payback:5.6 mo.
Annual ROI:215%
Annual Savings:$96,816
Life Expectancy Savings: $1,936,320 (20 years)
Equipment Payback = $45,009 vs. Lifetime Fuel Savings = $1,891,311
Fuel Savings RTR
Each cell represents one month of operation over equipment lifetime (240 months = 20 years).

Fin Coil Recovery - FCR

Boiler Economizer Market
DATA without a Cain SystemPERFORMANCE with a Cain System
500 HP Steam BoilerFCR
Heat SinkProcess WaterBoiler Feedwater Flow25 GPM
Waste Exhaust Temp.400°FFinal Exhaust Temp.268°F
Water Temp. Inlet120°FWater Temp. Outlet168.6°F
BTU/hr Burner Input20,922 MBTUWater Pressure Drop6.6 PSIG
Fuel TypeNatural GasExhaust Pressure Drop0.47" WC
O2 Content3%BTU/hr Recovered608,396
Excess Air18%Total Cost$6,717
Fuel Cost Per Therm$0.60
Annual Operating Hours6,000Payback:3.7 mo.
Annual ROI:326%
Annual Savings:$21,902
Life Expectancy Savings: $438,040 (20 years)
Equipment Payback = $6,717 vs. Lifetime Fuel Savings = $431,323
Fuel Savings FCR
Each cell represents one month of operation over equipment lifetime (240 months = 20 years).