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Industrial Energy Engineering

Engineering Cleaner
Industrial Heat

Specialists in biomass and coal-fired boiler systems, gasification, emission control, fuel transformation and energy-efficiency retrofit — delivering measurable performance and compliance for industrial clients worldwide.

200+
Boilers Installed
35%
Avg. Fuel Savings
98%
Emission Compliance
18+
Years in Industry
What We Do

Core Engineering Services

From new boiler installations to full emission-compliance retrofits, we cover the complete lifecycle of industrial thermal energy systems.

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Biomass Fired Boilers

Design, supply and commissioning of biomass boilers from 500 kW to 50 MW. Wood chips, agri-residues, bagasse and mixed biomass fuels supported with automatic feed systems.

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Coal Fired Boiler Systems

Stoker-fired, fluidised bed and pulverised coal boiler engineering. Performance optimisation, combustion tuning, and thermal efficiency upgrades for existing plant.

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Fuel Conversion & Retrofit

Coal-to-biomass and coal-to-gas conversion programmes. Burner replacement, grate modification, and fuel-handling redesign with minimal operational downtime.

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Emission Compliance

Flue gas treatment — electrostatic precipitators, bag filters, SCR/SNCR NOx reduction, SO₂ scrubbing. Full compliance with IED, MATS, and local environmental regulations.

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Gasification Systems

Coal, biomass and municipal solid waste gasification for syngas production. Downdraft, updraft and fluidised-bed gasifier design with gas cleaning and power generation integration.

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Biogas Engineering

Anaerobic digestion plant design, biogas upgrading to biomethane, combined heat and power (CHP) integration, and landfill gas utilisation projects.

Technical Solutions

In-Depth Technology Platforms

Engineered systems built around your fuel source, capacity and compliance requirements.

Biomass & Coal Boiler Engineering

Our boiler systems are engineered around your specific fuel profile, capacity requirement and steam parameters. We supply complete turnkey packages from grate to stack — including fuel handling, combustion control, economisers, and ash management.

All designs include live combustion management via PLC/SCADA with remote monitoring as standard.

  • Steam output range 0.5 – 50 MW
  • Operating pressure Up to 65 bar
  • Thermal efficiency Up to 88%
  • Fuel moisture tolerance Up to 55%
  • NOx emissions (biomass) <150 mg/Nm³
  • Boiler availability >95%
Request Specification
STEAM DRUM Steam out Feed H₂O Fuel Flue gas ECO Schematic: Water-tube biomass boiler

Coal, Biomass & Waste Gasification

Gasification converts solid fuels into a combustible syngas (CO + H₂ + CH₄), which can be used for power generation, industrial heating, or chemical synthesis. Our gasifier designs cover downdraft, updraft and circulating fluidised-bed (CFB) configurations.

All systems include tar reforming, gas cooling, filtration and pre-treatment for engine or turbine use.

  • Input fuel capacity 100 kg/h – 10 t/h
  • Cold gas efficiency 70–85%
  • Syngas calorific value 4–6 MJ/Nm³
  • Tar content (post-cleaning) <50 mg/Nm³
  • Feedstocks Coal, biomass, MSW, RDF
Request Specification
DRYING PYROLYSIS OXIDATION REDUCTION Fuel in Air / O₂ Syngas Ash GAS CLEANING Schematic: Downdraft gasifier

Flue Gas Treatment & Compliance

Our emission control systems are engineered to meet the strictest regulatory thresholds — IED (EU), NAAQS (US), and local EIA requirements. We offer integrated packages or standalone add-on systems for existing plant.

  • Particulate (PM) control Bag filter / ESP
  • NOx reduction SCR / SNCR
  • SO₂ removal Wet / Dry scrubber
  • HCl / HF removal Dry sorbent injection
  • CO burnout Secondary air / catalytic
  • Monitoring CEMS (continuous)
Get Compliance Audit
BOILER Raw flue gas BAG FILTER Dust <10mg SCR De-NOx NOx <100mg WET SCRUBBER SO₂ <50mg STACK Compliant CEMS Emission treatment train

Biogas, Biomethane & CHP Systems

We design complete anaerobic digestion and biogas utilisation plants — from feedstock pre-treatment and digester sizing through to gas upgrading and CHP integration. Feedstocks include agricultural waste, food waste, sewage sludge and energy crops.

  • Digester capacity 250 m³ – 10,000 m³
  • Biogas yield 350–500 Nm³/t VS
  • Biomethane purity >98% CH₄
  • CHP electrical efficiency 38–42%
  • HRT (hydraulic retention) 20–40 days
Request Specification
FEED Waste / crops ANAEROBIC DIGESTER Biogas GAS STORE CHP Power + Heat Digestate / Fertiliser Biogas plant schematic
How We Work

Our Engineering Process

A structured methodology that takes your project from initial audit through to commissioning and long-term support.

01
Audit
02
Design
03
Supply
04
Install
05
Commission
06
Support

Site & Fuel Audit

We begin with a comprehensive site audit — fuel quality analysis, existing plant assessment, steam/energy demand profiling and flue gas sampling. This produces a baseline performance report and opportunity register that informs all downstream design decisions.

Duration1–2 weeks
DeliverableAudit Report
Fuel lab analysisIncluded
Savings Tool

Fuel & Energy Savings Calculator

Estimate your potential fuel cost reduction and CO₂ savings from a boiler efficiency improvement or fuel conversion project.

📊 Projected Annual Savings
85% Target efficiency
Current annual fuel cost $600,000
Projected fuel cost (post-upgrade) $508,235
Annual cost saving $91,765
CO₂ reduction (est.) 1,450 t/yr
Estimated payback period 2.7 years
Case Studies

Selected Projects

A sample of completed installations across industrial sectors and geographies.

20 MW Bagasse Boiler — Sugar Mill
Punjab, Pakistan
Biomass
Capacity20 MW steam
FuelBagasse + biomass mix
Efficiency gain+14 percentage points
CO₂ saved8,400 t/year
Status✓ Commissioned
Coal-to-Biomass Conversion
Lahore Industrial Estate
Retrofit
Original system8 MW coal stoker
New fuelRice husk + wood chips
Fuel saving$210,000 / year
Payback2.1 years
Status✓ Commissioned
Biomass Gasification CHP Plant
Faisalabad, Pakistan
Gasification
Gasifier typeDowndraft, 2 MW
FeedstockCotton stalks + wood
Power output800 kWe
Heat output1.1 MWth
Status✓ Operational
Emission Retrofit — Cement Plant
Karachi, Pakistan
Coal
Treatment trainESP + SCR + FGD
PM reduction98.5%
NOx reduction75%
ComplianceIED 2010/75/EU
Status✓ Compliant
Biogas Plant — Dairy Farm
Gujranwala, Pakistan
Biogas
Digester volume1,200 m³
FeedstockCattle manure
Biogas output480 Nm³/day
Electricity generated180 kWe
Status✓ Operational
MSW Gasification Feasibility
Multan, Pakistan
Gasification
Input capacity150 t/day MSW
Syngas output12,000 Nm³/h
Power generation3.5 MWe
Landfill diversion54,750 t/year
Status⧗ In Development
Environmental Performance

Emission Compliance & Reduction

Our installations consistently achieve — and often exceed — the most stringent national and international emission standards.

Achieved Reductions vs. Baseline

Particulate Matter (PM₁₀)–96%
Nitrogen Oxides (NOx)–74%
Sulphur Dioxide (SO₂)–88%
Carbon Monoxide (CO)–81%
CO₂ (fuel switch projects)–45%

Technologies Deployed

  • Electrostatic precipitators (ESP) for high-volume particulate capture at temperatures up to 400°C
  • Pulse-jet bag filters with anti-static fabric for fine PM and condensables
  • Selective catalytic reduction (SCR) with V₂O₅/TiO₂ catalyst beds for NOx <100 mg/Nm³
  • Selective non-catalytic reduction (SNCR) urea injection — cost-effective retro-fit option
  • Semi-dry and wet flue gas desulphurisation (FGD) using lime or limestone slurry
  • Dry sorbent injection for HCl, HF and SO₂ in smaller installations
  • Continuous Emission Monitoring Systems (CEMS) with regulatory data reporting
  • Optimised combustion control to minimise CO and unburnt carbon in ash
Talk to Our Engineers

Start Your Project

Let's solve your energy challenge together.

Whether you're planning a new installation, need to cut fuel costs, or face an emission compliance deadline — our engineering team is ready to help. We respond to all enquiries within one business day.

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Head Office Industrial Zone, Lahore, Punjab, Pakistan
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Phone +92 321 846 3310
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Email sales@kaxisgroup.com
umersyedkaxis@gmail.com
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Office Hours Mon–Sat, 9:00 am – 6:00 pm PKT
We respond within 1 business day
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