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    • ORC systems for decentralised power generation

    Increased efficiency through intelligent waste heat recovery

    Many industrial processes sometimes generate large amounts of waste heat that goes unused – even though it offers significant energy potential. An ORC (Organic Rankine Cycle) system can harness this potential, efficiently converting heat into electrical energy. CAW integrates ORC systems into existing or new facilities, enabling cost-effective and low-emission electricity generation directly on-site.

    How does an ORC systems work?

    An ORC system uses an organic working fluid that evaporates even at moderate temperatures due to its low boiling point. This makes it possible to harness heat and waste heat sources for commercial electricity generation, particularly those whose temperature is too low for conventional steam turbines.

    Basic principle of an ORC turbine-generator system

    • An existing heat source, such as waste heat from combustion processes, thermal oil heaters or other hot gas streams, heats the organic working fluid in the evaporator.
    • The working fluid vaporizes under pressure and flows into a single-stage or multi-stage axial or radial turbine.
    • Mechanical energy is generated in the turbine, which drives a three-phase generator.
    • In the condenser, the working fluid is then liquefied and returned to the cycle.
    • A feed pump maintains the required pressure in the working cycle.

    Technical features

    • Power generation from heat sources ranging from approx. 80 and 350 °C, depending on the working medium and design.
    • Low mechanical stress on the turbine due to moderate rotational speeds.
    • Closed working cycle with high operational reliability.
    • High flexibility regarding heat sources: thermal oil, hot water, hot and exhaust gas streams.

    Advantages of an ORC system

    Efficient use of waste heat

    Generating electricity from energy that would otherwise go unused and be irreversibly dissipated.

    Increase in overall efficiency

    Existing systems such as thermal oil heaters, thermal production systems, and thermal process systems operate much more efficiently.

    Low operating costs

    The ORC process is fully automated and requires minimal maintenance.

    High system availability

    Robust and proven technology, suitable for continuous operation.

    Flexible integration

    Can be retrofitted into existing systems or incorporated into new ones.

    Emission reductions

    Higher heat recovery and utilisation rates reduce both fuel consumption and CO2 emissions per unit produced.

    Eligible for funding

    Many countries offer attractive subsidy programs for waste heat recovery and efficiency improvements.

    Industries and typical applications of ORC systems

    ORC systems are suitable for any application where thermal energy (exergy) is continuously generated but not fully utilized. Due to the wide variety of possible heat sources, they can be used across a range of industries.

    Typical industries

    Biomass and waste incineration

    Wood industry and wood-based materials production

    Chemical and petrochemical industry

    Food and agricultural industry

    Plastics and rubber industry

    Oil and gas industry

    Machinery and plant engineering

    Industrial processes using hot air or hot gas streams

    Examples of applications

    • Power generation from exhaust gases of combustion plants.
    • Integration with thermal oil systems to utilize excess heat.
    • Integration into production lines, preferably those with high continuous loads and constant waste heat potential.
    • Power generation from hot water or thermal oil circuits.
    • Increased efficiency of combined heat and power plants (CHP) through additional utilization of waste heat.

    Heat sources and media for ORC systems

    ORC systems can be adapted to various primary and secondary heat sources. A sufficiently high temperature difference between the evaporator and condenser is crucial.

    Possible heat sources

    • Hot air and hot gases from industrial and heat treatment furnaces
    • Exhaust gases from incinerators and thermal processes
    • Thermal oil from high-temperature circuits
    • Hot water from stationary or mobile heating systems
    • Waste heat from production machinery or drying systems

    Working fluids

    • Organic fluids with low boiling points
    • Fluids with high thermal stability and good evaporation characteristics
    • Optimizable fluid selection for temperature range, pressure level, and turbine performance.

    Why CAW’s ORC systems are the right choice

    CAW combines ORC systems from the world’s leading manufacturers with their own state-of-the-art industrial heating and combustion technology. Our comprehensive solutions are robust, durable and precisely tailored to your existing heat and / or waste heat sources. Whether for retrofitting or new construction – we develop systems that sustainably improves your efficiency and process economics while also generating electricity.

    We would be happy to advise you on the technical possibilities, the economic potential, and the optimal integration of an ORC system into your processes.

    References

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