ORC waste heat power plant
Convert industrial waste heat into valuable electrical power
An ORC waste heat power plant converts unused thermal energy into electricity. Using the Organic Rankine Cycle (ORC), companies can generate power from industrial waste heat that would otherwise be released into the environment.
ORC technology is suitable for waste heat recovery from industrial processes, engines, turbines, CHP (combined heat and power) units, refrigeration systems and energy infrastructure. Even low- and medium-temperature heat sources can often be utilised efficiently, helping operators improve overall energy performance.
By generating electricity directly on site, companies can lower energy costs, increase energy independence and reduce CO₂ emissions. Together, BITZER and BPower provide ORC solutions for a wide range of industrial applications and temperature levels.
What is an Organic Rankine Cycle?
Uses an organic working fluid instead of water
The Organic Rankine Cycle is a thermodynamic cycle. It first converts heat into mechanical work and then into electrical energy.
Unlike conventional steam power plants, an ORC system does not use water as the working fluid. Instead, organic fluids are used, for example suitable refrigerants. These fluids evaporate at lower temperatures. This enables an ORC waste heat power plant to use heat sources that are not sufficient for conventional steam turbines.
Compared with conventional steam-based power generation, ORC technology can operate efficiently with lower heat source temperatures. This makes the Organic Rankine Cycle a widely used solution for industrial waste heat recovery, waste heat-to-power projects and energy efficiency improvements in manufacturing and infrastructure applications.
The Organic Rankine Cycle is particularly suitable for power generation from waste heat at a low to medium temperature level.
Which applications is ORC suitable for?
ORC systems are used wherever industrial waste heat is continuously available. Whether in a production process, data center or energy system: economic efficiency depends on heat quantity, temperature level, operating hours and on-site power demand.
Metal and glass industry
High-temperature melting, furnace and cooling processes generate substantial waste heat. ORC systems recover this energy and convert it into additional electrical power to improve efficiency.
Chemical industry and cement plants
Food production
Drying, heating and cooling processes produce usable waste heat. ORC systems transform this thermal energy into power and improve resource utilisation.
Data centers
Data centers generate large amounts of continuous waste heat. ORC technology can recover this energy and contribute to a more efficient energy concept.
Power plants and energy supply
ORC systems utilise residual heat from energy generation processes to produce additional electricity and increase overall system efficiency.
How ORC generates power from waste heat
ORC power generation uses a closed thermodynamic cycle that converts waste heat into electricity. The process enables productive use of thermal energy that would otherwise remain unused. The following overview shows the most important components of an ORC system and their function:
- An ORC system transfers waste heat in an evaporator to an organic working fluid.
- The fluid evaporates, is under pressure and then flows into an expander.
- There it expands and generates mechanical energy.
- This mechanical energy drives a generator.
- The generator converts it into electric power.
- The working fluid then condenses in the condenser.
- A pump brings it back to the required pressure and returns it to the evaporator. The cycle starts again.
ORC systems and expander solutions from BITZER
BITZER and BPower provide ORC solutions for industrial waste heat recovery projects. Depending on the available heat source, temperature level and operating conditions, systems can be configured to maximise power generation and energy efficiency.
BPower has been part of the BITZER Group since 2023 and supports projects from planning and project engineering through to installation and technical service.
A central component is the BITZER screw expander with integrated generator. It efficiently converts the thermal energy of the working fluid into mechanical power and forms the basis for power generation. Thanks to its semi-hermetic design, it does not require a shaft seal: this reduces the risk of refrigerant losses and supports reliable operation.
The compact and modular system concepts are suitable for various industrial applications. They help companies make better use of existing energy sources and configure their energy supply more efficiently.
When an ORC waste heat power plant pays off
An ORC waste heat power plant uses energy that is already available.
ORC combines energy efficiency with economic benefits. Companies generate power from existing waste heat and thereby reduce their external energy demand. This can reduce operating costs and increase supply reliability.
At the same time, ORC supports the decarbonisation of industrial processes. The technology uses existing thermal resources and converts them into low-emission electrical energy. This allows companies to reduce CO₂ emissions without placing additional load on their heat source.
ORC is particularly attractive for systems with high operating time, a stable heat source and a relevant temperature range. Whether an ORC waste heat power plant pays off depends on the specific application. Key factors include heat quantity, temperature level, operating hours, power demand and integration into the existing system.
Typical evaluation criteria include waste heat availability, operating hours, electricity prices and project-specific return on investment (ROI). A technical assessment helps determine the economic potential of an ORC installation.
FAQ
Frequently asked questions about ORC waste heat power plants
Check your ORC potential
Would you like to know whether your waste heat source is suitable for an ORC waste heat power plant? Together, we review the heat source, temperature level, operating hours and economic potential.