Organic Rankine Cycle (ORC) Systems

Detailed overview of innovation with sample startups and prominent university research


What it is

Organic Rankine Cycle (ORC) systems are a type of power generation technology that utilizes waste heat to generate electricity. They operate on a similar principle as steam turbines, but instead of using water as the working fluid, they use organic fluids with lower boiling points. This allows ORC systems to efficiently convert low-grade waste heat, which is often unusable in traditional power generation systems, into electricity.

Impact on climate action

Organic Rankine Cycle (ORC) Systems in Industrial Waste Heat Recovery optimize energy efficiency by converting waste heat into electricity. By capturing and utilizing heat that would otherwise be lost, these innovations reduce reliance on fossil fuels, lower emissions, and promote sustainable industrial practices, contributing to climate action and resource conservation.

Underlying
Technology

  • Evaporator: Waste heat from an industrial process or other source is used to vaporize the organic working fluid.
  • Turbine: The high-pressure vapor expands through a turbine, generating mechanical energy.
  • Generator: The turbine is connected to a generator, which converts the mechanical energy into electricity.
  • Condenser: The vapor leaving the turbine is condensed back into a liquid by rejecting heat to a cooling medium, such as water or air.
  • Pump: The liquid working fluid is then pumped back to the evaporator to complete the cycle.

TRL : 7-8


Prominent Innovation themes

  • Advanced Working Fluids: Researchers and companies are developing new organic working fluids with improved thermodynamic properties, such as higher thermal stability and lower environmental impact.
  • High-Efficiency Expanders: Innovations in turbine and expander design are improving the efficiency of ORC systems, leading to higher electricity generation from the same amount of waste heat.
  • Compact and Modular ORC Systems: Companies are developing compact and modular ORC systems that can be easily integrated into existing industrial facilities or used for distributed power generation applications.
  • Hybrid ORC Systems: Hybrid ORC systems combine ORC technology with other power generation technologies, such as solar thermal or biomass gasification, to improve overall system efficiency and flexibility.

Other Innovation Subthemes

  • Enhanced Thermodynamic Fluids
  • Turbocharger Development
  • Scalable Modular Designs
  • Integration with Renewable Sources
  • Waste Heat Utilization Strategies
  • Heat Pump Synergy
  • Next-Gen Turbine Technology
  • Advanced Condensing Techniques
  • Heat Recovery Optimization
  • Waste Heat Mapping
  • ORC Retrofit Solutions
  • Smart Control Systems
  • Novel Heat Exchanger Designs
  • Multi-stage Expander Innovations
  • ORC Performance Monitoring

Related Innovations

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Sample Global Startups and Companies

  1. Enertime:
    • Technology Enhancement: Enertime specializes in the development and implementation of Organic Rankine Cycle (ORC) systems for waste heat recovery and renewable energy generation. Their ORC technology utilizes organic fluids to convert low-temperature heat sources, such as industrial waste heat or geothermal energy, into electricity. Enertime’s systems are designed for high efficiency and reliability, offering customized solutions tailored to specific applications and operational requirements.
    • Uniqueness of the Startup: Enertime stands out for its focus on ORC technology and its commitment to sustainable energy solutions. Their expertise in ORC systems spans various industries, including manufacturing, oil and gas, and geothermal power generation. Enertime’s innovative approach to waste heat recovery and renewable energy conversion helps industries reduce energy consumption, lower emissions, and improve energy efficiency.
    • End-User Segments Addressing: Enertime serves industrial companies, energy producers, and municipalities seeking to harness waste heat and renewable energy resources for power generation. Their ORC systems are deployed in a wide range of applications, including industrial processes, geothermal power plants, biomass facilities, and waste-to-energy projects.
  2. Ormat Technologies:
    • Technology Enhancement: Ormat Technologies is a leading provider of geothermal and recovered energy generation solutions, including Organic Rankine Cycle (ORC) systems. Their ORC technology converts low-temperature heat sources, such as geothermal brine or industrial waste heat, into electricity. Ormat’s ORC systems feature modular designs, advanced control algorithms, and proprietary organic fluids optimized for maximum energy conversion efficiency.
    • Uniqueness of the Startup: Ormat Technologies stands out for its extensive experience in geothermal and recovered energy development and its global presence in renewable energy markets. With a focus on innovation and sustainability, Ormat has successfully deployed ORC systems in geothermal power plants, oil and gas facilities, and industrial processes worldwide, contributing to the transition to clean and renewable energy sources.
    • End-User Segments Addressing: Ormat Technologies serves utility companies, independent power producers (IPPs), and industrial clients seeking reliable and cost-effective energy solutions. Their ORC systems are deployed in geothermal power plants, biomass facilities, cement kilns, and other industrial applications, providing clean and renewable electricity generation while reducing environmental impact.
  3. Exergy International:
    • Technology Enhancement: Exergy International specializes in the design, engineering, and manufacturing of Organic Rankine Cycle (ORC) systems for waste heat recovery and renewable energy generation. Their ORC technology is optimized for various heat sources, including biomass, industrial processes, and solar thermal systems. Exergy’s systems feature high-performance turbomachinery, advanced heat exchanger designs, and customizable configurations to maximize energy efficiency and reliability.
    • Uniqueness of the Startup: Exergy International stands out for its focus on custom-engineered ORC solutions tailored to specific customer requirements and operating conditions. With a strong emphasis on innovation and quality, Exergy delivers turnkey ORC systems that enable industries to capture and utilize waste heat effectively, reduce energy costs, and lower carbon emissions.
    • End-User Segments Addressing: Exergy International serves industries, utilities, and renewable energy developers seeking sustainable energy solutions for power generation and waste heat recovery. Their ORC systems are deployed in a wide range of applications, including steel production, chemical processing, biomass cogeneration, and concentrated solar power (CSP) plants, helping customers optimize energy use and enhance operational efficiency.

Sample Research At Top-Tier Universities

  • Technical University of Munich (TUM):
    • Research Focus: TUM is actively engaged in research on Organic Rankine Cycle (ORC) Systems for Industrial Waste Heat Recovery, focusing on developing advanced ORC technologies and system integration strategies to efficiently harness low-grade waste heat from industrial processes.
    • Uniqueness: Their research involves the design and optimization of ORC power plants, heat exchangers, and working fluids tailored to the specific temperature and pressure conditions of industrial waste heat sources. They also investigate novel control algorithms, thermal storage solutions, and waste heat utilization schemes to enhance overall system performance and flexibility.
    • End-use Applications: The outcomes of their work find applications across various industrial sectors, including steel manufacturing, chemical processing, and food production. By converting waste heat into electricity or useful thermal energy, TUM’s research contributes to improving energy efficiency, reducing greenhouse gas emissions, and enhancing the sustainability of industrial operations.
  • National Renewable Energy Laboratory (NREL):
    • Research Focus: NREL conducts pioneering research on ORC Systems for Industrial Waste Heat Recovery, leveraging its expertise in thermodynamics, fluid mechanics, and renewable energy technologies to advance the state-of-the-art in waste heat utilization and power generation.
    • Uniqueness: Their research encompasses experimental testing, numerical modeling, and techno-economic analysis of ORC systems under various operating conditions and waste heat sources. They also collaborate with industry partners to demonstrate prototype ORC systems, validate performance models, and identify cost-effective deployment opportunities.
    • End-use Applications: The outcomes of their work have applications in diverse industrial settings, including oil and gas refineries, pulp and paper mills, and data centers. By recovering waste heat for electricity generation or process heating, NREL’s research helps industries reduce energy costs, increase competitiveness, and achieve sustainability goals.
  • KTH Royal Institute of Technology (Sweden):
    • Research Focus: KTH is at the forefront of research on ORC Systems for Industrial Waste Heat Recovery, leveraging its expertise in thermodynamic analysis, heat transfer, and renewable energy conversion to develop innovative ORC solutions tailored to industrial applications.
    • Uniqueness: Their research involves the development of compact, modular ORC systems, micro-scale heat exchangers, and advanced control strategies optimized for decentralized waste heat recovery. They also explore the integration of ORC technology with district heating networks, thermal energy storage, and combined heat and power (CHP) systems to maximize energy efficiency and grid flexibility.
    • End-use Applications: The outcomes of their work find applications in various industrial sectors, including manufacturing, automotive, and wastewater treatment. By recovering and utilizing waste heat resources, KTH’s research supports the transition to a circular economy, enhances energy security, and reduces environmental impact associated with industrial processes.

commercial_img Commercial Implementation

ORC systems are being implemented in various industries around the world, including cement, steel, glass, and chemical production, as well as in waste-to-energy plants and geothermal power plants. For example, Enertime has deployed ORC systems in industrial facilities in Europe and Asia, recovering waste heat and generating electricity.



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