INDUSTRIAL WASTE HEAT | HEAT SOURCES
It is estimated that as much as 20 to 50% of the energy consumed in industrial processes is ultimately lost via waste heat contained in streams of hot exhaust gases and liquids.
Turboden ORC units are uniquely positioned to utilize waste heat from a variety of industrial heat sources.
| Gas | Liquid | Steam/Vapor | |
| Cement | • | ||
| Glass | • | ||
| Oil & Gas | • | • | • |
| Chemical | • | • | • |
| Steel | Non ferrous | • | • | • |
| Pulp & Paper | • | ||
| Food | • | • | |
| Waste treatment | • | • | • |
| Thermal Oxidizers | • |
INDUSTRIAL WASTE HEAT | APPLICATION EXAMPLES
I. INDUSTRIAL WASTE HEAT | APPLICATION EXAMPLES| CEMENT PLANTS
Cement plants present a prime opportunity for heat recovery projects with Turboden ORC units.
In the cement production process, large quantities of heat at medium temperatures are wasted both in preheating the kiln and in cooling the clinker. While heat recovery plants based on the steam cycle have difficulties in adapting to varying operating conditions and often sidetrack the production process, Turboden ORC units demonstrate an excellent behavior at varying loads, are completely automatic in operation and start-stop procedures and allow for electricity generation to be truly a side activity by retaining full focus on the core business.
Exhaust gas streams Kiln pre-heater gas › High dust content
› Varying operating conditions
Clinker cooler gas Cement plants | Turboden References Description PRS PRS | CC PRS | CC Location Ait Baha | Morocco Alesd | Romania Slovakia Customer Italecementi Group Holcim Romania | Holcim Group Holcim Slovakia | Holcim Group Heat source Exhaust gas @ 330°C PRS @ 360°C | CC @ 250 °C PRS @ 360°C | CC @ 310 °C ORC electric power 2 MWe 4 MWe 4967 KWe For more details and project photos click here
II. INDUSTRIAL WASTE HEAT | APPLICATION EXAMPLES | STEEL INDUSTRY
Steel production is highly energy intensive and accordingly generates large amounts of heat which is typically wasted in the environment. Several different processes can support a waste heat recovery unit based on a Turboden ORC. Recovering heat for electricity generation with Turboden ORC units can increase process efficiency, lower energy costs, and reduce the carbon footprint in a steel plant.
Exhaust gas streams Rolling | Forging › Relatively clean exhaust gas at moderate temperature
Strip processing Heat treatment Cost effective for ORC ≥ 600/800 kWe; BOF › High flows, temperatures and dust content
› Large variations in operating cycle
Blast furnaces Sinter Interface between process and energy recovery unit is critical Electric Arc Furnace ORCs proposed where heat recovery exchangers are available 
Electric Arc Furnace
› 25 - 30% of the energy input in the furnace is lost in the exhaust
› 70% of the lost power could be recovered
› Target output: 3 - 5% of the EAF installed power
Steel plants | Turboden References Description Steel Rolling Mill Electric Arc Furnace Location Singapore Riesa | Germany Customer Natsteel | Tata Group ESF Elbe Stahlwerke Feralpi GmbH Heat source Exhaust gas @ 400°C Exhaust gas from EAF ORC electric power ca. 0.7MWe 2680 kW For more details and project photos click here
III. INDUSTRIAL WASTE HEAT | APPLICATION EXAMPLES | WASTE TREATMENT
In waste treatment plants, Turboden ORC units can be coupled to both exhaust gas and liquid heat streams.
While typically employed in incineration plants, Turboden units can also operate in gasification facilities based on the combustion of syngas in a thermal oil boiler. Turboden ORC units can also be coupled to the exhaust gas of internal combustion engines operating with landfill gas, or biogas in anaerobic digestion facilities. For more info on this type of application click here
Below is a process graph of a custom Turboden application in a waste incinerator in Belgium generating app. 3MW of electric power from hot water @ 180°C
Waste plants | Turboden References Description Waste incineration Waste incineration Waste incineration Waste gasification Waste incineration Location United States Belgium Italy Turkey France ORC electric power 1000 kW 3000 kW 500 kW 5286 kW (x2) 2700 kW For more details and project photos click here