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Waste Heat Recovery

Turboden ORC units can produce electricity by recovering heat from industrial processes and in combined cycles with reciprocating engines and gas turbines. The power of Turboden turbo generators in this application generally ranges up to 20 MW electric per single shaft.

47

plants*

134.7

MWe total

2008

first plant delivered

*14 plants are under construction

  • TURBODEN WASTE HEAT RECOVERY ORC SYSTEM FOR ITALCEMENTI CEMENT PLANT
  • TURBODEN WASTE HEAT RECOVERY ORC SYSTEM FOR ORI MARTIN STEEL PLANT
  • TURBODEN WASTE HEAT RECOVERY ORC SYSTEM FOR CRH CEMENT PLANT
  • TURBODEN DIRECT EXCHANGE HEAT RECOVERY ORC SYSTEM FOR CEMENTIROSSI CEMENT PLANT
  • TURBODEN SOLUTIONS FOR INDUSTRIAL PROCESSES
  • REDUCE YOUR ENERGY BILL BY GENERATING YOUR OWN POWER

In heat recovery applications, Turboden ORC units can be a valuable way to convert residual, low-grade heat into useful power in production processes, such as cement, glass, steel, other ferrous and non- ferrous metals.

HEAT RECOVERY FROM PRODUCTION PROCESSES

Heat recovery from cement production
Heat recovery from cement production
  • High cycle efficiency up to 25%
  • Heat input from gaseous, liquid and condensing streams starting from 100°C
  • Ease of integration into the industrial process, not affecting the production
  • No impact on prime equipment (engine, gas turbine) operation

TYPICAL SOLUTIONS

ORC size location customer status notes
1.3 MWe Eclépens, Switzerland Cadcime SA / Holcim Suisse Eclépens – LafargeHolcim group In operation since 2020 Electric power production from waste heat in cement production process
2 MWe Ait Baha, Morocco Ciments Du Maroc In operation since 2010 Electric power production from waste heat in cement production process + CSP (Hybrid plant)
2 MWe Piacenza, Italy Industria Cementi Giovanni Rossi Under construction Electric power production from waste heat in cement production process
2.3 MWe Möriken-Wildegg, Switzerland Jura-Cement-Fabriken AG (CRH Group) In operation since 2016 Electric power production from waste heat in cement production process
3.8 MWe Fieni, Dâmboviţa County, Romania S.C. Carpatcement Holding S.A. (Heidelberg Group) In operation since 2015 Electric power production from waste heat in cement production process
4 MWe Aleşd, Romania Holcim SA In operation since 2012 Electric power production from waste heat in cement production process
5 MWe Rohožník, Slovakia CRH In operation since 2014 Electric power production from waste heat in cement production process
7 MWe Kahramanmaraş, Turkey CTP Team Srl / Cimko Narli Cement In operation since 2019 Electric power production from waste heat in cement production process
7.3 MWe Adana Yumurtalık, Turkey CTP Team Srl / Sönmez Çimento Under construction Electric power production from waste heat in cement production process
7.2 MWe Portugal CTP Team Srl / Secil-Group S.A. Under construction Electric power production from waste heat in cement production process + solar field (hybrid plant)
5 MWe Eskişehir, Turkey CTP Team Srl, CTN Makina / Enerjisa Müsteri Cözümleri A.S. Under construction Electric power production from waste heat in cement production process
10 MWe Fujairah, United Arab Emirates Undisclosed Under construction Electric power production from waste heat in cement production process
8 MWe Souselas, Portugal CTP Team Srl / Cimpor Under construction Electric power production from waste heat in cement production process
6 MWe Alhandra, Portugal CTP Team Srl / Cimpor Under construction Electric power production from waste heat in cement production process
10 MWe Akdere Mersin, Turkey CTP Team Srl, CTN Makina / Medcem Madencilik ve Yapı Malzemeleri San Tic. A.Ş. Under construction Electric power production from waste heat in cement production process

TYPICAL SOLUTIONS

ORC size location customer status notes
0.7 MWe Singapore NatSteel Holdings Pte Ltd Off Electric power production from waste heat in steel industry (Rolling mill)
1.2 MWe Gwangyang City, South Korea POSCO ICT Company Off Electric power production from waste heat in steel industry (Submerged Arc Furnace)
7 MWe Cremona, Italy Arvedi S.p.A. In operation since 2018 Electric power production from waste heat in steel industry (Electric Arc Furnace)
2.2 MWe Brescia, Italy ORI Martin S.p.A. In operation since 2016 Electric power production from waste heat in steel industry (Electric Arc Furnace)
2.5 MWe Nagoya, Japan Mitsubishi Heavy Industries / Aichi Steel Under construction Electric power production from waste heat in steel industry (Electric Arc Furnace)
2.7 MWe Riesa, Germany ESF Elbe Stahlwerke Feralpi GmbH In operation since 2013 Electric power production from waste heat in steel industry (Electric Arc Furnace)

TYPICAL SOLUTIONS

ORC size location customer status notes
0.5 MWe Villotta di Chions (PN), Italy BDF Industries In operation since 2015 Electric power production from waste heat in container glass production process
1.2 MWe Sriperumbudur, India GEA Bischoff GmbH / Saint-Gobain India Pvt.Ltd. - Chennai In operation since 2019 Electric power production from waste heat in float glass production process
1.2 MWe Pisa, Italy GEA Process Engineering S.p.A. In operation since 2019 Electric power and compressed air production from waste heat in float glass production process
1.3 MWe Cuneo, Italy Gea Bischoff/AGC In operation since 2012 Electric power production from waste heat in float glass production process
6.2 MWe Beyköy - Düzce, Turkey Çalbıyık Grup / Düzce Cam In operation since 2018 Electric power production from waste heat in float glass production process
1.5 MWe Soniyana, District Chittorgarh, Rajasthan, India Asahi India Glass Under construction Electric power from waste heat in float glass production process
1.7 MWe Roorkee, District Haridwar, Uttarakhand, India Asahi India Glass Under construction Electric power from waste heat in float glass production process
1 MWe Udine, Italy Vetrerie del Nord Under construction Electric power production from waste heat in container glass production process
2.3 MWe Piegaro, Italy Vetreria Cooperativa Piegarese Soc. Coop. A R.L. Under construction Electric power production from waste heat in container glass production process
1.8 MWe Samut Prakan, Thailand AFT Float Glass Thailand Under construction Electric power production from waste heat in glass production process
1 MWe Seingbouse, France E.ON Business Solutions SAS / AGC INTERPANE GLASS France In operation since 2023 Electric power production from waste heat in glass production process
undisclosed Ujazd, Poland Euroglas Polska Sp. Z o.o Under construction Electric power production in glass production process

TYPICAL SOLUTIONS

ORC size location customer status notes
0.7 MWe Torbole Casaglia (BS), Italy Fonderia di Torbole In operation since 2016 Electric power production from waste heat from cast iron cupola furnace
0.8 MWe Radenthein, Austria Veitsch-Radex GmbH & Co In operation since 2009 Electric power production from waste heat in refractory production process
1.7 MWe Germany undisclosed Under construction Electric power production from waste heat in aluminum production process
1.9 MWe Negeri Sembilan, Malaysia Invest Energy In operation since 2019 Electric power production from waste heat from chemical vapor infiltration furnace
2.2 MWe Vercelli, Italy Sacal S.p.A. In operation since 2019 Electric power production from waste heat in aluminum production process

OUR EXPERIENCE

In 1996, Turboden realized its first heat recovery plant in an iron foundry in Brescia. Since then, Turboden has been involved in ORC projects in different industrial processes, such as cement industry, glass industry, steel industry, waste incineration, and mining. Turboden ORC units can produce electricity also by recovering heat from combined cycles, reciprocating engines, internal combustion engines, gas turbines, and gas compressor stations. In 2010, an innovative project was installed in Russia to recover heat, from the associated gas released from the process of oil extraction, through controlled combustion (instead of flaring). The plant generates both heat and power: the hot water is used to warm up the extracted oil while the electric power is used in the extraction station. The ORC turbogenerator produces 1,800 kW of electric power.

Another project was installed in Russia, in the Moscow region: this heat recovery ORC unit is coupled with five MTU engines, 2 MWe each. The exhaust gas of these engines is conveyed the ORC module by thermal oil.

Turboden was also awarded an order for a 4 MW ORC unit to recover heat in the cement industry in Slovakia. The plant produces 4 MW by recovering waste heat from the exhaust gas of the kiln and clinker cooler. The recovered heat is conveyed to the ORC by two different loops using thermal oil and water. This project represents another step of Turboden’s growth in the cement industry, coming after the successful startup of the 2 MW Ait Baha plant for Italcementi in December 2010. In February 2013, Turboden started-up its first application in the steel industry: a heat recovery system for power generation, in Singapore. The ORC is a 700 kW unit that recovers waste heat from a billet reheating furnace.

Furthermore, one of the latest innovative projects is a new 3 MW ORC unit that uses the heat from a portion of the saturated steam recovered from the exhaust gases of an EAF (Electric Arc Furnace), in Germany. This plant is part of the H-REII DEMO Project (Heat Recovery in Energy Intensive Industries), that the DG Environment of the European Commission decided to co-finance under the LIFE+ program for its technological innovation and environmental value.




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