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Waste Heat Recovery with Organic Rankine Cycle (ORC) System for the Manufacturing Industry

Problem

Each year, a significant amount of industrial energy input is lost as waste heat in the form of steam vented into the atmosphere. A client in the manufacturing industry seeking to reduce their energy costs and improve their environmental footprint recognized the potential for capturing this waste heat and using it to boost their energy efficiency and promote their overall sustainability efforts.

Solution

Our team here at n2 Integrated Energy Solutions, LLC designed a system to recover the steam heat generated by the manufacturing process and use it to produce electricity that would be considered carbon neutral. We engineered an Organic Rankine Cycle (ORC) system that captures the steam and utilizes organic fluid with a boiling point lower than water to recover the heat, which transforms the fluid into high pressure vapor that drives a turbine coupled to an electrical generator. The surplus heat is no longer discharged into the atmosphere, instead, it provides a 15% to 30% increase in plant energy efficiency.

In addition to the financial benefit of lower utility costs, this project qualified for the utility's rebate program, and the payback period is estimated to be 3.5 to 4.5 years. With a more efficient way to drive their large pump motor loads, this plant has substantially reduced its impact on the environment.

Contact us directly if you are interested in learning more about this project or are interested in putting your waste heat to productive use.

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Organic Rankine Cycle (ORC) System
Organic Rankine Cycle (ORC) System

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