SciTransfer
DECAGONE · Project

Industrial Waste Heat Recovery System for Carbon-Free Power Generation

energyPilotedTRL 7

Imagine a giant factory that leaks a huge amount of heat into the air. This project builds a high-tech machine that catches that escaping heat and turns it back into electricity. It's like putting a recycling plant for energy right inside the factory to lower power bills.

By the numbers
2 MW
Installation capacity at TŘINECKÉ ŽELEZÁRNY
16
Consortium partners
6
Other industrial sectors evaluated for transposability
The business problem

What needed solving

Energy-intensive industries lose massive amounts of money and emit CO2 by letting waste heat escape. Current recovery systems are often too bulky, expensive to maintain, or inefficient for diverse industrial temperatures.

The solution

What was built

A 2 MW ORC-based waste-heat-to-power system featuring a hermetic turbogenerator with active magnetic bearings and an AI-driven monitoring layer.

Audience

Who needs this

Steel mill operatorsCement plant managersGlass manufacturersOil and gas refinery engineersEnergy Service Companies (ESCOs)
Business applications

Who can put this to work

Steel and Metals
enterprise
Target: Iron and steel manufacturers

If you are a steel mill dealing with massive heat loss from furnaces — this project developed a 2 MW installation that converts waste heat into electricity for self-consumption. This reduces reliance on the external grid and lowers carbon emissions.

Glass and Cement
enterprise
Target: High-temperature material producers

If you are a cement plant dealing with high-temperature exhaust gases — this project developed a compact ORC system with disruptive turbomachinery. It allows for more effective heat recovery in tight industrial spaces with near-zero maintenance.

Oil, Gas and Refineries
enterprise
Target: Petrochemical refineries

If you are a refinery dealing with complex heat streams — this project developed an intelligent monitoring system using machine learning for real-time efficiency. This ensures the energy recovery system operates at peak performance automatically.

Frequently asked

Quick answers

What is the cost or pricing model for this technology?

Based on available project data, the project is exploring new financing and business models, specifically the ESCO (Energy Service Company) model to contract, finance, and operate the facilities.

Can this be deployed at an industrial scale?

Yes, the technology is being demonstrated with a 2 MW installation at the TŘINECKÉ ŽELEZÁRNY steel mill in the Czech Republic.

What is the IP or licensing status?

Based on available project data, specific licensing terms are not mentioned, but the project involves disruptive turbomachinery and innovative active magnetic bearings.

How is the system integrated into existing plants?

Integration is achieved through a compact ORC-based system using IoT, innovative probes, and machine learning algorithms for real-time efficiency improvement.

What is the expected maintenance requirement?

The proposed hermetic turbogenerator design uses active magnetic bearings to achieve near-zero maintenance.

Consortium

Who built it

The consortium is heavily industry-driven with a 56% industry ratio, comprising 9 industrial partners and 4 SMEs. This strong commercial presence, spanning 10 countries and 16 total partners, suggests a high focus on market transposability and practical deployment rather than pure academic research.

How to reach the team

Contact ENERTIME SA in France for technical specifications on the 2 MW ORC system.

Next steps

Talk to the team behind this work.

Contact us to find similar waste-heat-to-power technologies for your industrial site.