Country: Poland
Focus area:Green
Thematic area:
Renewable energy technologies, Waste reduction and Recycling Technology , Energy-Efficient Technologies, Carbon Capture & Storage Technologies
TRL phase: TRL 9 - actual system launched on the market (System launched)
Addressed business processes: MANUFACTURING OPERATIONS process , TECHNOLOGY DEVELOPMENT process
Solution overview
Our company, Upthermo, specializes in the Organic Rankine Cycle (ORC) technology, which efficiently converts waste heat from industrial processes into clean electricity. This solution is designed to address the critical need for energy recovery and efficiency within industries. By capturing and repurposing waste heat, our technology not only reduces energy wastage but also significantly contributes to lowering carbon emissions. The primary target users of our solution are industries focused on enhancing their energy efficiency and reducing their environmental impact through sustainable practices.
Key features
Key features that differentiate our solution
High efficiency at low temperatures: Our ORC technology operates efficiently even at lower temperatures compared to traditional systems, making it ideal for industries with moderate waste heat streams.
Scalability and modularity: The solution is highly flexible, thanks to its modular design, allowing for easy adaptation to the specific energy recovery needs of various industrial applications, regardless of their size or complexity.
Advanced turbine technology: We use modern turbines that maximize energy conversion efficiency, delivering higher power output from the same amount of waste heat.
Environmentally friendly working fluids: Our ORC systems use environmentally safe working fluids with low Global Warming Potential (GWP), ensuring compliance with stringent environmental standards.
Robustness and reliability: Our ORC systems are designed with durability in mind, providing reliable, low-maintenance operation, minimizing downtime, and enabling long-term energy recovery.
Easy integration: The ORC solution is designed to be easily integrated into existing industrial processes, requiring minimal modifications to current systems and infrastructure.
Integration and adaptability in manufacturing environments
Integration with existing manufacturing processes
The ease of integrating our ORC solution into existing manufacturing processes largely depends on the specific setup of the facility. In cases where there is an existing heat node, integration can be relatively straightforward, requiring only the connection of our system to the heat source. However, in situations where such a node is not available, a customized heat exchanger may need to be designed and installed to capture and utilize the waste heat effectively.
Customization and compatibility
Our solution is highly customizable to meet specific manufacturing requirements. We work closely with each client to ensure that the system is tailored to their unique needs, whether that involves modifying the heat recovery process or adapting the system to fit within the constraints of their current infrastructure.
Compatibility with common technologies and equipment
Our ORC technology is designed to be compatible with a wide range of common manufacturing technologies and equipment. We prioritize seamless integration to minimize disruptions during implementation and ensure that our system can operate efficiently alongside existing processes.
Implementation support and training for manufacturers
We offer comprehensive support services to manufacturing companies throughout both the implementation and post-implementation phases. During implementation, our team provides on-site assistance to ensure the smooth integration of the ORC system into your existing processes. This includes detailed assessments, customized installation plans, and close collaboration with your engineering teams to address any challenges that may arise.
Post-implementation, we offer ongoing support to ensure the optimal performance of the system. This includes regular maintenance services, system performance monitoring, and prompt technical support to address any issues. Our goal is to ensure that the system operates efficiently and continues to deliver energy savings over the long term.
Our support ensures that your team is fully equipped to operate the system effectively, allowing you to fully leverage the energy efficiency and sustainability benefits of our ORC technology.
Sustainability, compliance and certifications in the EU
Yes, our ORC solution fully complies with all relevant environmental regulations and industry standards in the EU. We design and manufacture our systems in strict accordance with EU directives on energy efficiency, waste reduction, and environmental protection. This ensures that our technology not only meets but often exceeds the regulatory requirements, helping our clients to achieve their sustainability goals while remaining fully compliant with the law.
Certifications and accreditations
Our ORC solution is backed by several certifications and accreditations that validate its performance and sustainability. These include CE marking, which demonstrates compliance with EU safety, health, and environmental protection standards. Additionally, our system has undergone rigorous testing and certification by independent bodies, ensuring that it delivers the promised energy efficiency and environmental benefits. We are also in the process of obtaining additional green certifications to further validate our commitment to sustainability.
These certifications provide our clients with confidence that they are investing in a proven, reliable, and environmentally responsible technology.
Expected return on investment (ROI)
For manufacturing companies, particularly those in the biogas sector, the expected return on investment (ROI) when adopting our ORC solution is highly favorable. With the current available subsidies, companies can anticipate achieving full ROI within a period of up to 2 years. This quick payback period is driven by the significant energy savings and efficiency improvements provided by our technology, along with the reduction in operational costs and carbon emissions.
Cost overview: implementation and ongoing expenses
The initial cost for implementing our ORC solution is approximately 2 million PLN for each 1MW of low-temperature heat. This investment covers the complete setup, including system design, customization, and installation.
In terms of ongoing expenses, maintenance costs are relatively low, amounting to about 2 percent of the initial investment per year. This includes regular servicing, performance monitoring, and any necessary technical support to ensure the system continues to operate efficiently over its lifetime.
