ORC Waste Heat Recovery System for a Fertilizer Plant
Release Date:
2026-04-24
Industrial production generates substantial amounts of medium- and low‑grade high‑temperature waste heat. Conventional treatment typically involves direct cooling and discharge, which not only wastes energy and increases the operating costs of circulating water systems but also runs counter to current trends toward industrial energy conservation, carbon reduction, and green manufacturing. Terui’s ORC waste‑heat recovery power generation system enables the efficient utilization of waste‑heat resources and on‑site power generation.
I. Project Background and Pain Points
II. Core Project Parameters and System Configuration
(1) Heat Source Conditions
- Heat source medium: high-temperature hot water generated during the production process.
- Hot water flow rate: 300 t/h
- Inlet and outlet water temperatures: 143°C / 120°C
- Power generation capacity: 2 × 900 kW (dual-unit configuration, total installed capacity of 1,800 kW)
(II) Working Fluid and Key Equipment Parameters
- Working fluid: R245fa (pentafluoropropane). This refrigerant boasts excellent thermal stability, is non‑flammable, and has an ODP of zero, ensuring compliance with environmental regulations. It is well suited for medium- and low‑temperature waste‑heat power generation applications and can operate reliably under heat‑source temperatures of 120–150°C.
- Working fluid flow rate: 130 t/h
- Working fluid inlet and outlet temperatures: inlet 38.4°C (liquid), outlet 126.5°C (gas).
- System design pressure: 25 bar
- Heat exchanger configuration:
- Preheater: Used to preheat the working fluid, thereby improving energy utilization efficiency.
- Evaporator: Adopting a modular design, with a total heat transfer area of 191 m² + 286 m², it is tailored to meet the high-efficiency heat exchange requirements of the heat source and working fluid.
(3) System Process Description
This ORC waste heat recovery system employs a dual‑heat‑exchanger configuration comprising a preheater and an evaporator: high‑temperature hot water first passes through the preheater to provide preliminary heating to the low‑temperature working fluid, after which it enters the evaporator to vaporize the working fluid. The resulting vapor then expands through a turbine to perform work, driving a generator to produce electricity. The exhaust steam, having done its work, is condensed into a liquid in the condenser and subsequently pumped back to the preheater by the working‑fluid pump, completing a closed loop that enables continuous conversion and utilization of waste heat.
III. Project Implementation Value and Advantages
(1) Economic Benefits
(II) Energy-Saving and Carbon-Reduction Benefits
(3) Technological and Operational Advantages
- Strong working fluid compatibility: Utilizing R245fa as the working fluid, which features a moderate boiling point and excellent thermal stability, it enables efficient phase change under a 143°C heat source. The system operates at stable pressures, with no risk of corrosion or scaling, resulting in low maintenance costs.
- High system reliability: The closed-loop design eliminates the risk of working fluid leakage and obviates the need for complex deaeration and desalination systems. Compared with conventional steam Rankine cycles, it features a simpler structure and easier operation and maintenance, making it well suited to the continuous production conditions of fertilizer plants.
- Modular design for flexibility: The dual‑unit configuration combined with a modular evaporator allows for flexible adjustment of operating load in response to heat‑source fluctuations, accommodating varying production demands at fertilizer plants and ensuring long‑term system stability.
IV. Demonstrative Significance for the Industry
Service Hotline – Engineer Wang
No. 1 Chuangli Road, National Economic and Technological Development Zone, Zengcheng District, Guangzhou City
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