DECAGONE

Demonstrator of industrial CArbon-free power Generation from Orc-based waste-heat-to-Energy systems

16 partners from 10 countries will work together to demonstrate the potential of organic Rankine cycle (ORC) technology for the recovery of waste heat in all sectors of European industry. The EU-funded DECAGONE project will develop innovative technology for exploitation of industrial waste heat. It will make ORC systems more efficient, cost-effective and adaptable to more diverse sectors. This step is particularly important, considering that a third of energy for industrial thermal processes is lost through waste heat. According to the project, the potential power generation from this resource through full use of ORC technology represents around 7.6 million tonnes of CO₂ equivalent saved per year at European level.

Energy efficiency of intensive industrial processes and particularly waste heat recovery (WHR) technologies have been identified by international and regional organisations like IEA, EU or ADEME in France as a major game changer for CO₂ emissions reduction. The DECAGONE consortium led by ENERTIME proposes a project demonstrating the potential of ORC technology in waste heat-to-power conversion for self-consumption of industrial plants at a large industrial scale.
Targeting the waste heat potential of the company TŘINECKÉ ŽELEZÁRNY (mother company of partner Energetika Trinec), located in Czech Republic and historical manufacturer of iron & steel, the DECAGONE project will develop an innovative ORC-based WHR system using enhanced capture designs and disruptive turbomachinery. The proposed hermetic turbogenerator design will run on innovative active magnetic bearings for increased compacity, higher availability and safety as well as cost reduction with near-zero maintenance. Dedicated studies improve organic fluids or mixtures for higher stability and improved transposability to other industries. The project will also provide advanced monitoring using innovative probes, IOT and machine learning algorithms for real-time efficiency improvement.
Within the scope of the project, six other significant industrial sectors will be evaluated in terms of potential market and transposability at the European scale (aluminium, gas-energy, oil & gas, glass, LNG and co-generation). New financing and business models will also be investigated, supporting long-term operations of the erected assets, coping with long-lasting and resilient industrial processes. The use of the ESCO model to contract, finance and operate energy efficiency facilities will be part of the project preparing for the future operation of the facility by a specialised company. Lastly, diffusion of good practices all over Europe will use European partners in the consortium in co-ordination with regional energy agencies.