Turning a Problem into a Profit. ORC Technologies: Decarbonization Cement Industry

The cement industry faces growing pressure to decarbonize. As one of the largest contributors to global CO₂ emissions, accounting for nearly 8% of total emissions (World Economic Forum), the sector must adopt innovative technologies to meet regulatory demands and achieve sustainability targets. From production to shipping, Organic Rankine Cycle (ORC) technology offers a transformative solution to reduce emissions, lower energy costs, and enhance operational efficiency.
UNLOCKING EFFICIENCY IN CEMENT PLANTS WITH ORC TECHNOLOGY

Cement production is highly energy-intensive, requiring substantial thermal and electrical energy for operations such as raw material grinding, clinker production, and final cement grinding. As a result, cement plants generate significant amounts of waste heat in processes such as:
Preheater Exhaust Gases: High-temperature gases from preheating raw materials.
Clinker Cooler Air: Heat dissipated during clinker cooling.
Kiln Shell Radiation: Thermal energy lost through the kiln surface.
Traditionally, waste heat recovery for electricity production in cement plants has focused primarily on high-temperature sources, such as preheater exhaust gases and clinker cooler air, utilizing steam Rankine cycles or high-temperature ORC systems. These conventional approaches have neglected lower-temperature waste heat streams, which were often considered economically unviable for power generation.
ORC technology changes this paradigm. By efficiently converting low-temperature heat streams (as low as 75°C) into clean electricity, Climeon maximizes energy recovery potential. This advancement broadens the scope of waste heat recovery, enabling cement plants to harness previously untapped heat from sources such as conditioning towers, preheater towers, or cooler vent filters, traditionally considered unusable for power generation.

 
KEY BENEFITS OF LOW-TEMP ORC WASTE HEAT RECOVERY FOR CEMENT MANUFACTURERS:
Expand usable waste heat streams, significantly increasing total energy recovery.
Reduce purchased power consumption and reliance on fossil-fuel-based sources of power.
Lower CO₂ emissions by capturing and utilizing waste heat.
Future-proof facilities against rising electricity costs and stricter regulations.
By integrating ORC technology, cement manufacturers can achieve greater energy efficiency while addressing key economic and environmental challenges.
DECARBONIZING CEMENT LOGISTICS WITH ORC HEATPOWER
The cement industry’s value chain extends beyond production. Cement carriers—essential for transporting bulk materials—play a role in the sector’s carbon footprint as well. PRO WASTE introduces ORC technology is equally impactful in the maritime sector, offering another means to lower the industry’s environmental impact.
Large ships, including cement carriers, typically lose over 50% of their fuel energy as waste heat. A significant portion of this waste heat falls within the low-temperature range (50-150°C). PRO WASTE ORC system is specifically designed to harness this untapped energy, converting it into electricity to support onboard systems. By utilizing this energy more effectively, the technology helps reduce fuel consumption and associated emissions, contributing to compliance with the International Maritime Organization’s (IMO) carbon intensity targets.
A COMPREHENSIVE SUSTAINABILITY SOLUTION FOR CEMENT PRODUCERS
PRO WASTE ORC systems is a versatile and impactful solution tailored to the cement industry’s unique challenges. Designed for maximum efficiency from low-temperature heat sources, it enables cement manufacturers to utilize previously untapped waste heat in both production and transport. This broadens the potential for energy recovery across the entire value chain. The system's robust and straightforward design, along with its flexible components that adapt to varying heat sources, ensures seamless integration into new-build plants, retrofitted facilities, and maritime vessels. Furthermore, PRO WASTE ORC technology supports ESG initiatives and contributes to Scope 2 emissions reductions, helping cement companies meet their sustainability goals. By lowering electricity costs and enhancing power reliability, ORC strengthens the competitive position of cement manufacturers and supports their long-term decarbonization strategies.  
BUILDING A GREENER FUTURE FOR THE CEMENT INDUSTRY                                     
As the cement industry strives to balance economic growth with environmental responsibility, ORC technology offers a valuable solution to support decarbonization efforts. By converting low-temperature waste heat into clean electricity, PRO WASTE enables cement producers to:
Achieve substantial energy savings.
Reduce greenhouse gas emissions across production and logistics.
Strengthen their competitive position in a rapidly evolving market.
Ready to decarbonize your cement operations? Contact PRO WASTE today to explore how ORC can transform your production and shipping processes.
                       

        FREQUENTLY ASKED QUESTIONS:
1. WHAT MAKES PRO WASTE’S LOW-TEMPERATURE ORC TECHNOLOGY SUITABLE FOR WASTE HEAT RECOVERY IN CEMENT PLANTS?
ORC technology operates efficiently at temperatures as low as 75°C. This allows it to capture and convert heat from sources like conditioning towers and lower stages of preheater towers, which are traditionally considered too low-grade for energy recovery.
2. HOW CAN ORC TECHNOLOGY HELP REDUCE EMISSIONS IN CEMENT LOGISTICS?
ORC technology captures waste heat from the engines of cement carriers during marine transport, converting it into electricity. This reduces fuel consumption and lowers greenhouse gas emissions, supporting compliance with IMO carbon intensity targets.
3. WHAT IS THE ECONOMIC IMPACT OF IMPLEMENTING ORC TECHNOLOGY?
By reducing purchased power consumption and improving energy efficiency, ORC systems help lower operational costs and provide a strong return on investment (less than 5 years), particularly in energy-intensive industries like cement manufacturing. The return on investment for ORC system will be determined in the evaluation process and is impacted by factors such as site integration, operational profile and the alternative cost of electricity.
4. HOW DOES PRO WASTE ORC SYSTEM HANDLE PRODUCTION FLUCTUATIONS IN CEMENT PLANTS?
The PRO WASTE ORC system features an advanced control mechanism that autonomously adjusts to changes in heat loads, ensuring consistent performance without manual intervention.