Dyckerhoff generates green electricity from waste heat: New Orcan Energy ORC system commissioned at the Geseke plant

 

Munich and Geseke, 27.05.2024 – The Dyckerhoff plant in Geseke has taken another important step in terms of energy efficiency: After a six-month construction period, the trial operation of the ORC (Organic Rankine Cycle) system was successfully initiated following its winter repairs. This is an innovative module system from the Munich-based company Orcan Energy. The modules convert the previously unused waste heat flows from the clinker cooler into green electricity.

At the heart of this technology is a newly installed heat exchanger weighing around 50 tonnes, which transfers the waste heat to the ORC modules via a water circuit. The modules convert heat into electricity at a lower temperature level than the classic steam turbine. The generated electricity is used directly on-site.

"The effective use of waste heat to generate electricity not only reduces energy costs at the Geseke site but also makes it possible to reduce greenhouse gas emissions," says Dyckerhoff's production manager Ralf Schmees.

"Efficiency technologies play a crucial role in the cement sector, as they not only help to reduce energy consumption but can also significantly reduce CO2 emissions. As a result, cement manufacturers can not only increase their competitiveness but also make a significant contribution to climate protection. We are delighted to have implemented this project with Dyckerhoff so quickly," adds Markus Lintl, Head of Industry & New Business at Orcan Energy.

Dyckerhoff can use the self-generated electricity from waste heat directly on-site. The continuous operation of the plant, which will always run parallel to the rotary kiln except for shorter maintenance periods, is projected to produce over 1,000,000 kWh per year. This corresponds to the annual electricity consumption of around 250 households with four people. The energy generated purely from waste heat will also avoid around 900 tonnes of CO2 per year.

The planning and installation of the ORC system was funded by the BAFA (Federal Office of Economics and Export Control), which covered around 20% of the costs.

Following the successful commissioning of the DeCONOx plant in 2019, which significantly reduced emissions of NOx, CO, and organic compounds, the construction of the innovative ORC plant is another step on the way to environmentally friendly and climate-neutral production at the Dyckerhoff cement plant in Geseke.

 

About Dyckerhoff

Dyckerhoff is an international manufacturer of cement and ready-mixed concrete. We are a Buzzi company. Buzzi is a company based in Italy and operates plants in 13 countries with around 10,000 employees worldwide.

In Germany, we operate seven cement plants and around 110 ready-mixed concrete plants. Further production sites are located in Luxembourg, the Netherlands, Poland, the Czech Republic, Slovakia, Russia and Ukraine. Dyckerhoff's head office has been located in Wiesbaden since its foundation over 150 years ago.

We support our customers not only with high-quality products, but also with construction advice and other services. Our production is based on the latest findings in building material technology. We use limited resources responsibly.