---
title: Electricity from Waste Heat with Cyplan®
url: "https://www.envanio.com/en/air-pollution-control-and-heat-recovery/products/product/electricity-from-waste-heat-with-cyplan"
date: 2026-10-12
modified: 2026-10-13
---
# Electricity from Waste Heat with Cyplan®
Organic Rankine Cycle
Electricity from Waste Heat with Cyplan®
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Envanio’s Cyplan® ORC system transforms industrial waste heat from decentralized heat sources into valuable CO₂-free electricity and usable heat. Designed for maximum flexibility, the Organic Rankine Cycle (ORC) technology efficiently recovers thermal energy from sources ranging from 90 °C to 600 °C, helping reduce energy costs, improve sustainability, and boost overall energy efficiency. As a turnkey solution, Cyplan® is tailored to seamlessly integrate into existing operations without impacting the primary process.
[ Request a Consultation ](https://www.envanio.com/en/contact-sales-envanio)
### Sustainable Energy from Waste Heat
Turn previously unused waste heat into valuable energy. ORC systems generate CO₂-free electricity and usable heat, helping you improve energy efficiency, reduce emissions, and advance your sustainability goals.
### Lower Energy Costs for the Long Term
Generate electricity and useful heat directly on-site from existing heat sources. This reduces dependence on grid energy, cuts operating costs, and improves the overall profitability of your facility.
### Seamless Integration into Existing Processes
Designed around your specific requirements, ORC systems can be customized to fit virtually any application and integrated into existing operations without impacting the primary process.
[ Flexible Solutions ](#c1565)
[ Benefits ](#c1566)
[ How It Works ](#c1567)
[ Typical Applications ](#c1568)
[ Service ](#c1569)
[ FAQ ](#c1570)
[ Request a Consultation ](https://www.envanio.com/en/contact-sales-envanio)
Flexible ORC Solutions for Efficient Waste Heat Recovery
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Envanio’s Cyplan® ORC solutions convert waste heat and other thermal energy sources into valuable electricity, with outputs ranging from 120 kW to several megawatts. Prefabricated and TÜV-certified modules ensure fast, reliable deployment, while the modular design allows each system to be tailored to specific process requirements. Compatible with a wide range of heat sources, Cyplan® maximizes flexibility and efficiency. Its innovative direct evaporation technology enables the direct utilization of flue gases without an intermediate loop, delivering highly efficient and cost-effective energy recovery.
[Get in Touch](https://www.envanio.com/en/contact-sales-envanio)
Benefits of Our Cyplan® ORC Systems
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Cyplan® from Envanio is one of the most flexible ORC solutions on the market, efficiently converting waste heat into electricity even at lower output levels. Its unique ability to utilize a wide range of heat transfer media, including hot water, steam, exhaust gases, hot air, molten salt, and thermal oil, allows the system to be tailored to virtually any industrial application. This exceptional flexibility enables companies to unlock untapped energy potential, improve energy efficiency, and maximize the value of their existing processes.
###### Hermetically Sealed Working Fluid Circuit
A fully hermetic working fluid circuit prevents any leakage of the working fluid, protecting the environment, conserving resources, and ensuring reliable, uninterrupted operation.
###### High-Efficiency Single-Stage Expansion Turbine
The robust, single-stage Cyplan® turbine is engineered for maximum efficiency and dependable performance. Its advanced design enables electricity generation even at partial loads as low as 20%, maximizing energy recovery under varying operating conditions.
###### Combined Heat and Power (CHP)
Cyplan® ORC systems can simultaneously generate electricity and usable heat, achieving overall efficiencies of more than 95% when recovered heat is utilized. The secondary heat can be used for applications such as heating or drying, increasing energy utilization without affecting the primary process.
###### Flexible Heat Source Integration
Designed for exceptional versatility, Cyplan® ORC systems can utilize a wide range of heat transfer media, including flue gas, thermal oil, molten salt, saturated steam, and hot water. This flexibility allows seamless integration into diverse industrial processes and applications.
###### Remote Monitoring and Low Operating Costs
Cyplan® ORC systems are built for reliable operation and minimal maintenance. Easy access to key components, readily available spare parts, and remote monitoring capabilities help reduce operating costs, simplify maintenance planning, and ensure optimal system performance at all times.
How Our Cyplan® ORC Systems Works
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01
Evaporator
In the evaporator, thermal energy from the waste heat source is transferred to an organic working fluid. The fluid absorbs the heat, vaporizes, and is pressurized to prepare it for power generation.
02
Turbine
The high-pressure vapor flows through a turbine, causing it to spin and drive a generator. This process converts recovered thermal energy into clean, usable electricity.
03
Condenser
After leaving the turbine, the vapor enters the condenser, where it is cooled and returned to a liquid state. The released heat can be recovered for applications such as district heating or industrial processes, further improving overall system efficiency.
04
Pump
The pump circulates the liquefied working fluid back to the evaporator, completing the cycle. This continuous process enables reliable and efficient electricity generation from available waste heat.
01/04
Typical Applications for Our Cyplan® ORC Systems
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With Cyplan® from Envanio, you can turn unused waste heat into a valuable source of energy. This highly flexible ORC technology converts thermal energy from a wide range of industrial processes into clean electricity, helping you increase energy efficiency, lower operating costs, and reduce emissions. By transforming wasted energy into economic and environmental value, Cyplan® helps you get more from every unit of energy your facility consumes.
###### Cement, Lime, and Building Materials Industry
Energy-intensive production processes and rotary kilns generate significant amounts of waste heat that often remain unused. Cyplan® from Envanio transforms this untapped thermal energy into valuable electricity, helping manufacturers reduce energy costs, improve energy efficiency, and lower CO₂ emissions. By recovering energy from existing processes, companies can strengthen both their sustainability performance and long-term competitiveness.
###### Steel and Metals Industry
Continuous high-temperature processes make the steel and metals industry an ideal application for ORC technology. Cyplan® from Envanio reliably converts waste heat into valuable electricity, helping manufacturers reduce energy costs, improve energy efficiency, and maximize the value of existing production processes.
###### Glass Industry
Glass manufacturing generates substantial amounts of high-temperature waste heat that can be efficiently recovered and reused. Cyplan® from Envanio transforms this untapped energy into electricity, increasing overall plant efficiency, lowering operating costs, and supporting sustainability objectives.
###### Biomass Energy Utilization
Biomass combustion and biochar production create valuable waste heat that can be used to generate additional electricity. Cyplan® from Envanio captures this energy and converts it into power, improving overall plant efficiency, increasing energy output, and maximizing the return from existing renewable energy resources.
###### Data Centers
Data centers, particularly those with on-site power generation, can unlock additional value from existing energy resources with Cyplan®. By converting waste heat from gas engines and gas turbines into electricity, the system increases overall facility efficiency, reduces energy costs, and improves the economics of data center operations.
###### Combustion Plants
Cyplan® converts waste heat from combustion processes into valuable electricity, maximizing the efficiency of energy-intensive operations. The technology can utilize heat generated from a wide range of fuels, including biomass, wood waste, sewage sludge, and municipal solid waste. By recovering both power and heat, Cyplan® helps operators reduce energy costs, improve sustainability, and increase the overall value of their energy assets.
###### Geothermal Energy
Cyplan® from Envanio unlocks the full potential of geothermal energy for reliable and efficient power generation. Its modular design makes it ideal for both new installations and existing geothermal power plants, while cascade configurations help maximize energy recovery and plant performance. Built for demanding environments, Cyplan® delivers dependable operation, high availability, and long-term efficiency.
###### Solar Thermal
Cyplan® converts solar thermal energy into clean, sustainable electricity with exceptional flexibility. Suitable for both high-temperature solar power plants and thermal storage applications, the system delivers excellent part-load performance and operates without water consumption. Its compatibility with hybrid power plants makes Cyplan® a powerful solution for maximizing renewable energy utilization and overall plant efficiency.
###### Engines and Combined Heat & Power (CHP) Units
Cyplan® enhances the performance of stationary gas and diesel engines by converting exhaust heat into additional electricity. Compatible with biogas, sewage gas, and landfill gas engines, the system can increase electrical output by up to 10% while reducing overall fuel consumption. By recovering energy that would otherwise be lost, Cyplan® improves efficiency, lowers operating costs, and increases the value of existing CHP assets.
Global Service for Maximum System Availability
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Keep your ORC system operating at peak performance with Envanio’s global service and support network. From commissioning and preventive maintenance to upgrades, spare parts, and fast technical assistance, our experts are by your side throughout the entire lifecycle of your system. We help maximize availability, optimize performance, and reduce operating costs wherever your facility is located.
[All Services](https://www.envanio.com/en/service/air-pollution-control-and-heat-recovery)
FAQ
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###### Is my system suitable for ORC?
In general, ORC technology is suitable for many industrial processes that generate continuous waste heat. Whether your site is technically and economically suitable for the use of an Envanio Cyplan® ORC system depends primarily on the amount of available heat, the temperature level, and the operating hours. Our experts will work with you to analyze your site’s potential and develop a customized solution.
###### At what temperature does ORC become economically viable?
Even waste heat at a comparatively low temperature can be used economically to generate electricity with an Envanio Cyplan® ORC system. However, actual economic viability depends on several factors, such as the amount of available heat and the annual operating hours. As part of a customized potential analysis, we determine the economic potential of your application.
###### Does an ORC system require additional fuel?
No. Envanio Cyplan® ORC systems use only the waste heat already generated by your process. No additional fuel is required for electricity generation.
###### How significant are the CO₂ savings?
Envanio Cyplan® ORC systems generate electricity from existing waste heat, thereby reducing the need to purchase electricity from external sources. Since electricity is generated without the use of additional fuel, your site’s carbon footprint improves, and you actively contribute to achieving your sustainability and ESG goals.
###### Can an existing plant be retrofitted?
Yes. Envanio Cyplan® ORC systems are frequently integrated into existing plants as retrofit solutions. This approach utilizes the existing waste heat without significantly altering the actual production process. As a result, existing energy potential can be tapped quickly and efficiently.
###### Does my process need to be modified for installation?
In most cases, no significant changes to the existing production process are required. Our experts integrate the Envanio Cyplan® ORC system in such a way that existing interfaces are utilized optimally, and ongoing operations remain as unaffected as possible.
###### How do Envanio Cyplan® ORC systems handle fluctuating exhaust air volumes and contaminated exhaust air?
Envanio Cyplan® ORC systems can generally be operated reliably even with fluctuating exhaust air volumes. Since the working fluid circulates in a closed loop, it does not come into direct contact with the exhaust air and is therefore protected from contamination. ORC systems can also be used with contaminated or polluted exhaust air streams. If the exhaust air requires additional treatment or if legal emission requirements are not met, Envanio offers complementary air pollution control solutions from a single source.
Let's Talk
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Please contact us directly to schedule a personal consultation or submit your project details using our contact form to receive a complementary, no-obligation quote.
Fabian Trefz
Senior Manager Cyplan ORC
[ +49 7142 7863571 ]() [ sales@envanio.com ](#)
[ Get in Touch ](https://www.envanio.com/en/contact-sales-envanio)
