Power Generation

Combustion Engines

Combustion engines, such as those used in diesel generators or gensets, have seen extensive use across the globe for their reliable power generation capabilities. From diesel prime power for remote power generation to providing power for industrial processes, combustion engines have the ability generate anywhere from just a couple kilowatts to several megawatts of electricity. However even with huge leaps in technology, gensets typically lose over 50% of the their input energy to waste heat.

ElectraTherm’s organic Rankine cycle (ORC) solutions, the Power+ Generator and Active Cooler, are able to capture this waste heat – increasing efficiency and reducing energy costs. There are several other benefits you could also capitalize on such as reducing engine de-rate and selling excess electricity to the grid.

Factors That Make A Successful Application


The amount of heat available is the largest factor in determining if a heat source is viable for ORC heat recovery. While heat sources as low as 70°C can be used, heat sources above 100°C are considered ideal. Other variables that play a role in determining output are the flow rate and hot/cold water temperature differential.

Run Hours

The more time an application is operational, the more heat there is available to convert into electricity. There are 8760 hours in a year and suitable applications will experience 80% up-time, however applications with 90% up-time offer the best economics.

Cost of Power

Installing an ElectraTherm ORC heat recovery system comes with several benefits, from reduced carbon footprint to increased efficiency. However the most tangible benefit realized is the value of electricity produced. Ideal projects have electrical costs greater than $0.10/kWh.

Increase Efficiency,
Decrease Costs

ElectraTherm’s ORC solutions convert engine waste heat – either from the jacket water or exhaust gas – into usable power. This process reduces the radiator cooling load and generates electricity that can be used to provide additional horsepower, improve the engine’s fuel economy, or sold for profit.

By taking advantage of waste heat- and with no additional fuel consumption or emissions – efficiency is increased up to 10%. Our heat recovery solutions reduce energy costs and increase power output, plus they may even qualify for local incentives.

Typical Energy Split in Combustion Engine

Combined Heat and Power

ElectraTherm’s Power+ Generator can double as a CHP unit to improve efficiency and your bottom line. Our larger Power+ Generators, the 6500B and 6500B+, are capable of producing up to 125 kWe of clean electricity while providing up to 85°C of usable thermal.

These larger models, optimal for CHP, are capable of transferring 2 megawatts of heat. This reduces the cooling load substantially, reducing energy costs and possibly even acting as a complete radiator replacement.

Net-Zero Cooling To Power,
Replace Your Radiator

Engines and industrial processes generate large amounts of heat and require cooling. This waste heat and cooling load places a burden on the engine, stealing away valuable power. With the ElectraTherm Active Cooler you can cool your engine while generating electricity as a secondary function.

ElectraTherm’s ORC solutions reduce the jacket water loop cooling load 70-100%, significantly decreasing the intercooler radiator. This cooling effect allows ElectraTherm to provide 100% full-load cooling for the engine, independent of the unit’s status.

By utilizing your waste heat and reducing dependence from the grid, direct and indirect emissions are reduced. A fully utilized Power+ Generator on a diesel genset has the ability to reduce emissions by over 600 metric tons annually.


Remote Power Generation in Alaska

Three Power+ Generators (4400 series) were installed at a power station in Dutch Harbor, Alaska with the goal of improving energy efficiency. The units provide 75 kW (net) to the site as well as reduce the cooling load enough to replace one of the existing radiators. The Alaska Energy Authority estimates $250,000 in annual energy savings. Additionally, by serving as a radiator alternative, electrical consumption is reduced by 8,000 kW monthly - saving 6,000 gallons of fuel annually.


Ten Power+ Generator Scalable System

ElectraTherm commissioned 10 Power+ Generators (4400B series) on a district heating system powered by two Rolls Royce gas turbines in Levice, Slovakia. Incorporating exhaust gas heat exchangers, each 4400B unit uses the waste heat provided to generate 50 kW (net) each, amounting to 500 kW total. This emission-free electricity is then sold back to the utility - providing a significant revenue stream for decades to come.


Island of Pohnpei Increases Energy Efficiency

ElectraTherm has been awarded a contract to provide a complete waste heat recovery system for the small island state, Pohnpei in Micronesia. The system will incorporate exhaust gas heat exchangers and three containerized 6500B+ units complete with high efficiency coolers. Pohnpei Utilities Corporation expects to produce an additional 1,700 MWh of clean electricity annually while reducing emissions by over 1,000 tons annually. Maximizing energy efficiency is crucial for long-term viability in remote island nations with inadequate access to mainland utilities.


DOD Increases Fuel Efficiency By 10%

In collaboration with the U.S. Department of Defense, ElectraTherm commissioned a fully packaged Power+ Generator integrated with a 1.1 MW engine. The ORC system increased fuel efficiency by 10% while completely offsetting the cooling load. By serving as a radiator alternative, capital costs and operating expenses are significantly reduced.


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