References
For a deeper insight into Cyplan® ORC solutions across various industries, we have provided below an excerpt from our references along with detailed descriptions of selected completed projects.
Combustion, Biomass CHP
| Application | Combustion, Biomass CHP |
| Customer | EWZ (CH) |
| Model | Cyplan® ORC 350 HT CHP TO |
| Heat Source | Polytechnik moving grate furnace with thermal oil heat transfer |
| CHP | Hot water for the Ilanz district heating network |
| Location | Ilanz, Switzerland |
| Status | In operation since 2014 |
Over ten years ago, EWZ – the Zürich Municipal Electricity Works – became the first commercial project to use the Cyplan® ORC with a thermal oil interface. This was also the first time the 350 kW turbine was deployed. A particular challenge was the significant fluctuation in load conditions: in summer the system had to handle very low partial loads while in winter full-load operation was required. This issue was successfully resolved through continuous improvement of the turbine setup.
It was also the first project where Cyplan was involved from the very beginning of the plant’s construction, requiring us to gain a comprehensive understanding of the biomass heating plant. Another special feature of this facility is that the hot water generated is supplied to the Ilanz district heating network.
Over the past ten years, ongoing development has resulted in extremely high system availability—to the complete satisfaction of the customer.
Biogas
| Application | Biogas |
| Customer | Stadtwerke Groß-Gerau Versorgungs GmbH |
| Model | Cyplan® ORC 70 HT CHP |
| Heat Source | MWM TCG 2016 V16C (800 kW) |
| CHP | Hot water at 90 °C (herb drying facility) |
| Location | Groß-Gerau, Germany |
| Status | In operation since 2012 |
The customer operates a biogas-fueled combined heat and power (CHP) unit that produces more heat than is needed for the biogas plant’s own requirements. To optimize the heat utilization, a Cyplan®ORC system was installed, which not only significantly increases electricity yield but also provides waste heat at a temperature level of 90°C for a nearby herb drying facility. The major innovation of this solution is the direct exhaust gas evaporation minimizing transfer losses and achieving maximum efficiency and performance. The compact and space-saving ORC module also allows for flexible heat extraction up to 95°C and, thanks to the few wear parts, incurs only minimal maintenance costs, resulting in an extremely economical and profitable package. For this innovative integration, which is unrivaled in its performance class, the project was honored with the Environmental Technology Prize of Baden-Württemberg.
Geothermal Energy
| Application | Geothermal Energy |
| Customer | Deutsches GeoForschungsZentrum |
| Model | Cyplan® ORC 500 LT |
| Heat Source | Hot water intermediate loop |
| CHP | Dry Cooler |
| Location | Lahendong, Indonesia |
| Status | In operation since 2017 |
As part of this project, a steam turbine powered by geothermal energy is used with hot thermal water from a geothermal borehole first serving for power generation. To make optimal use of the geothermal supply potential, a Cyplan® ORC 500 LT system was installed which efficiently converts the remaining thermal energy of the hot water into electrical energy—without impacting the existing power generation process. Thanks to its robust design the ORC system is ideally suited to the harsh local environmental conditions and grid fluctuations. The working fluid is individually selected to match project requirements, significantly increasing efficiency and performance, while the low number of wear parts ensures minimal maintenance costs, resulting in a highly economical and profitable overall solution.
Incinerations
| Application | Incinerations |
| Customer | Emter GmbH |
| Model | Cyplan® ORC 250 HT CHP |
| Heat Source | Sewage sludge combustion |
| CHP | Hot water at 85 °C |
| Location | Altenstadt, Germany |
| Status | In operation since 2024 |
Emter GmbH produces phosphate fertilizer from sewage sludge in Altenstadt, utilizing the heat generated from combustion to supply various internal processes via a thermal oil system. Since these processes require different temperatures, the Cyplan® ORC system was designed to directly supply low-temperature consumers with its condensation heat while simultaneously generating electricity. In this way, the ORC system functions as a “power-generating heat exchanger” with a heat utilization rate of over 95%. The goal of saving 30% of the company’s own electricity consumption was fully achieved.
This concept clearly demonstrates that existing thermal oil systems can be easily supplemented with ORC technology for combined heat and power applications. Proven plant concepts are preserved while enabling efficient on-site electricity generation. This results in significant cost savings, a lasting reduction in the CO2 footprint and increased competitiveness for the site.
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Germany
1925 Highway 51 - 138
53589 Stoughton, WI
United States