Philipp Daniel Engler
Technical and Economic Potential of Organic Rankine Cycle (ORC) Systems in the Cement and Glass Industry: A Comparative Assessment for Germany and Italy.
Rel. Alessandro Casasso. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Gestionale (Engineering And Management), 2026
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Abstract
Energy-intensive industries like cement and glass production generate substantial amounts of recoverable waste heat, much of which remains unused despite increasing energy costs and high lying decarbonization targets in the EU. This thesis assesses the technical and economic potential of Organic Rankine Cycle (ORC) systems for waste heat recovery in the cement and glass sectors in Germany and Italy. A two-stage approach is applied. At the macro level, sector-specific performance indicators are derived from a global database of real-world ORC installations and used to estimate national electricity generation potential, installed capacity, and CO₂ emission reductions under different scenarios. At the micro level, representative cement and glass plants are evaluated through thermodynamic modelling and a detailed cash flow analysis, including Payback Period, Net Present Value (NPV), Internal Rate of Return (IRR), sensitivity analysis, and Monte Carlo simulation.
Results indicate substantial remaining technical potential and strong economic attractiveness, with payback periods lying around three years
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