Elite Engineering Integrated Orc Power Generation Solutions

Organic Rankine Cycle (ORC)

Company Capability Overview

Elite Engineering provides complete EPC solutions for Organic Rankine Cycle (ORC) systems, including in-house design, engineering, manufacturing support, equipment supply, system integration, and project execution supervision.

We deliver fully integrated ORC power generation packages that enable industrial clients to convert waste heat into reliable and efficient electrical power across various energy and industrial sectors.

Elite Engineering is positioned as a single-source EPC solution provider for ORC projects, ensuring quality, operational efficiency, reliability, and seamless project execution from concept to commissioning.

ORC System Concept

The Organic Rankine Cycle (ORC) is a closed-loop thermodynamic process that converts low- to medium-temperature heat into electrical power using an organic working fluid instead of water or steam.

Compared to conventional steam power systems, ORC technology offers:

  • No water or steam handling requirements
  • Lower operating pressures
  • Compact and modular skid-mounted configurations
  • Reduced maintenance and operational complexity
  • High efficiency in waste heat recovery applications 

Process Description Industrial ORC Flow

The Elite ORC system operates through a continuous thermodynamic cycle designed for efficient heat-to-power conversion.

1. Heat Input Evaporator (4 → 5)

Heat from the following sources is transferred to the working fluid through the evaporator system:

  • Gas turbine or engine exhaust
  • Thermal oil systems
  • Industrial waste heat streams
  • Renewable energy sources (geothermal / biomass) 
The working fluid absorbs heat and transforms into high-pressure vapor.

2. Expansion – Turbine & Generator (5 → 6)

The high-pressure vapor expands through the turbine, generating mechanical energy, which is converted into electrical power through the generator system.

3. Heat Recovery – Regenerator (6 → 7)

Residual heat from the turbine exhaust is recovered through the regenerator to preheat the incoming working fluid, improving overall system efficiency and energy recovery.

4. Condensation – Condenser (7 → 8 → 1)

The vapor is condensed back into liquid form using:

  • Air-cooled condenser systems
  • Water-cooled condenser systems 

5. Circulation Pump System (1 → 2)

The working fluid is pressurized by the circulation pump and returned to the evaporator, completing the continuous ORC cycle.

Engineering & Project Execution

Elite Engineering provides complete EPC execution support for ORC projects.

Engineering Services

  • Process design and thermodynamic calculations
  • PFD and P&ID development
  • Equipment sizing and selection
  • 3D skid layout and modular integration

Fabrication & System Integration

  • Modular skid fabrication and assembly
  • Piping fabrication, welding, NDT, and hydrotesting
  • Equipment installation, alignment, and integration

Project Execution & Commissioning

  • Site installation supervision
  • Commissioning and startup support
  • FAT / SAT and performance testing

Market Relevance

ORC systems play a critical role in:

  • Energy efficiency improvement initiatives
  • Decarbonization and emission reduction strategies
  • ESG and sustainability targets
  • Distributed and modular power generation
  • Industrial waste heat recovery optimization

Scope of Supply Complete ORC Package

Elite Engineering supplies complete ORC power generation packages, including:

Process Equipment

  • Evaporators and Heat Exchangers
  • ORC Turbine / Expander Systems
  • Power Generators
  • Condensers (Air-Cooled / Water-Cooled)
  • Working Fluid Pumps
  • Regenerator Systems

Mechanical & Piping Systems

  • Complete piping packages (Carbon Steel / Stainless Steel / Alloy Steel / Duplex Steel)
  • Modular skid-mounted structures
  • Structural supports and insulation systems

Valve & Control Systems – Elite Core Strength

  • Manual Valves
  • Shutdown Valves (SDV/ESDV)
  • Control Valves
  • Specialized valves for corrosive and critical process services

Instrumentation & Electrical Systems

  • Field instrumentation (PT, TT, FT, LT)
  • PLC / SCADA automation systems
  • Remote monitoring and Industry 4.0 integration
  • Electrical panels and grid synchronization systems

Applications & Industries

Elite ORC systems are suitable for:

  • Oil & Gas Facilities
  • Refineries and Petrochemical Plants
  • LNG Terminals
  • Power Plants and Waste Heat Recovery Systems
  • Cement, Steel, and Heavy Industries
  • Renewable Energy Projects (Biomass / Geothermal)
  • Industrial Waste Heat Recovery Applications

Key Value to Clients

  • Conversion of waste heat into usable electrical power
  • Reduced energy costs and operational emissions
  • Compact, modular, and fast-track installation
  • Reliable operation with low maintenance requirements
  • Improved energy efficiency and sustainability performance
  • Single-source responsibility resulting in reduced project risk

Elite Engineering Positioning

Elite Engineering delivers complete ORC power generation solutions from concept development to commissioning combining strong expertise in valves, piping systems, process integration, and modular skid engineering to provide safe, efficient, and reliable power generation solutions for industrial and energy sector applications.