The Need

Industrial chemical and physical processes consume large quantities of thermal energy and steam, yet most facilities still rely on external power generation or low‑efficiency Rankine‑cycle systems to meet their electricity demand. This leads to significant energy losses, high operating costs, and suboptimal water utilization. There is a clear unmet need for solutions that dramatically improve heat‑to‑power efficiency while integrating seamlessly with existing steam‑intensive industrial processes, without requiring a wholesale redesign of plant infrastructure.

The Technology

OSU engineers have developed a modular electric power co‑generation approach that integrates steam turbines and thermal conditioning units directly into existing steam‑using industrial processes. Rather than condensing steam after power generation, the system recovers electrical energy from high‑pressure steam and then delivers the steam at process‑ready conditions for downstream chemical or physical use. By coupling power generation with process steam utilization, the platform enables exceptionally high thermal‑to‑electric efficiency while maintaining core process performance.

Benefits/Advantages

• Ultra‑high efficiency: Achieves >70% thermal‑to‑electric efficiency, far exceeding conventional steam power cycles
• Retrofit‑friendly: Can be integrated into existing steam‑based plants with minimal process disruption
• Energy self‑sufficiency: Generates on‑site electricity to offset purchased power and enable new revenue streams
• Improved resource utilization: Enhances both thermal energy recovery and water use efficiency