Clemson University works with partners to turn waste heat into electricity

Clemson University researchers are working with partners to test and validate a system that is designed to capture waste heat from industrial processes and turn it into usable electricity.

The 1-megawatt heat-recovery system is a prototype that is designed for use at data centers, natural gas compression sites, industrial facilities, geothermal operations and other locations where waste heat can be captured.

Turning waste heat into electricity could make operations more energy efficient, lower costs and reduce strain on the grid, researchers said.

The system stands as an example of how Clemson researchers work with companies to shepherd technology through the toughest stages of development on the path to market.

It was designed by the project team, built by subcontractor A G Equipment Company outside Tulsa, Oklahoma and will be shipped later this year to the Clemson University Restoration Institute in North Charleston for testing and validation, said Ramtin Hadidi, an associate professor of electrical and computer engineering and the principal investigator for the project.

The system is the focal point of a $6.3-million research grant that the U.S. Department of Energy provided to Clemson, TECO-Westinghouse Motor Company and the National Laboratory of the Rockies.

“This project has been a strong example of what can be achieved through close collaboration between Clemson and our industry and national lab partners,” Hadidi said. “I’ve been very pleased with how the team has worked together to bring the system to a full-scale build, and we’re looking forward to the next phase.”

The system is the latest project in a longstanding partnership between Clemson and TECO-Westinghouse Motor Company

Dean Sarandria, vice president at TECO-Westinghouse Motor Company, said the system has been nearly a decade in the making.

“It’s exciting to see this work reach a point where we can begin testing and demonstrating its potential,” said Sarandria, who is among the system’s patent holders. “We’re now focused on validating that the system can reliably convert waste heat into power and deliver the expected performance.”

The system is based on a technology called an Organic Rankine Cycle, or ORC.

Heat is used to convert a fluid into a high-pressure gas that spins a turbo expander.

The spinning turbo expander turns a high-speed shaft connected to a generator that produces electricity.

The system operates at very high speeds, with components running at around 15,000 revolutions per minute.

Researchers see high potential especially at data centers, which generate lots of heat and are hungry for electricity.

Hai Xiao, chair of the Holcombe Department of Electrical and Computer Engineering, said the project highlights Clemson’s role in advancing energy and manufacturing technologies through research and collaboration.

“This work shows how our faculty and partners are tackling real-world challenges with innovative solutions,” Xiao said. “I congratulate the team on reaching this significant milestone in its research.”

About TECO-Westinginhouse

TECO-Westinghouse is a global leader in electric motors and generators, offering products from 1/4 hp to 100,000 hp for a wide range of industrial applications. In recent years, the company has expanded into new business areas, including power transformers, modular data centers, fiber optic cable integration, and agricultural UAV powertrains. Headquartered in Texas, TECO-Westinghouse was established in 1995 following TECO Electric & Machinery Co., Ltd.’s acquisition of Westinghouse’s motor business. For more information, please visit: https://www.tecowestinghouse.com/