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Boosting efficiency by generating power from waste heat using Dürr Cyplan ORC plant


Bietigheim-Bissingen, May 23, 2016 - Bio.S Biogas GmbH based in Grimma near Leipzig operates a biogas plant at its Beiersdorf beef farm. The electrical output of 527 kWel is fed into the public grid, while the thermal output of 578 kWth is used for heating a biogas plant, offices, livestock sheds and an aspargus field. Recently, an Eco+Energy ORC plant from Dürr Cyplan was added, which significantly improves the efficiency and economy of the biogas plant.

ORC stands for Organic Rankine Cycle, a steam cycle process that uses an organic working fluid. Using the thermal energy in the exhaust gas of the biogas motor, the Eco+Energy ORC plant provides a further 45 kW of electrical power. "Thanks to the additionally generated electrical energy, the valuable raw materials are used with even greater efficiency", explains Jens Liebscher, CEO of Bio.S.

"ORC is a key technology for using waste heat from distributed energy plants", according to Stefan Ochs. His company, ETS Economic Trading Solutions GmbH, specializes in applying this innovative technology and provides consultation services to operators of biogas plants and energy suppliers.  "The ORC plants from Dürr offer outstanding efficiency and reliability and can be integrated easily into existing plants", explains Ochs.

The plant configuration of Bio.S Biogas GmbH is typical of the 6,000 or more biogas plants in Germany.  According to the German Biomass Research Center (DBFZ), an output of 500 kWel represents the most commonly implemented size of plant  for which greater plant efficiency is becoming increasingly important.  That is why Dürr Cyplan developed a specially adapted ORC plant for this size of motor, according to Fabian Trefz, Product Manager for ORC plants:  "For gas motors rated between 500 and 600 kW, we offer the possibility of raising efficiency while still being able to utilize the heat generated.  Our customers benefit from both the efficiency and flexibility of this plant concept".

Jens Liebscher is certain that the Bio.S plant concept will spawn many imitators: "Anyone who would like to see for themselves how reliable this plant is an how easily it can be integrated is welcome to visit us at Beiersdorf at any time." 

The Dürr Group is one of the world's leading mechanical and plant engineering firms. Products, systems and services offered by Dürr enable highly efficient manufacturing processes in different industries. Business with automobile manufacturers and their suppliers accounts for approximately 60% of Dürr's sales. Other market segments include, for example, the mechanical engineering, chemical and pharmaceutical industries and - since the takeover of HOMAG Group AG in October 2014 - the woodworking industry. The ORC technology developed by Dürr's subsidiary Cyplan offers operators of thermotechnical plants and systems cost-effective solutions for boosting the energy efficiency of biogas plants, cogeneration plants or industrial processes. Dürr has 92 business locations in 28 countries. With just under 15,000 employees, the Group generated sales revenues of € 3.77 billion in 2015. The Dürr Group operates in the market with five divisions:

  • Paint and Final Assembly Systems: paint shops and final assembly systems for the automotive industry
  • Application Technology: robot technologies for the automatic application of paint as well as sealants and adhesives
  • Measuring and Process Systems: balancing and cleaning systems as well as assembly, testing and filling technology
  • Clean Technology Systems: exhaust-air purification systems and energy efficiency technology
  • Woodworking Machinery and Systems: machinery and equipment for the woodworking industry

Dürr Cyplan Ltd.
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Phone  +49 7142 78-2914
Fax +49 7142 78-55 2469
Email info(at)

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