Screw Expander Market By Application (Waste Heat Recovery, Geothermal, Biomass Power Generation); By End User (Industrial, Commercial, Utilities); By Geography, Segment Revenue Estimation, Forecast, 2024–2030

Introduction And Strategic Context

The Global Screw Expander Market will witness a steady CAGR of 6.8% , valued at USD 5.1 billion in 2024 , and is expected to appreciate to USD 7.6 billion by 2030 , according to Strategic Market Research.

 

This market revolves around the design, manufacture, and deployment of screw expander systems — mechanical devices that convert thermal or pressure energy from steam, gas, or other working fluids into useful mechanical or electrical power. These systems are increasingly integrated into waste heat recovery setups, geothermal power plants, and industrial energy optimization projects.

 

From a strategic perspective, 2024–2030 is shaping up to be a transformative period for the industry. Demand growth is being fueled by energy efficiency mandates, decarbonization targets, and the growing economic viability of waste heat-to-power systems. Governments in Europe, Asia-Pacific, and North America are implementing stricter industrial emission norms, which, in turn, are driving adoption in heavy industries such as steel, cement, and chemicals.

 

Technological advancements are also making screw expanders more compact, reliable, and efficient, lowering the barrier to adoption for small and medium-scale operations. This trend is particularly relevant in emerging markets where industrial modernization programs are underway. Additionally, the rise of distributed energy solutions and hybrid renewable systems is expanding the addressable market for screw expanders beyond traditional applications.

 

Key stakeholders include original equipment manufacturers (OEMs), component suppliers, EPC contractors, industrial facility operators, renewable energy developers, government agencies, and investment firms focusing on clean energy infrastructure. The competitive field is a blend of large industrial engineering firms and specialized niche players, each pursuing innovations in sealing technology, rotor design, and integration with digital monitoring platforms.

 

Market Segmentation And Forecast Scope

The screw expander market is typically analyzed through four key segmentation dimensions: product type, application, end user, and geography. This segmentation allows a comprehensive understanding of both current market priorities and emerging demand patterns over the 2024–2030 forecast horizon.

By Product Type
The market is broadly categorized into single-screw expanders and twin-screw expanders. Single-screw units are often preferred for compact installations with moderate power output needs, while twin-screw expanders dominate in heavy-duty industrial operations where higher efficiency and robustness are critical. As of 2024, twin-screw expanders account for roughly 62% of total market revenue, reflecting their suitability for waste heat recovery in energy-intensive sectors.
 

By Application
Screw expanders find application in waste heat recovery, geothermal power generation, biomass energy systems, and other niche uses such as pressure let-down in industrial gas networks. Waste heat recovery is the largest segment, driven by regulatory incentives and cost-reduction targets for industrial energy use. Geothermal applications, while smaller in share, are forecast to register the fastest growth rate due to increased investment in low-enthalpy geothermal plants.
 

By End User
Key end-user industries include oil and gas, manufacturing, power generation, and chemical processing. Manufacturing leads the adoption landscape, particularly in steel, cement, and paper mills, where thermal energy recovery can meaningfully cut operating costs. The power generation sector is increasingly using screw expanders in renewable and hybrid plant configurations.
 

By Region
Geographically, the market is segmented into North America, Europe, Asia Pacific, Latin America, and the Middle East & Africa. Asia Pacific holds the largest share in 2024, supported by rapid industrialization in China, India, and Southeast Asia. Europe follows closely, driven by strong policy support for energy efficiency technologies. North America’s growth is being bolstered by industrial retrofitting projects and the development of small-scale geothermal facilities.

The forecast scope for 2024–2030 captures technological advancements, competitive shifts, and policy changes that could reshape demand across these segments. Special attention is given to the adoption rates in developing economies, where industrial energy efficiency is becoming a core component of national sustainability agendas.

 

Market Trends And Innovation Landscape

The screw expander market is evolving through a mix of technology-driven innovation and regulatory influence. Over the 2024–2030 period, advancements in rotor geometry, sealing materials, and digital integration are expected to reshape performance benchmarks. Manufacturers are focusing on reducing leakage losses and enhancing thermal efficiency, enabling screw expanders to operate effectively across wider temperature and pressure ranges.

One notable trend is the integration of screw expanders into modular waste heat recovery units. These modular systems are designed for quick deployment in industrial settings, offering scalability without significant downtime. This development aligns with the growing preference for retrofit-friendly solutions that can be implemented in existing facilities without major infrastructure overhauls.
 

The application scope is expanding due to synergies with renewable energy systems. In particular, low-enthalpy geothermal plants and biomass-powered generation units are adopting screw expander technology to optimize power yield. This diversification is helping the market reduce its dependence on a few core industries, making it more resilient to sector-specific downturns.
 

Digital monitoring and predictive maintenance platforms are increasingly embedded into screw expander systems. By using sensors and analytics, operators can track performance metrics in real time, detect anomalies before they cause failures, and extend equipment lifespan. This trend is accelerating in regions where downtime costs are high and skilled maintenance staff are scarce.
 

In the competitive space, recent years have seen an uptick in collaborations between OEMs and research institutions to push design innovation. Partnerships are also forming between screw expander manufacturers and renewable project developers, aiming to integrate the technology into hybrid power plants.
 

Industry analysts anticipate that the next competitive frontier will be achieving high efficiency at smaller scales, unlocking applications in distributed energy systems and remote industrial operations. Such advancements could significantly broaden the technology’s addressable market, particularly in off-grid regions where compact, robust, and low-maintenance power generation is a necessity.

 

Competitive Intelligence And Benchmarking

The screw expander market is characterized by a blend of established industrial equipment manufacturers and specialized engineering firms targeting niche applications. Competition is driven by factors such as efficiency improvements, lifecycle cost reduction, and the ability to customize systems for specific industrial processes.

Atlas Copco maintains a strong presence in industrial energy recovery systems, leveraging its broad engineering portfolio to offer integrated screw expander solutions with air compression and vacuum technology. Their strategy focuses on targeting large-scale manufacturing facilities in high-energy consumption industries.
 

Kaishan Group has expanded its international footprint through aggressive export strategies, supplying both standalone screw expanders and integrated waste heat recovery systems. Their emphasis is on cost competitiveness while still maintaining durability in challenging operational environments.
 

Rotrex is recognized for its precision-engineered turbo machinery components, with screw expanders forming part of its broader efficiency solutions portfolio. Its differentiation lies in compact designs suitable for constrained spaces, making them attractive for retrofit projects.
 

Air Squared specializes in oil-free screw expander technology, primarily targeting small-scale and renewable energy applications. The company has positioned itself as a leader in compact systems for distributed generation, particularly in geothermal and organic Rankine cycle setups.
 

Turboden , part of the Mitsubishi Heavy Industries Group, stands out for its strong presence in the organic Rankine cycle market. Its screw expander technology is integrated into advanced power recovery systems, often in hybrid configurations with other energy conversion technologies.
 

Benchmarking reveals that larger players are focusing on industrial-scale, high-output units, while smaller firms excel in delivering customized, application-specific solutions. This split in market approach creates space for collaboration and technology licensing agreements, as companies aim to fill capability gaps without overextending their R&D budgets.
 

Looking ahead, competitive advantage will hinge on the ability to deliver plug-and-play systems with minimal maintenance requirements, meeting the needs of industries seeking to balance efficiency gains with operational simplicity.

 

Regional Landscape And Adoption Outlook

Regional adoption of screw expander technology varies considerably, influenced by industrial structure, energy policy, and infrastructure maturity. While the market has global reach, growth patterns differ sharply between developed and emerging economies.

North America benefits from a well-established industrial base and ongoing investment in energy efficiency retrofits. The U.S. leads the region, with screw expanders increasingly deployed in manufacturing, oil and gas, and renewable hybrid power plants. Canada is also seeing uptake in biomass and geothermal applications, particularly in off-grid communities where energy self-sufficiency is a priority.
 

Europe’s market is underpinned by strong policy drivers. The EU’s industrial decarbonization targets and waste heat utilization incentives have encouraged adoption across heavy industries. Germany, Italy, and the Nordic countries are leading in integrating screw expanders into district heating and combined heat and power (CHP) systems. Eastern Europe is emerging as a promising sub-market due to modernization of older manufacturing infrastructure.
 

Asia-Pacific holds the largest overall market share, driven by rapid industrialization in China, India, and Southeast Asia. In China, policy-backed industrial upgrades and the expansion of low-enthalpy geothermal capacity are fueling demand. India’s emphasis on improving manufacturing efficiency under programs like “Make in India” is supporting adoption, especially in cement and steel sectors. Japan and South Korea are focusing on integrating screw expanders into renewable and waste heat recovery systems for advanced manufacturing hubs.
 

Latin America’s adoption is more gradual but gaining traction in mining, oil refining, and sugar production. Brazil and Chile are key players, with geothermal exploration in the Andean regions creating additional opportunities.
 

The Middle East & Africa present a developing opportunity profile. The Middle East’s oil and gas sector is exploring screw expanders for pressure let-down and waste heat recovery, while African nations are beginning to integrate the technology into small-scale renewable energy projects and industrial modernization programs.
 

Overall, the adoption outlook is strongest where energy efficiency targets intersect with industrial modernization needs, and where policies or incentives lower the upfront investment barrier for large-scale deployment.

 

End-User Dynamics And Use Case

End-user adoption of screw expander technology is driven by a combination of operational cost pressures, regulatory requirements, and sustainability commitments. While the technology has cross-sector applicability, uptake intensity varies based on energy usage patterns and process characteristics.

Manufacturing industries, particularly steel, cement, and paper production, account for a significant share of installations. These sectors generate substantial waste heat during operations, making screw expanders a practical choice for converting thermal energy into electricity or mechanical power. The ability to retrofit systems into existing lines without major disruptions is a major factor in adoption.
 

The oil and gas sector applies screw expanders for pressure let-down in gas distribution systems, as well as for recovering energy from process steam in refining. This helps operators improve efficiency while meeting emissions reduction commitments.
 

In power generation, screw expanders are deployed in biomass plants, small-scale geothermal facilities, and combined heat and power systems. Their ability to operate efficiently at lower temperature differentials makes them suitable for renewable integration, especially in organic Rankine cycle configurations.
 

Chemical processing plants use screw expanders to capture value from high-temperature waste gases and steam. For these facilities, the return on investment is often accelerated by both energy savings and avoided emissions penalties.

 

Use Case Example
A cement manufacturing plant in South Korea implemented a twin-screw expander system to capture waste heat from its clinker cooling process. The recovered energy was used to power auxiliary equipment, reducing electricity purchases from the grid by 12%. The installation, completed within four months without disrupting production, achieved a payback period of just under three years. Additionally, the plant reported a measurable reduction in CO2 emissions, supporting its compliance with national environmental targets.

Such examples highlight the dual operational and environmental benefits that make screw expanders an increasingly attractive option for energy-intensive industries worldwide.

 

Recent Developments + Opportunities and Restraints

Recent Developments (Last 2 Years)

• Atlas Copco introduced an upgraded screw expander system in 2024 with higher thermal efficiency, targeting industrial waste heat recovery applications.

• Heliex Power partnered with a European pulp and paper manufacturer in 2023 to deploy screw expanders for sustainable power generation from process steam.

• Zhejiang Kaishan Compressor launched a next-gen oil-free screw expander in 2024 aimed at geothermal and low-pressure energy recovery markets.

• Mitsubishi Heavy Industries began pilot testing a modular screw expander unit in Japan in late 2023 for small-scale biomass power plants.

 

Opportunities

• Growing adoption of waste heat recovery systems in cement, steel, and chemical industries is creating sustained demand for screw expanders.

• Expanding geothermal energy projects in Asia-Pacific and Latin America present a strong growth pipeline for screw expander manufacturers.

• Decentralized power generation initiatives in rural and off-grid locations offer significant potential for compact screw expander installations.

 

Restraints

• High initial capital costs for screw expander systems can deter adoption, particularly among small and medium-sized industrial operators.

• Limited awareness and technical expertise in emerging markets can slow market penetration despite available opportunities.
   

7.1. Report Coverage Table

Report Attribute	Details
Forecast Period	2024 – 2030
Market Size Value in 2024	USD 5.1 Billion
Revenue Forecast in 2030	USD 7.6 Billion
Overall Growth Rate	CAGR of 6.8% (2024 – 2030)
Base Year for Estimation	2024
Historical Data	2019 – 2023
Unit	USD Million, CAGR (2024 – 2030)
Segmentation	By Application, By End User, By Region
By Application	Waste Heat Recovery, Geothermal, Biomass Power Generation
By End User	Industrial, Commercial, Utilities
By Region	North America, Europe, Asia-Pacific, Latin America, Middle East & Africa
Country Scope	U.S., UK, Germany, China, India, Japan, Brazil, etc.
Market Drivers	- Increasing focus on energy efficiency - Rise in renewable energy adoption - Government incentives for waste heat recovery
Customization Option	Available upon request