Addressing the challenge of difficulties in comprehensive utilization of low-temperature flue gasLow-temperature flue gas waste heatWaste heat from high-energyEnergy-consumption aluminum electrolysis operations within the “dual-carbonCarbon” (carbonCarbon peak and carbonCarbon neutrality) policy framework, this study developed a waste heatWaste heat power generationPower generation system based on the Organic Rankine CycleOrganic Rankine cycle (ORC) principle. Air-like aluminum electrolysis flue gas, averaging ~140 °C, served as the heat source. The organic working fluid R245fa was selected, and a direct heat exchange configuration between the flue gas and the working fluid was implemented. An integrated system was established, comprising an insulated flue gas collection system, a flue gas-to-working fluid heat exchange system, an organic working fluid power generationPower generation system, a circulating cooling water system, an electrical power distribution system, and a centralized control system. The system is projected to achieve a thermal efficiency of 10.5%, enabling electricity savings of over 80 kWh per ton of aluminum produced.