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LIMITED QUANTITIES, BE HURRY – HEAT PUMPS AT DISCOUNT PRICES!
LIMITED QUANTITIES, BE HURRY – HEAT PUMPS AT DISCOUNT PRICES!
We are in the past in our heat pump guides have discussed technologies that effectively solve the heating needs of residential buildings and smaller properties. Now we are entering a world that is much larger than the previous one, where energy management is not just a matter of comfort or savings, but a critical part of production efficiency, business continuity and strategic competitiveness. We are talking about industrial heat pumps.
An industrial or commercial heat pump is not just a larger version of a home appliance. It is a customized, high-tech system whose true genius lies in its ability to be integrated into production processes and the building's energy cycle. Its primary function is not only to produce heat, but above all to collect and process energy that would otherwise be wasted. It is a customized, high-tech system whose genius lies in its ability to turn waste heat into operating profit, cut emissions and improve the balance sheet.
This article is aimed at decision-makers in industry and large properties. We explain why an industrial heat pump is one of the most effective tools available today to radically cut energy costs, meet emissions targets and implement the principles of a circular economy.
Expert perspective: This article was written by Jukka Poikela, Technical Director at Renewe. He has over 15 years of experience in designing energy systems for the most demanding industries and large buildings in Finland, where process optimization and waste energy utilization are key.
Every industrial process, data center, cold storage facility or large commercial building produces a huge amount of waste heat. It comes from compressed air compressors, production equipment cooling cycles, server cooling or store refrigeration. Traditionally, this heat has often been blown out into the open air as expensive waste, while expensive new energy has been purchased to heat the building.
Industrial heat pump breaks this wasteful cycle. It can be connected to a source of waste heat – for example, the return circuit of cooling water. The heat pump collects this low-temperature (e.g. +15–40 °C) energy and uses a high-tech compressor process to refine it to a higher temperature.
The end result is high-temperature water or steam, even over +100 °C, which can be utilized in many ways:
Often, the largest source of waste heat in industry is also its largest cooling requirement. Processes and facilities need to be cooled reliably, and this is typically achieved by using water coolers or chillersTraditionally, a water cooler has only transferred the heat it has collected to the outside air.
When an industrial heat pump and a water chiller are combined, a perfect symbiosis is created. The cooling process produces heat, and the heat pump needs heat to operate. The system is designed so that the condensation heat produced by the water chiller does not go to waste, but serves as an energy source for the heat pump.
This means that the same electrical energy is used to produce two goods: critical process cooling and valuable high-temperature thermal energy. The overall efficiency of the system increases to exceptionally high levels (up to COP 7–8), and the investment pays for itself much faster.
This technology is not an off-the-shelf product, but a customized solution based on the site and needs. It is best suited for sites that simultaneously have a significant heating need and a usable source of waste heat, such as:
There are always at least three sides to a project: a cold source, a heat pump and a heat load. The source is waste heat, for example, cooling water from compressors, process heat exchangers, condensation heat from a refrigeration unit or cooling from a data center. Heat pump raises the temperature to the desired level and transfers the heat to the accumulators, heating circuits, hot water or district heating connection. Storage on the cooling and heating side makes the timing flexible: buffer accumulators and intelligent control balance loads and cut power peaks. High temperatures are achieved as needed with single-stage, two-stage or cascaded solutions, and to ensure process hygiene, heat transfer is carried out with plate heat exchangers without mixing of flows.
An industrial heat pump is one of the most effective ways to reduce the carbon footprint of industry. A single system can reduce emissions by up to thousands of tons of CO2 equivalent per year, depending on the size and application. This supports companies' ESG goals and prepares for future tightening emission standards. The EU's Green Deal and Fit for 55 package are setting stricter requirements for industrial emissions. An industrial heat pump is not only a cost-saving measure, but also a strategic investment in preparing for future regulations.
An industrial heat pump is a significant investment, but its payback period is often surprisingly short, typically 3–6 years. This is based on the huge savings in purchased energy and potential sales revenue. In addition, the state strongly supports the green transition of industry. It is possible to apply for projects Business Finland energy support, which can cover a significant part of the investment costs and further improve the profitability of the project. In addition to Business Finland's energy support, projects can apply for support from the EU Innovation Fund. The ELY Centres also grant energy investment support to SMEs. Large companies can benefit from EU ETS emissions trading credits when emissions are significantly reduced.
Concrete calculation, a production plant whose cooling process continuously produces 400 kW of +25 °C condensate, which is blown into the magpies. At the same time, the plant purchases 5,000 MWh of district heat per year for heating the property and domestic water.
An industrial heat pump is not an expense, but a highly productive investment that radically cuts energy costs and immediately improves a company's bottom line and sustainability profile. Leasing is also very popular because the savings often exceed the leasing payments.
Renewe's experts are ready to help you through every step of the project. Book a free survey – we will design a heat pump system that suits your needs and provide a clear cost and benefit estimate.
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How is the reliability of the system ensured if it is connected to a critical production process? Reliability is the starting point of the design. Systems are always designed and built with redundancy, using multiple compressors and parallel components. This means that the failure or maintenance of one part does not stop the entire system. In critical locations, the old system is often also kept as a backup, which guarantees 100% operational reliability in all situations.
How can high temperatures be achieved with an industrial heat pump? Modern technology has advanced enormously. Just a few years ago, +75°C was the typical maximum, but today the most advanced high-temperature heat pumps can produce up to +120°C water or low-pressure steam. This greatly expands their applicability from traditional heating applications to demanding industrial processes.
How is the project progressing and how long will it take? The project always begins with a thorough preliminary study and profitability analysis, in which we map out existing waste heat potential and heating needs. After this, we move on to detailed technical planning, equipment selection and scheduling. The installation and commissioning phase itself is always planned in such a way that it causes as little disruption to ongoing production as possible, for example by utilizing planned maintenance downtime. The total duration of the project varies from a few months to a little over a year, depending on its scope.
Can the system be expanded later? Yes, industrial heat pump systems are often designed to be modular. This means that capacity can be increased by adding compressors or parallel units without having to replace the entire system. This is especially important for companies whose energy needs increase over time.
How does an industrial heat pump produce heat above 100 °C? In this case, solutions that are suitable for the site, often multi-stage or cascaded, are used and the refrigerant is selected according to the technical requirements. The lower the required temperature increase, the better the efficiency. What if there is too much or too little waste heat at times? Buffer tanks balance out the fluctuations and the control prioritizes direct utilization. Excess production can be fed into district heating, for example, within the framework of the contract, and the shortfall is covered by reserve heat so that processes and conditions remain stable.
What input do you need for planning? Case template; Target, industry, location and area. Initial situation: cooling load, heat demand, energy consumption and costs with 12 months of data. Renewe's solution: waste heat source, selected heat pump technology, target temperatures and storage. Integration: water chiller and heat pump connection, control principle and backup. Results: estimated annual production for heat, energy efficiency of cooling, reduction of purchased energy, emission reductions and financial indicators. Monitoring: meters, reporting and service model.
