As industries move toward carbon reduction and energy efficiency, recovering low-grade waste heat has become an essential strategy.
An industrial high-temperature waste-heat recovery heat pump converts low-temperature waste heat (30–80°C) into usable process heat up to 90–120°C,
providing major cost savings and environmental benefits compared with traditional gas and coal boilers.
1. Technology Overview
Many manufacturing facilities release large amounts of low-grade heat through cooling water, condensate, or exhaust systems.
A high-temperature industrial heat pump can capture and upgrade this energy, reducing fuel consumption and operating costs while delivering consistent thermal energy to production lines.
2. Working Principle
The heat pump process involves:
- Collecting waste heat (cooling loops, condensate, flue condensate)
- Compressing refrigerant to boost pressure and temperature
- Delivering high-grade heat through industrial heat exchangers
- Recirculating refrigerant to complete the cycle
Typical COP ranges from 3.0 to 4.2, depending on system design and waste-heat temperature.
3. Applicable Industries
- Chemicals – reaction heating, solvent recovery
- Food & beverage – sterilization, hot water supply
- Pulp & paper – preheating and drying processes
- Textile dyeing – dye bath heating, drying
- Pharmaceuticals – concentration, drying
- Rubber & plastics – mold heating, vulcanization
- Metal finishing – bath heating, drying
4. System Architecture
4.1 Waste-Heat Source Evaluation
- Cooling water: 35–60°C
- Process condensate: 45–80°C
- Oil cooling circuits: 30–70°C
- Flue-gas condensate: 30–70°C
4.2 Core Equipment
- Industrial high-temperature compressor
- High-temperature heat exchangers
- Refrigerant circulation module
- PLC control system with remote monitoring
- Hot-water or hot-air distribution system
4.3 Output Heat Forms
- 90–120°C hot water
- Low-pressure steam (via secondary generator)
- 80–105°C hot air for drying
5. Key Advantages
- 50–70% energy savings compared with boilers
- 1–2.5 years payback depending on recovered heat
- Significant CO₂ emission reduction
- High reliability with industrial compressors
- Smart automated control
6. Real Case | Food Processing Plant (Jiangsu)
The facility previously used a gas boiler for 95°C process hot water, costing more than 1.5 million CNY annually.
A large amount of cooling-water heat (48–55°C) was wasted.
Implemented System
A 200 kW high-temperature waste-heat recovery heat pump was installed to produce stable 95°C hot water.
| Metric | Result |
|---|---|
| COP | 3.6 |
| Hot Water Output | ≈ 4.3 t/h |
| Boiler Load Reduction | 80% |
| Annual Savings | ≈ 920,000 CNY |
| Payback Period | ≈ 18 months |
7. Frequently Asked Questions (FAQ)
1. What waste-heat temperatures are suitable for a high-temperature industrial heat pump?
Most systems perform best with source temperatures between 35°C and 80°C. Higher inlet temperatures typically yield higher efficiency (COP).
2. Can a High-temperature heat pump fully replace a gas or coal boiler?
Yes, for processes requiring 90–120°C hot water or hot air. For steam users, it can significantly reduce boiler load via a secondary steam generator.
3. What refrigerants are used for high-temperature heat pumps?
Industrial systems commonly use CO₂, HFO refrigerants, or cascade designs depending on required temperature and environmental considerations.
4. How long does installation take?
Typical installation and commissioning take 30–60 days depending on system size and plant integration requirements.
5. What is the expected equipment lifetime?
With proper maintenance, industrial heat pumps generally operate for 12–18 years with high reliability.
For custom project evaluations and engineering support, visit
Zhenmingzhu Official Website
