Application of industrial heat pumps

Proven applications in 2012 for Megawatt+

Heatpumps within a technical, commercial and
sustainable framework

Dave Pearson, Director of Innovation, Star Refrigeration Ltd

Philippe Nellissen, Product Manager Industrial applications,
Emerson Climate Technologies GmbH

Emerson Is a Leader in Its Core Global

Businesses & Markets

#1 AC & DC Power Systems

#1 OEM Embedded Power
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#1 Control Valves
#1 Measurement Devices
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#1 Compressors
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2011
US $24.2 Billion
in Sales

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Emerson Climate Technologies

Core Offerings & Key Brands

Residential Heating
& Air Conditioning

Commercial Heating
& Air Conditioning

Commercial &
Industrial Refrigeration

Electronic Services
& Solutions

Technologies that deliver

indoor comfort and reduce
energy costs

High-quality, reliable and

energy efficient HVAC
solutions for every type
of work space

Proven refrigeration solutions

to protect
and safeguard food
and the environment

Facility design,
commissioning and energy
management, including 24/7
energy monitoring

Sales

2011 Sales

$4.0B

Star Refrigeration
Largest in
UK

Est. 1970

350+
employees

Wheres the value for Industrial Heat Pumps ?

Heat
Source

Heat
Needs

Equipment
Capability

EndUser
Vision

ReturnOn
Investment
5

Source and Need: How does it work?

Other sources ?

High temperature (high pressure) needed

Low pressure ratio capability (two-stage) needed

The compressor is the engine of the application

Single
Screw
Technolog
y
61.5 bar std
operating point99C

The limits of any application - pressure

Same Temperature as Hot Water Boiler
61.5 Bar

Ammonia

99C

Factors affecting economic viability

z
z

Investment; likely 10x cost of a gas burner

Operating cost spare parts (remember the Red line
analogy!)

An emerging market but little life cycle data over 10 years

z

Reliability
Uptime is crucial (a heatpump cant save money if it isnt operating)

ROI
Complex assessment - hourly energy cost variances
Options for power company rebates if managed connection accepted

COP > Elec price/gas price

OPEX SAVING FOR CAPEX PAYBACK

Factors affecting economic viability

Heat
Demand
kW
1000

Costof
Gas
/kWh
0.030

Costof
Electricity
/kWh
0.080

COPb COPh
0.8

HeatDemand CostofGas CostofElectricity COPb

kW
/kWh
/kWh
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8
1000
0.030
0.080
0.8

3
COPh
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3

Capital
Utilisation
cost
/KW
hrs/pa
350
4000

CostGas
Heating
/pa
150,000

Capitalcost Utilisation CostGasHeating CostofHeatpumpQ BreakEvenPoint

/KW
hrs/pa
/pa
/pa
Years
350
4000
150000
106667
8.08
333
4000
150000
106667
7.67
316
4000
150000
106667
7.29
300
4000
150000
106667
6.92
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58
285
4000
150000
106667
6.58

A simple model of
Cost
Utility price
Efficiency
Break Even Point

10

CostofHeatpump BreakEven
Q
Point
/pa
Years
106,667
8.08

Factors affecting economic viability

Heat
Demand
kW

Costof
Gas
/kWh

Costof
Electricity
/kWh

1000

0.030

0.080

Heat
Demand
kW
1000
1000
1000
1000
1000
1000

Costof
Gas
/kWh
0.030
0.030
0.030
0.030
0.030
0.030

Costof
Electricity
/kWh
0.080
0.080
0.080
0.080
0.080
0.080

COPb COPh

0.8

COPb COPh
0.8
0.8
0.8
0.8
0.8
0.8

3
3
3
3
3
3

Capital
Utilisation
Cost
/kW
hrs/pa
350

4000

Capital
Utilisation
Cost
/kW
hrs/pa
350
4000
333
4000
316
4000
300
4000
285
4000
285
4000

CostGas
Heating
/pa
150,000
CostGas
Heating
/pa
150000
150000
150000
150000
150000
150000

CostofHeatpump BreakEven
Q
Point
/pa
Years
106,667

CostofHeatpump BreakEven
Q
Point
/pa
Years
106667
8.08
106667
7.67
106667
7.29
106667
6.92
106667
6.58
106667
6.58

8 Years B.E.P!
Make it cheaper?

11

8.08

But lowering the cost by 5% 4times makes

little difference.

Factors affecting economic viability

Heat
Demand
kW
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

Costof
Gas
/kWh
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030

Costof
Electricity
/kWh
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080
0.080

COPb COPh
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8

3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.6

Capital
cost
Utilisation
/kW
hrs/pa
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000

CostGas
Heating
/pa
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000

CostofHeatpump BreakEven
Q
Point
/pa
Years
106667
8.08
103226
7.48
100000
7.00
96970
6.60
94118
6.26
91429
5.98
88889
5.73
86486
5.51
84211
5.32
82051
5.15
80000
5.00
78049
4.86
76190
4.74
74419
4.63
72727
4.53
71111
4.44
69565
4.35

8 Years B.E.P!
Make it better higher COP!

Increasing the COP by 50% halves the B.E.P. And

can be easy to do.

12

Factors affecting economic viability

Heat
Demand
kW
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

13

Costof
Gas
/kWh
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030
0.030

Costof
Electricity
/kWh
0.080
0.084
0.088
0.093
0.097
0.102
0.107
0.113
0.118
0.124
0.130
0.137
0.144
0.151
0.158
0.166
0.175

COPb COPh
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8

3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3

Capital
cost
Utilisation
/kW
hrs/pa
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000

CostGas
Heating
/pa
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000
150000

CostofHeatpump BreakEven
Q
Point
/pa
Years
106667
8.08
112000
9.21
117600
10.80
123480
13.20
129654
17.20
136137
25.25
142944
49.60
150091
NA
157595
NA
165475
NA
173749
NA
182436
NA
191558
NA
201136
NA
211193
NA
221752
NA
232840
NA

The Dooms Day Scenario

widening Gas vs. Electricity price
Time to go to the Pub!

Factors affecting economic viability

Heat
Demand
kW
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

Costof
Gas
/kWh
0.030
0.032
0.033
0.035
0.036
0.038
0.040
0.042
0.044
0.047
0.049
0.051
0.054
0.057
0.059
0.062
0.065

Costof
Electricity
/kWh
0.080
0.084
0.088
0.093
0.097
0.102
0.107
0.113
0.118
0.124
0.130
0.137
0.144
0.151
0.158
0.166
0.175

COPb COPh
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8

3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3

Capital
cost
Utilisation
/kW
hrs/pa
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000
350
4000

CostGas
Heating
/pa
150000
157500
165375
173644
182326
191442
201014
211065
221618
232699
244334
256551
269378
282847
296990
311839
327431

CostofHeatpump BreakEven
Q
Point
/pa
Years
106667
8.08
112000
7.69
117600
7.33
123480
6.98
129654
6.64
136137
6.33
142944
6.03
150091
5.74
157595
5.47
165475
5.21
173749
4.96
182436
4.72
191558
4.50
201136
4.28
211193
4.08
221752
3.89
232840
3.70

Rising Energy Cost Gas & Electricity price

14

Factors affecting economic viability

Heat Costof Costof
Capital
Cost
CostofHP
COPb COPh
Utilisation
BEP
Demand Gas Electricity
cost
GasHeating
Q
kW

/kWh

/kWh

1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

0.030
0.032
0.033
0.035
0.036
0.038
0.040
0.042
0.044
0.047
0.049
0.051
0.054
0.057
0.059
0.062

0.080
0.084
0.088
0.093
0.097
0.102
0.107
0.113
0.118
0.124
0.130
0.137
0.144
0.151
0.158
0.166

0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8

3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5

/kW

hrs/pa

/pa

/pa

350
350
350
350
350
350
350
350
350
350
350
350
350
350
350
350

4000
4200
4410
4631
4862
5105
5360
5628
5910
6205
6516
6841
7183
7543
7920
8316

150000
165375
182326
201014
221618
244334
269378
296990
327431
360993
397995
438789
483765
533351
588019
648291

106667
113806
121551
129949
139055
148928
159632
171237
183821
197466
212264
228313
245722
264608
285100
307338

NPV(10yr)*

Years ( savings cost)

8.08
6.79
5.76
4.93
4.24
3.67
3.19
2.78
2.44
2.14
1.88
1.66
1.47
1.30
1.16
1.03

83,333
165,685
257,753
360,657
475,637
604,067
747,468
907,524
1,086,102
1,285,267
1,507,308
1,754,761
2,030,431
2,337,427
2,679,191
3,059,532

Rising Energy Cost Gas & Electricity price

Improving COP and increasing utilisation
B.E.P 1.03 years.
And significant Net Present Value > 3M

NPV(15yr)*
( savings
cost)
300,000
423,528
561,630
715,985
888,455
1,081,100
1,296,202
1,536,286
1,804,153
2,102,900
2,435,963
2,807,141
3,220,646
3,681,141
4,193,786
4,764,298

*Assumes zero bank interest

Investment = 350,000

15

Factors affecting economic viability

Heat Costof Costof
Capital
Cost
CostofHP
COPb COPh
Utilisation
BEP
Demand Gas Electricity
cost
GasHeating
Q
kW

/kWh

/kWh

1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000

0.030
0.031
0.031
0.032
0.032
0.033
0.034
0.034
0.035
0.036
0.037
0.037
0.038
0.039
0.040
0.040

0.080
0.082
0.083
0.085
0.087
0.088
0.090
0.092
0.094
0.096
0.098
0.099
0.101
0.103
0.106
0.108

0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8

3
3.05
3.1
3.15
3.2
3.25
3.3
3.35
3.4
3.45
3.5
3.55
3.6
3.65
3.7
3.75

/kW

hrs/pa

/pa

/pa

350
350
350
350
350
350
350
350
350
350
350
350
350
350
350
350

4000
4080
4162
4245
4330
4416
4505
4595
4687
4780
4876
4973
5073
5174
5278
5383

150000
156060
162365
168924
175749
182849
190236
197922
205918
214237
222892
231897
241266
251013
261154
271704

106667
109157
111735
114404
117166
120024
122981
126040
129203
132475
135858
139356
142972
146711
150575
154570

Moderate Fuel Cost rises, Good Application Fit,

Moderate Utilisation
16
A very attractive NPV and ROI

NPV(10yr)*

Years ( savings cost)

8.08
7.46
6.91
6.42
5.97
5.57
5.20
4.87
4.56
4.28
4.02
3.78
3.56
3.36
3.17
2.99

83,333
119,033
156,299
195,206
235,830
278,251
322,552
368,821
417,145
467,619
520,341
575,410
632,934
693,021
755,786
821,347

NPV(15yr)*
( savings
cost)
300,000
353,549
409,448
467,808
528,745
592,376
658,829
728,231
800,717
876,429
955,511
1,038,116
1,124,401
1,214,531
1,308,678
1,407,021

*assumeszerobankinterest
Investment
350,000

ROI(NPV/Inv)/10

13.5%

Factors affecting economic viability

All in one graph
COP=3
Gas= 0.03 /kW
Elec= 0.08 /kW
4000 hr/yr

8.5

5%Utilisationincrease

8.0

5%GasIncrease

7.5

5%GasandElectricityIncrease

7.0

0.1COP,5%GasandElectricity,UtilisationIncrease

6.5

0.05COP,2%GasandElectricity,UtilisationIncrease

BreakevenPointinYears

6.0

2%GasandElectricity,UtilisationIncrease

5.5

COP=3
Gas=0.062/kW
Elec=0.166/kW
4000hr/yr

5.0
COP=3
Gas=0.0404/kW
Elec=0.108/kW
5383hr/yr

4.5
4.0
3.5 COP=3
3.0 Gas=0.03/kW

COP=3
Gas=0.062/kW
Elec=0.08/kW
4000hr/yr

Elec=0.08/kW

2.5 8316 hr/yr

2.0

COP=3.75
Gas=0.0404/kW
Elec=0.108/kW
5383hr/yr

1.5

COP=4.5
Gas=0.062/kW
Elec=0.166/kW
8316hr/yr

1.0
0.5
0.0
0.030

17

0.035

0.040

0.045

0.050

GasPrice/kWh

0.055

0.060

0.065

Already developed tool for optimised

installations-Optimised COP

18

Case Studies
From several hundred kW to Several MW
z

Actual (8 actual projects = 30MW supply)

District Heating @ Drammen
Chocolate Factory @ Nestl
Emerson Compressor Plant
See more @ www.neatpumps.com

Potential
LARGE CHEMICAL PRODUCER
POWER STATION OPTIMISATION
FRACTIONAL DISTILLATION PLANT

19

Case Studies
From several hundred kW to Several MW
16000
14000

HEATINGCAPACITYkW

12000

#2

#3

10000
8000
6000
4000

#1

2000
0
60

65

70

75

80

HOTWATERTEMPERATUREC

20

85

90

95

The worlds largest ammonia heatpump?

14 MW, 90C, District heating
3 x 2 stage 4.6 MW Systems

COPheating = 3.0

21

Evaporating temp. 2C

Condensing temp. 89C

Sea water 8 to 4C

District heating water 60 90C

Physical arrangement

Water intake pipe

New District heating plant

22

COPh 3.3

23

COPh 3.0

COPh 2.8

Factory manufacturing

24

Drammen building

25

Operating data collection

Total Heating

12726 kW

Total Abs Power

3996 kW

Total Cooling

8730 kW

COPh

3.18
(59C to 85C)

26

Nestl Halifax, England

England..
1.6 MW, 61C, Process heating
2 x 1 stage 0.8 MW Systems

COPheating = 3.39

27

Evaporating temp. -5C

Condensing temp. 60C

Glycol/water 5 to 0C

Process heating water 12 60C

Food Factory Heating System

28

Emerson Compressor Factory

Process
Equipment
Heating
490kW
65C
320000kg CO2
29

Test
Lab
Cooling
330kW
3C

Case Studies #1 Boiler make up

z

LARGE CHEMICAL PRODUCER (total loss steam use)

Process

Cooling
Heating

30

Case Studies #1 Boiler make up

z

LARGE CHEMICAL PRODUCER (total loss steam use)

20,000 l/hr of make up 24/7/365
10C to 90C = 80K pre-heat
=1887 kW demand
=817,600 / year

Heating

31

Even pre-heating to 60C

= 50K pre-heat = 511k / year

Cooling

Case Studies #2 Flue gas systems

z

32

CHP plant

Case Studies #2 Flue gas systems

Fluegas 32C
80C

Neatpump
30C

Fluegas 120C

District
Heating

50C
51C
Electricity

COPh: 5.5

33

Case Studies #2 Flue gas systems

z

CHP plant
Heat available at varying temperatures
Can be boosted to 90C
Allows heat recovery even when District return water is warm
10,000kW @ COPh = 5.5 and gas @ 0.03 and elec @ 0.09
With gas, efficiency 80%, 10MW, 8000hrs costs
3.0M per year
With Electricity, efficiency 95% and COPh = 5.5, 10MW, 8000hrs costs
1.38M per year (and the flue gas cooling costs are removed)
Saving 1.62M per year

34

B.E.P for 3M Neatpump = 1.85 years

Case Studies #3 Ethanol Distillation

z
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88.9 Billion liters of ethanol produced per year world wide

Generally accepted this has a negative energy yield
more energy used in production than eventual combustion!

35

Case Studies #3 Ethanol Distillation

36

R. Katzen, P.W. Madson and G.D. Moon, Jr

KATZEN International, Inc., Cincinnati, Ohio, USA

Case Studies #3 Ethanol Distillation

10MW heat
12.5MW gas
@80%
Cooling
COPh > 6.0
1.66MW elec
3.22MW gas
@50%
Heating

37

Conclusions

Find
Observe
Control
Utility
Satisfaction
38

Thank You
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Ir MM Philippe Nellissen

dpearson@star-ref.co.uk

+32476943481

+447976607746

Visit our respective Webwites

www.star-ref.co.uk

Our Industrial Heat Pump website

www.neatpump.com

39

Dave Pearson

philippe.nellissen@emerson.com

www.emersonclimate.eu
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