EFFICIENT POWER PLANTS

AND WASTE HEAT RECOVERY

Heat pumps, upgrading heat and producing

cooling energy from waste heat

Antti Uusitalo
UPGRADING HEAT WITH HEAT PUMPS

One option to utilize low temperature heat is to upgrade the heat to a higher temperature
level by using a heat pump.

Can increase efficiency in processes in where relatively high temperature heat is needed
and the waste heat does not have sufficient temperature level to be utilized for heating
directly.

Commercial heat pumps can upgrade low temperature (30-40 oC) waste heat to about 100
oCtemperature level.

Rapid development especially in high temperature heat pumps in the recent years.
SOME EXAMPLE WASTE HEAT SOURCES
Gaseous and liquid low-grade heat sources from industrial processes/data centers/energy production

Exhaust air from buildings

Water (sewage, water treatment plants etc.)

Condenser heat of supermarket refrigerators/freezers

12.01.2024 Footer 3
EXAMPLE OF SIMPLE HEAT PUMP CONFIGURATION
− Refrigerant working fluid circulates in the
process in a closed loop
3
2
− Condensation at high pressure and high
temperature, evaporation at lower pressure
4 and lower temperature
1

− In evaporation heat is extracted to the

working fluid

− In condensing heat is removed from the

working fluid
 THERMODYNAMICS OF A SIMPLE
HEAT PUMP
T log p

ϕcond 2s 2 ϕcond
3 2s 2
3

4 1 4 1
ϕevap ϕevap

s h
T-s logp-h
1-2 compression in compressor
2-3 removing the superheating and condensation
3-4 expansion in valve
4-1 evaporation and small superheating
12.01.2024
 ZEOTROPIC FLUID MIXTURE: GLIDING
EVAPORATION AND CONDENSING
TEMPERATURE
1-2 compression

T 2-3 cooling and condensing

3-4 expansion
ϕC 2 4-1 evaporation and superheating

With a refrigerant mixture the

1 evaporation and condensing
4 ϕE temperature is changing because
of the different saturation
temperatures of the fluids
s
T-s -chart

12.01.2024
TWO STAGE HEAT PUMP WITH
FLASH INTERCOOLER
− Two stage configuration can be used if
the temperature difference between
the evaporator and condenser is high -
> high pressure ratio

− Using two stage process reduces the

power needed for the fluid
compression when compared to a
Flash intercooler
simple process

− Flash intercooler(component in the

middle) transfers the heat between the
two stages

− Vapor is at the top and liquid at the

bottom of the intercooler.

12.01.2024 Footer
TWO STAGE HEAT PUMP CYCLE
− High temperature heat pump cycle with
a tank on intermediate pressure and
two stage compression (used by HP Expansion valve
Friotherm)
Condenser

HP Compressor
Tank

LP Compressor

Evaporator
LP Expansion valve

Arpagaus, C., Bless, F., Uhlmann, M., Schiffmann, J., & Bertsch, S. S. (2018). High
temperature heat pumps: Market overview, state of the art, research status,
12.01.2024 Footer 8
refrigerants, and application potentials. Energy.
CASCADE HEAT PUMPS
− In cascade heat pumps the heat is Condenser
transferred in a cascade heat
exchanger between the cycles and the
fluids of the low pressure (LP) and high HP compressor
pressure (HP) circulates in a closed
HP expansion
loop. valve
Cascade heat
exchanger
− Different working fluids can be used in
LP and HP cycle as the fluids remain
unmixed. LP compressor
LP expansion
valve

Evaporator
THERMODYNAMICS OF A TWO STAGE HEAT PUMP
(FLASH INTERCOOLER)
Two stage configuration
Red lines represent a simplified comparison for a single stage cycle having similar pressure ratio
Better performance (higher COP) can be reached with the two stage configuration
log p
T

s h

12.01.2024
THERMODYNAMICS OF A TWO STAGE HEAT PUMP
(CASCADE)
COEFFICIENT OF PERFORMANCE (COP)
COP = Heat power/compressor input power
 For heat pump:
ϕ
𝐶𝑂𝑃 =
𝑃

Theoretical (Carnot) 𝐶𝑂𝑃 = =

 For cooling/refrigeration machine:

ϕ
𝐶𝑂𝑃 =
𝑃

Theoretical (Carnot) 𝐶𝑂𝑃 = =

12.01.2024
COEFFICIENT OF PERFORMANCE (COP)
COP of direct electric heating can be considered to be 1 (for example by using electric heater with power of 1 MW you
get 1 MW heat power)

If the COP of a heat pump is higher than 1 you consume less electric power than in a direct electricity heating for
producing the same amount of heat power

Note! As the temperature difference between evaporator and condenser increases, COP decreases (see the definition
of Carnot-efficiency)
COP OF DIFFERENT HIGH TEMPERATURE HEAT
PUMPS Figure from: Arpagaus, C., Bless,
F., Uhlmann, M., Schiffmann, J., &
Bertsch, S. S. (2018). High
temperature heat pumps: Market
overview, state of the art, research
status, refrigerants, and application
potentials. Energy.

Note, The higher the ΔT, the lower the COP! About 80-100 oC supply temperatures are sufficient for
district heating, about 120-160 oC is required to produce steam for heating
TECHNICAL MARKET POTENTIAL IN EUROPE FOR INDUSTRIAL HEAT PUMPS IN
DIFFERENT TEMPERATURE LEVELS AND INDUSTRIAL SECTORS. (150 OC IS
CONSIDERED AS THE TECHNICAL LIMIT FOR HEAT PUMPS) 1 PJ = 278 GWH

Figure from: Arpagaus, C., Bless, F., Uhlmann, M., Schiffmann, J., & Bertsch, S. S. (2018). High temperature heat pumps: Market overview,
state of the art, research status, refrigerants, and application potentials. Energy.
TEMPERATURE RANGES OF DIFFERENT INDUSTRIAL PROCESSES

C. Arpagaus, F. Bless, M. Uhlmann, J. Schiffmann, and S. S. Bertsch, “High temperature heat

pumps: Market overview, state of the art, research status, refrigerants, and application
12.01.2024 Footer potentials,” Energy, vol. 152, pp. 985–1010, Jun. 2018, doi: 10.1016/j.energy.2018.03.166.
16
HEAT PUMP WORKING FLUIDS
A good working fluid for a heat pump is:
 High COP can be achieved
 Non-toxic
 Non-flammable
 Stable under the operation conditions
 Doesn’t mix with the compressor lubrication oil to enable the removal of oil leakages from
the system
 Non-corrosive
 Doesn’t have effect on the ozone layer (zero ODP)
 Low global warming potential (GWP)
 Good heat transfer, thermodynamic and fluid dynamic properties
 SOME EXAMPLE FLUIDS AND THEIR
CATEGORIZATION
Natural refrigerants

More restrictions to the use of fluorocarbons proposed in EU 2022-2023

(Fluorinated gases regulation 2022/0099(COD) - 05/04/2022 and new
12.01.2024 Footer PFAS-regulations )
 CRITICAL PRESSURE VS CRITICAL
TEMPERATURE

12.01.2024 Footer
 DIFFERENT HEAT PUMP COMPRESSOR TYPES
Different types of compressors are available
depending on the operational temperatures, fluid
and power level

The compressors can be generally devided into

volumetric compressors and kinetic compressors
depending on their operational principle

Volumetric compressors: Scroll, vane, screw and

piston compressors

Kinetic compressors: centirfugal compressors and

axial compressors

Figure from: Guzda and Szmolke, 2016

In high temperature heat pumps piston, screw and Compressors in Heat Pumps
turbocompressors are often used

12.01.2024 Footer
SCREW COMPRESSORS
Volumetric type of compressor
Fluid pressure increase along the decreasing volume
between two helical rotors
For relatively high power outputs
Advantages:
 Low flow pulsation and vibration
 No operating valves needed (compare to reciprocating
compressors)
 Suitable for small amounts of liquid in the gas
 Wide off-design operating range

Twin screw compressor http://www.air-compressor-guide.com

12.01.2024 Footer 21
PISTON(RECIPROCATING) COMPRESSORS
Volumetric type of compressor
Fluid pressure increase is done by means of piston
movement in a closed cylinder space
Parrallel connected pistons for higher flow rates or pistons in
series for higher pressure ratios
Isentropic efficiency is lower when compared to kinetic
compressors

Figure from: Guzda and Szmolke, 2016

Compressors in Heat Pumps

12.01.2024 Footer 22
 KINETIC(TURBO) COMPRESSORS

Mainly centrifugal type of compressors

Requires high rotational speeds in low power
systems –> more suitable for larger heat pumps Compressor
Higher isentropic efficiency when compared to wheels
volumetric compressors (over 80 % in a good
design)
With high pressure ratios the flow becomes
supersonic with many refrigerants -> shock waves

https://www.man-es.com/docs/default-source/document-sync/man-heat-pump-hpu-
eng.pdf?sfvrsn=e83c2883_2
12.01.2024 Footer 23
 KINETIC COMPRESSORS
Example structure of large scale compressor
unit (Friotherm Uniturbo 50FY)
Two centrifugal compressors
IGC (inlet guide vane) improves the off-
design performance
For halocarbon and hydrocarbon refrigerants

https://www.friotherm.com/wp-content/uploads/2017/12/turbo50fy_uk_g008.pdf
12.01.2024 Footer 24
 TRANSCRITICAL HEAT PUMP CYCLE WITH CO2

Figure from: Kim, Sung Goo, Yoon Jo Kim, Gilbong Lee, and Min Soo Kim. "The performance of a
transcritical CO2 cycle with an internal heat exchanger for hot water heating." International Journal of
Refrigeration 28, no. 7 (2005): 1064-1072.

12.01.2024 Footer
HIGH TEMPERATURE HEAT PUMPS (FOR ABOVE 100 OC SUPPLY TEMPERATURES)
Supplier Compressor type Working fluid Capacity Tmax supply
Fuji Electric Reciprocating R-245fa 0.03 MW 120 °C
Emerson Scroll and EVI scroll R-245fa, R410a, R-718 0.03 MW 120 oC
Mayekawa (EcoSirocco) Reciproating R-744 0.1 MW 120 °C
Mayekawa (EcoCircuit) Reciprocating R-1234ze(E) 0.1 MW 120 °C
Skala Fabrikk Piston R-290, R-600 0.3 MW 115 °C
Kobelco Compressors Corp. (SGH165) Twin-screw R-245fa/R-134a, R-718 0.4 MW 175 °C
Kobelco Compressors Corp. (SGH120) Twin-screw R-245fa 0.4 MW 120 °C Data collected from
Mitsubishi Heavy Industries Two-stage centifugal R-134a 0.6 MW 130 °C
ecop Centrifugal ecop fluid 1 0.7 MW 150 °C https://heatpumpingtechn
Mayekawa Europe (HS Comp) Piston R-600 0.8 MW 120 °C
Kobelco Compressors Corp. (MSRC160L) Twin-screw R-718 0.8 MW 175 °C
ologies.org/annex58/
Mayekawa Europe (FC Comp) Screw R-601 1.0 MW 145 °C
GEA Semi-hermetic piston R-744 0.1-1.2 MW 130 °C
Fenagy Reciprocating R-744 0.3-1.8 MW 120 °C
Rank Screw R245fa, R-1336mzz(Z), R-1233zd(E) 0.12-2.0 MW 160 °C
SRM Screw R-718 0.25-2.0 MW 165 °C
Combitherm Semi-hermetic screw R-1233zd(E) 0.3-3.3 MW 120 °C
Sustainable Process Heat Piston HFOs 0.3-5.0 MW 165 °C
Hybrid Energy Piston, Screw R-717, R-718 0.5-5.0 MW 120 °C
Johnson Controls Reciprocating R-717, R-600 (cascade) 0.5-5.0 MW 120 °C
ToCircle Rotary vane R-717, R-718 1.0-5.0 MW 188 °C
Weel & Sandvig Turbo R-718 1.0-5.0 MW 160 °C
Olvondo Piston (double acting) R-704 5.0 MW 200 °C
Heaten Reciprocating, custom design HFOs 1.0-6.0 MW 165 °C
Enerin Piston R-704 0.3-10.0 MW 250 °C
Ohmia Industry Centrifugal / Piston R-717, R-718 1.2-10.0 MW 150 °C
Enertime Centrifugal R-1336mzz(Z), R-1224yd(Z), R-1233zd(E) 2.0-10.0 MW 160 °C
Spilling Piston R-718 1.0-15.0 MW 280 °C
Epcon HP centrifugal fan R-718 0.5-30.0 MW 150 °C
Turboden Turbon Application specific 3.0-30.0 MW 200 °C
MAN Energy Solutions Centrifugal turbo with expander R-744 10.0-50.0 MW 150 °C
Piller Turbo R-718 1.0-70.0 MW 212 °C
Siemens Energy Turbo (Geared / single-shaft) R-1233zd(E) /R-1234ze€ 8.0-70.0 MW 160 °C
Qpinch Chemical adsorption heat R-718, H3PO4 and derivatives >2.0 MW 230 °C
EXAMPLES OF LARGE-SCALE HEAT PUMPS IN
FINLAND
Fortum, Suomenoja Espoo:
 Heating capacity 23,5 MW
 Cooling capacity 17,3 MW
 2x Friotherm Unitop 50 heat pumps
 In operation since 2016

HELEN, Katri Vala heat pump, Helsinki

 Heating capacity 120 MW
 Cooling capacity 80 MW
 Friotherm Unitop 50 heat pumps
 In operation since 2006 https://www.friotherm.com/products/unitop/unitop-50/

Turku Energia
 Heating capacity 21.2 MW
 Cooling capacity 15.3 MW
 2 x Friotherm Unitop 50 heat pumps
 In operation since 2009 (second unit 2013)
 EXAMPLE PROJECT: LARGE-SCALE CO2 HEAT PUMP AT ESBJERG DENMARK

Heat pump from MAN Energy Solutions

CO2 as working fluid
Use of seawater as heat source to produce 50
MW heating power
In operation in 2023
MAN uses multistage centrfiugal compressors
connected to a high speed electric motor

1= heat sink heat exchanger

2 = recuperator
3 = compressor unit
4 = Co2 separator
5 = Evaporator

Material from: https://www.man-es.com/company/press-releases/press-details/2021/02/04/man-energy-solutions-liefert-erstes-sektor-

%C3%BCbergreifendes-etes-w%C3%A4rmepumpensystem and https://www.man-es.com/docs/default-source/energy-storage/man-heat-
pump.pdf?sfvrsn=33f49700_6

12.01.2024 Footer 28
DATA CENTER HEAT RECOVERY EXAMPLE

Yandex data center with waste heat

recovery by means of heat pumps (in
operation 2015)
Produces district heating for Mäntsälä
region
Over 40 % of the Mäntäsälä center area
district heating was made from waste heat
in 2020 and 2021
Heat pumps from Calefa Oy (6 MW
heating power)

https://www.energiatalous.fi/?p=1841

12.01.2024 Footer 29
EXAMPLE IMATRA HEAT PUMP
Heat pump project by Fortum and Imatran Lämpö Oy.
Utilizes generator cooling water heat of a hydro power plant as heat source
In operation 2022
800 kW heat power to district heating network
Temperature of district heating network 85 oC

https://www.fortum.fi/media/2022/12/imatran-vesivoimalaitokseen-rakennettu-
lampopumppulaitos-otettu-kayttoon
PRODUCING COOLING ENERGY BY USING WASTE
HEAT
Heat pumps can be used also to produce cooling energy
In the heat pump evaporator the phase change of the working fluid extracts heat and cools down the other stream
Also co-generation of heat and cooling is possible, in this case one fluid is heated in the system condenser and the
other one is cooled in the evaporator.
Could be good option for example in large data centers in where there is a large amount of low temperature waste heat
that can be upgraded and also significant need for cooling energy

The word largest Co-generation heat pump is located in Helsinki (126 MW heating power and 80 MW cooling power):
https://www.helen.fi/en/company/energy/energy-production/power-plants/katri-vala-heating-and-cooling-plant/
KATRI VALA HEAT PUMP PRODUCING BOTH
HEATING AND COOLING ENERGY

Figure from: Helen Oy

PRODUCING COOLING ENERGY BY USING WASTE
HEAT
Instead of using compressor driven system, one option is to use absorption refrigeration cycle for producing cooling
energy from waste heat
Typically uses two fluids (e.g. water and ammonia or lithium bromide)
Main components are evaporator, condenser, absorber and generator(not an electric one!)
No compressor in the cycle, but the cycle is driven instead with pressure and temperature differences.

Good video explaining the operation principles of an absorption chiller can be found:
https://www.youtube.com/watch?v=0R84hLprO5s
ABSORPTION CHILLER: WATER-AMMONIA HEAT IN

In generator the other fluid is evaporated with

Condenser Generator
heat (ammonia is vaporized)
High pressure ammonia vapor is condensed
back to liquid in condenser (heat is removed)
Ammonia expands through expansion valve
Low pressure ammonia liquid is vaporized in Heat exchanger
evaporator and cooling energy can be utilized
Low pressure ammonia vapor is absorbed in Expansion valve Solution pump
absorber to weak solution forming strong Regulation valve
solution
Solution pump pumps the strong solution back
to high pressure and back to generator
Absorption chiller “COP” is defined as amount of Evaporator Absorber
useful cooling energy divided by heat input

Low temperature water

for cooling
EXAMPLE OF ABSORPTION CHILLER
INSTALLATION
In AIDA 6 cruise ship, low temperature waste heat (engine cooling heat) from the ship engines is used for producing
cooling energy for ship air conditioning

Absorption chiller as the installed technology

System can generate 1.3 MW of cooling energy from the engine low temperature waste heat

The use of absorption chiller reduces the electricity consumption for producing the required cooling energy
ESTIMATIONS ON ECONOMIC FEASIBILITY
Compressor driven heat pumps
 Investment cost typically 150-1000 €/kW (in most of the studies 400-1000 €/kW)
 Economically feasible if yearly operating hours > 4000 h/a (Bruckner et al. 2015)
 Also dependent on the electricity price and heat source

Industrial scale absorption chillers(Bruckner et al. 2015)

 Typical investment cost 800-2000 €/kW
 Can be economically feasible if the yearly operating time is high
 The investment costs should be further reduced to be more attractive in industrial applicatios

Ref: Brückner, Sarah, Selina Liu, Laia Miró, Michael Radspieler, Luisa F. Cabeza, and Eberhard Lävemann. "Industrial waste heat recovery technologies: An economic analysis
of heat transformation technologies." Applied Energy 151 (2015): 157-167.
COST BREAKDOWN OF LARGE SCALE HEAT PUMP
PROJECTS WITH DIFFERENT HEAT SOURCES

Pieper, H., Ommen, T., Buhler, F., Paaske, B. L., Elmegaard, B., & Markussen, W. B. (2018).
Allocation of investment costs for large-scale heat pumps supplying district heating. Energy
Procedia, 147, 358-367.
12.01.2024 Footer 37
SIMPLE HEAT PUMP EXAMPLE
We have waste heat flow at the temperature of 40 oC.
The heat is upgraded to 90 oC temperature and the produced heat is used for heating purposes.
The heat pump evaporator has heat rate of 2 MW and the heat pump COP is 3.

𝐶𝑂𝑃 =

-> 𝐶𝑂𝑃 =
SIMPLE HEAT PUMP EXAMPLE
Compressor power consumption
-> P = ϕ𝑒𝑣𝑎/(𝐶𝑂𝑃−1) = (2 𝑀𝑊)/(3−1) = 1 MW

Condenser heat rate (upgraded heat)

-> ϕ =ϕ + 𝑃 = 2 𝑀𝑊 + 1 𝑀𝑊 = 3 𝑀𝑊 (note! No heat losses assumed)

By using 2 MW low temperature waste heat and 1 MW compressor power we have 3 MW upgraded high temperature heat
that can be used for heating.
PUMPED THERMAL ENERGY STORAGES AND
CARNOT-BATTERY
Low grade heat
Heat loss
Cooling flow (air or water)

Thermal energy Power conversion

Heat pump storage process

Electricity Electricity
REFERENCES AND LITERATURE
Grassi W. Heat Pumps: Fundamentals and Applications, 2018 Springer

Arpagaus, C., Bless, F., Uhlmann, M., Schiffmann, J., & Bertsch, S. S. (2018). High temperature heat pumps: Market
overview, state of the art, research status, refrigerants, and application potentials. Energy.

IEA high temperature heat pump annex 58 https://heatpumpingtechnologies.org/annex58/

Antero Aittomäki (toim.), 2012 Kylmätekniikka, Suomen kylmäyhdistys Ry. (in Finnish)

Kaappola and Hakala, Kylmälaitoksen suunnittelu, 2005, Opetushallitus (in Finnish)