Electrification by high temperature heat pumps
Michael Bantle (PhD)
Senior Researcher, SINTEF Energy AS,
Christian Schlemminger, Ole Marius Moen, Elisa Magnanelli

Technology for a better societyMichael Bantle (PhD)
POSITIONKEY QUALIFICATIONSCONTACT

since 20122011 – 20122007 – 2011
2002 – 2007

Senior Researcher
Heat Pumps, Drying technology, Refrigeration
Thermal process engineering, Heat andmass
transfer, Food Technology, Food properties
and quality,
Michael.Bantle@sintef.no; +47 41014024

SINTEF Energy Research, Department Thermal Energy
Post-Doc at NTNU, Energy efficiency in drying processes
PhD at NTNU, Study of high intensity, airborne ultrasound in atmospheric freeze drying.
University of applied science, Konstanz Germany, Process and Environmental
engineering, Diploma thesis: Dimensioning of drying and conditioning unit for soybeans.

Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

What can the heat pump do inan electrified future?

https://www.sintef.no/globalassets/sintef-energi/industrialheat-pump-whitepaper/2020-07-10-whitepaper-ihp-a4.pdf
Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

What is the Technological
Readiness Level of HTHP ?
50-60°C
80-90°C
100-150°C

150-250°C

https://www.sciencedirect.com/science/article/abs/pii/S1359431118376087?via%3Dihub

Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

What is the heat source for high temperature(steam producing ) heat pumps?
→ Industrial Waste heat
→ Ambient Air→ Renewable energy Sources→ Geothermal→ Simultaneous cooling demand→…
• How can we integrated this heatsource with the steam demand?
• What is the recovery temperature?
Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

IEA Annex-58 High
Temperature Heat Pumps
State of the art, demonstration casesand development perspectives
Ole Marius Moen

Technology for a better society

Motivation• European process heating and cooling accounts for 50 % of
the final energy consumption of the industry• High-temperature heat pumps are a key solution to replacefossil fuel-based heat supply for industrial processes• 500 TWh potential - 21% of heat demand between 100200°C• Few demonstrated cases

Source: Heat Roadmap Europe (2017), Profileof the heating and cooling demand in 2015

Technology for a better society

Introduction and Objectives• Working group under Technology Collaboration
Program (TCP) umbrella of IEA• Participating organisations operating as National
Teams

Objectives• Provide overview of HTHP technology, possibillities
and applications• Lead by operating agent, Benhamin Zühlsdorf, DTI• Identify bottlenecks and technologicaldevelopments needs• 3 year duration (M1 2021 – M12 2023)• Develop best practice recommandations• Improve understanding among stakeholders

Annex name:Operating Agent:Participating countries:

Homepage:Annex 58 about High-Temperature Heat Pumps
Benjamin Zühlsdorf, PhD, bez@dti.dk
Danish Technological Institute, Energy and Climate•
Austria•
Belgium•
Canada•Denmark•
France•Germany•Japan•
Netherlands•
Norway•Switzerland
https://heatpumpingtechnologies.org/annex58/

Norwegian Team Contribution• Norwegian Team: SINTEF• 50% Supported by Enova: 950 kNOK for
the whole period• Participating on bi-monthly annexmeetings• Contribute to the annex-deliverables,‒ Task1: Technology development from a
Norwegian perspective• Share knowledge and experience fromrelevant projects
Technology for a better society

Scope of activities

Source: Zühlsdorf, B., et al (2022), IEA HPT Annex 58 about High-Temperature Heat Pumps State of the art review, demonstration cases and development perspectives, HTHP SymposiumTechnology for a better society

Timeline

Source: Zühlsdorf, B., et al (2022), IEA HPT Annex 58 about High-Temperature Heat Pumps State of the art review, demonstration cases and development perspectives, HTHP SymposiumTechnology for a better society

Task 1: Technologies• Overview of supplier technology with heat supply > 100°C‒ Market available (TRL 8-9)
‒ Prototype and demonstration systems (TRL 6-7)
‒ Lab/small-scale prototypes (4-5)• Overview of demonstration systems• Development perspectives

Technology for a better societyComparison between supplier technologies

Technology for a better society

Task 1 – Norwegian
contribution• Technology Mapping and description:‒ Norwegian HTHP Technology and system suppliers‒ Demo cases• Norwegian heat demand, heat pump potential
and future development perspectives• Overview of current and previous research
projects

Technology for a better societySupplier technology overview
Existing refrigeration industry- Standard, cost-effective compressor technology- Continous improvement for higher temperatures

Process industry- High capacity, low maintenance compressors

HTHP
MarketTechnology for a better society

Novel and adapted
technologies-automotive derived compressors- Stirling engines

Supply temperatures
Maximum heat supply [°C] and number of manufacturers
Indicated TRLlevelsTechnology for a better society

COP and efficiencies• Strong correlation between COPheating andthe mean temperature lift
• Lorenz efficiencies typically 30-60%• Efficiencies tend to increase for higher
temperature lifts• MVR based systems reported highest
efficiencies

Technology for a better society

Source: IEA Heat Pumping Technologies Programme Annex 58 (2022),
Task 1: Technologies State of the art and ongoing developments for systems and components (draft
report)Task 1 – Technology summary
Key summary:- TRL: 4-9- Max. heat supply temperatures: 115 – 280 °C- Capacities: 0.03 MW – 70 MW- Specific investment costs: 150 – 2000 €/kW
- Large variation in technology (working fluid,
compressors)- Trade-off between temperature, costs, and TRL

Technology for a better society

Source: Zühlsdorf, B., et al (2022), IEA HPT Annex 58 about High-Temperature Heat Pumps State of the art review, demonstration cases and development perspectives, HTHP SymposiumOverview of demonstration cases• 12 demonstration cases• Varied accross different industries• Applications‒ Steam generation for thermal separation‒ Steam and air based drying‒ Hot water generation

Source: IEA Heat Pumping Technologies Programme Annex 58 (2022),
Task 1: Technologies State of the art and ongoing developments for systems and components(draft report)

Development perspectives
120-140°C

Temperature160-180°C

Applications:Applications:Applications:

-

-

-

Pressurized hot water
Low pressure steam generation,
Steam and air based drying

Medium pressure steam
generation, drying and distilliation

Technologies
Technology perspectives

Technology perspectives--

Commerical heat pumps available
Large number of technologies
near market ready
Closed cycle heat pumps
Synthetic and natural refrigerants(CO2, HCs, HFOs, ammonia-water,
LP steam)
Cost reduction throughstandardisation

Technology for a better societyHigh pressure steam generation--

Large competition of suppliers andtechnologies
Steam as working fluid becomming
attractive, either stand-alone or asa top cycle
Pentane, Helium (Stirling cycle)
Open loop and closed loop heatpumps
First commercial systems in place
2-4 years for wider market
deployment

A few demonstration plants existing-

Large scale MVR technology (R-718)
Reversed Brayton (CO2)
Stirling cycle
Heat transformers-

Need more technology
developement:
More prototypes expected fordemonstration: 2-4 years-

INDUSTRIAL HIGH TEMPERATUREHEAT PUMP FOR SIMULTANEOUS
PROCESS COOLING AND HEATING
Christian Schlemminger, Marcel Ahrens
Email: christian.schlemminger@sintef.no
IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Christian Schlemminger (PhD)

POSITION

Research Scientist, SINTEF Energy Research

KEY QUALIFICATIONSHeat pumps, Refrigeration, Energy storage,
Thermal process engineering,
Integrated energy systems,
Component development,
Lab and industrial pilot scale tests

CONTACT

Christian.Schlemminger@sintef.no+47 41063418

22

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Outline
1. Motivation and Background
2. HTHP cases for dairy productioni.

Retrofit of Existing dairyii.

New build dairy

3. Comparison of HTHP perfromance

4. Summary

23

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Challenges are opportunities –Low-emission concepts combined with energy-efficientsolutions will strengthen the industry• Industrial process sectors heavily relies on fossil fuel• Climate targets are not reached due to lack of market ready technology• Long return of investment for climate-friendly energy supply• Low temperature excess heat is not utilized• Awareness of HTHP-technologies is gaining momentum ☺
• Primary energy reduction will reduce dependency on Russian natural gas• Demand for natural refrigerants as consequence of the regulation

24

1st generation - Natural

2nd generation - HF

(1830-1930)(1930-1990)

Work

Safety3rd generation - HFC

4th generation - HFO(1990-2010)(2010-?)Naturalrefrigerants

• CO2
• NH3
Ozone protection
Global warming• H2 O• HCs• ++Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022
Focus

Motivation – HTHP enables industry to increaseenergy efficiency and reduce GHG-emissions
TINE 2014
Districkt heating (GWh);
95• TINE aims to produce all diary products withrenewable energy in 2025
Electricity (GWh); 199

Districkt heating solde(GWh); -37• Situation for dairy production in 2014
• Total energy consumption 503 GWh• Heating 305 GWh

Gas (GWh); 116• Large demand for heating in temperature range of 90°C to
180°C
Oil (GWh); 17

Electricity heat (GWh); 114→ HTHPs and HPs can help TINE to achieve this goal
25

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Implementation cases
Case 1 – RETROFIT : Tine dairy Trondheim (Norway)•

Annual production: 75 mio. liter milk•

Cold supply:••

4 NH3-condensing units (2700 kWth, -1,5 °C / 33 °C)

Process heat supply:•

Hot water transcritical CO2-Heat pump 160 kWth, 0 °C / 10 °C
bis 75 °C•

Process electrical heat 3000 kWth 95 °C/115 °C•

District heating and oil burner as 100% Backup

Case 2 – NEW (2019): Tine dairy Bergen (Norway)• Annual production: 43,4 mio. liter Liter milk
products• Photo voltaic : 6 000 m²• Completely integrated process cold (-1,5°C) and hat
supply (snow smelting 20°C to Pasteurisation 95°C)

26
Sources: https://www.tine.no

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

RETROFIT – HTHP for combined cold and heat

supplySimplified process diagram – Process ice water and process hot water
HTHP-is connected in series with existing chillers and boilers → 100% Backup

LOSSES

COLD

27

Heat utilizedAim:• Utilisation of available waste heat
• Reduction of energy consumption• Reduction of CO2 Emissions

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

HEAT

RETROFIT - Propane-Butane cascade HTHP• HT circuit with R600 (Butane)
LT circuit with R290 (Propane),• Sink temperatures up to 115 °C
achievable with moderate pressuresabout 20 bar• Source temperatures (-15°C) 0 to 30°C
• High temperature lift (70…120 K)• HTHP is mounted in 10 feet shipping
container build after EN-NS-378➢Pilot installed available and flexible
system (high TRL-level)
28

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

RETROFIT - Process cold and heat demand (excluding
storage and building)
1 00
1200
00

e

• Large variation in heat consumption

heat

Weekend

Characteristics

0• Good match between cold andheat demand

00
00

r

• Low consumption at the weekend
l

r

00

e

• Large variation in cold consumption

1200

H t

a ter

H H

l

• Primary energy (electricity) 126 MWh
29• HTHP-Cascade 80 kW to 282 kW @ 90°C to 107°C
Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

ugu t 2021

hea t

ugu t 2021

r e

ugu t 2021

• Process cold 77 MWh

ugu t 2021

ugu t 2021

• Hot water 10,7 MWh

ugu t 2021

ugu t 2021

H H Hea t

ugu t 2021

• Process heat 117 MWh

72Energy demandr elNEW dairy - Fully heat pumps based system
Simplified process diagram

HEAT

All dairy process are integrated witheach other

Source: Hybrid Energy AS

COLD
30

The system design has focus on maximal waste heat utilisation. 95% waste heat utilisation
were documented.
Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

NEW dairy -Hybrid adsorption-compression HTHP
• Vapor compression cycle with additional solution circuit• NH3-H2O mixture as working fluid pair(zeotropic mixture)

Source: Hybrid Energy AS• Heat sink temperature up to 120 °C (130 °C) withcomparably low pressure ratio (3..6) and moderate highpressure 25 bar (32 bar)• High temperature lift with large heat source and sinkglides (>30 K)➢High system flexibility and adaptability due to solution
circuit➢Very high TRL Level (standard NH3 components) Ahrens, M. et al. (2019) Development of ammonia-water hybrid absorption-compression heat pumps,

31

in: 25th IIR International Congress of Refrigeration. IIF-IIR, Montréal , Canada, pp. 4942–4949

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

NEW – Cold and heat demand (entire dairy)
Summer

WinterWeekend

Weekend➢ Available heat and cold consumption arematching well
➢ Very very little use of backup system (3%)➢ Cooling demand is dominating→ too much waste heat available➢ Very very very little use of
backup system (<1%)➢ Weekend operation can be optimised➢ Optimised weekend operation➢ Peak are covered by the storages
32

Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Comparison of refrigeration HP and HTHP systems
10

Analysis covers0• NH3-Chillers0• NH3-Heat pumps• Transcritical CO2-HP for ice water 0.5°C to 4°C
and HW 10°C to 75°C production

02• NH3/H2O Hybrid HTHP
0

• R290/R600-Cascade HTHP

0

➢ Variation in Temperature lift and COP

20
HH➢ Comparable Carnot-efficiencies

H

0

0
H
H

0
hill2
hill1

100

120
H
2

H ri

➢ Simulations utilisation of evaporator andcondenser/gas cooler side is important for hightemperature lifts
33
Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Summary and conclusions• Simultaneous utilisation of evaporator and condenser/gas cooler is key• New dairy:•

Reduced process temperature requirements from 120 °C to 95°C•

Optimal thermal storage temperature level and size•

Energy savings up to 65%•

CO2-Reduction 95% (compared to gas + NH3-chiller)

Source: www.hybridenergy.no• Dairy retrofit:•

High Temperature lift (>110K) Cascade required --> high flexibility•

Industrial pilot R290/R600 300kWth @ 110°C to 115 °C integrated and in full operation•

Energy saving potential 62%, CO2-Reduction potential 94%•

Energy saving potential at Trondheim site 54%➢ Chillers, HP und HTHP with natural working fluids are favourable for sustainable and efficient foodproduction
34➢ Using natural refrigerants can prevent the uncertainty of future restrictions and ensure future-proof
operation
Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

Thank you for your attention ☺

The authors would also like to acknowledge the support of The Research Council of
Norway and the industrial partners through the grant NFR-296374 (SkaleUp), and NFR257632/E20 FME-HighEFF (Centre for Environment-friendly Energy Research).

35

Sustainable and efficient heat pump development for combined process heat andcool
Schlemminger et al. - IEA HPT TCP National Workshop – Heat pumps in Norway, Oslo 10.05.2022

DryFiciency
Michael Bantle

DryFiciency: Industrial
Demonstration
High temperature heat pumps up to 160ºC
Closed loop heat pump

17/05/2022

Open loop heat pump

Brick drying

Starch drying

Bio sludge drying

Wienerberger AG
Uttendorf (AT)AGRANA Stärke GmbH
Pischelsdorf (AT)

Scanship A/SDrammen (NO)he pr je t ha re eive fun ing fr m the Eur pean Uni n’ H riz n 2020 pr gramme f r energ effi ien
innovation action under grant agreement No. 723576.

an

37Open loop demo: ScanshipRefrigerant R718 (water)
▪

▪

▪

▪

Abundance and Safety:▪ Most abundant elements on earth; low cost and nearly unlimited available▪ From environmental point of view: water is ideal refrigerant above 0°C▪ Non-toxicity, non flammable, 0 Ozone Depletion Potential, 0 Global
Warming Potential
Regulatory Relief:▪ Not subject to present or future environmental or safety regulations
Efficiency:▪ High latent heat of evaporation (2270 kJ/kg); 4-5 times higher thanhydrocarbons or CO2▪ Critical temperature: 380-386°C▪ General high COP
Disadvantages▪ Requires high volume flow
▪ High superheating during compression
39

Open Loop heat pump:expectations and results
𝑚̇
Speed

Pressure
ratio

Tsat

Tlift

Heat
delivery

COP

COP(at 1 ar)

Speed

Carnotηsystem

RPM

%

kg/h

-

°C

K

kW

-

-

%

72000/
81000

90/90

756

4.23

146

45.6

494

4.54

9.2

49.4

68000/
81000

85/90

648

4.05

144

44.0

423

4.8

9.5

50.4 %

64000/
81000

80/90

720

3.59

140

39.7

461

5.2

10.4

50.5 %

64000/
76500

80/85

684

3.44

138

38.2

440

5.1

10.8

47.1 %

60000/
76500

75/85

648

3.21

136

35.9

413

5.8

11.4

50.5 %

56000/
72000

70/80

576

2.83

132

31.5

367

6.4

12.8

50.0 %

52000/
67500

65/75

504

2.49

127

27.3

325

6.5

14.7

44.2 %

48000/
63000

60/70

360

2.32

125

24.9

226

8.7

16.0

54.7 %

Figure modified from C. Apargaus, Book:"Hochtemperatur Wärmepumpen"

CLOSED LOOP HEAT PUMP

17/05/2022

41

Integration Principle

Cooling air from ambient

Exhaust air~200 t/h@52°C(48% RH)~1000 °C
Dry BrickFired Brick

ture
pera
Tem

Gas burner
20 °C

Kiln

50 °C
400°C

Steam
Dry product14 t/h
(10% moisture)

Drying agent (air)Hot airfrom kiln

Intermediate circuit(Water)Flow
stream
dryer

180°C

100°C
Condenser

120°C Intermediate circuit(Water)140°CCondenser

100°C

Wet product(35-40% moisture)

Water
(HRC)
~200 t/h@30°C

Exhaust air
50°C(60% RH)

Evaporator
Wet product

70°C
Dryingagent (air)17/05/2022

Closed loop
heat pump

90°C~200 t/h@158°C

70 t/h@115°C(2% RH)

10 t/h
(28% moisture)

40°C
30°C

waste
heat
recovery

90°C

Evaporator

60°C

Rel. humidity

Dry product
Recirculaton fans
(2% moisture)

Temperature

Tunnel Dryer Drying capacity 2.6t/h

42

Performance: Operating Hours• WBG:
4020 h until 31.8.2021• AGA:
4008 h until 31.8.2021
17/05/2022

43

Overview on heat pump operation

other IHP from Arpagaus et al. Hightemperature heat pumps: Market
overview, state of the art, researchstatus, refrigerants, and application
potentials, Energy (152), p.985-1010,
2018.

17/05/2022

44

Impact of the demonstrators
AgranaWienerberger

138ºC

120ºC

final energy reduction

2388 MWh/a = 72%

2163 MWh/a = 82%

primary energy reduction

1690 MWh/a = 46%1904 MWh/a = 66%

CO2 emissions reduction

659 t/a = 73%592 t/a = 83%

heat supply temperature

17/05/2022

reductions compared to a natural gas burner with the same heating capacity
45

End energy and CO2 emissions

17/05/2022

46

Summary, Discussion andQuestionsSummary and Discussion: Can we integrate
HTHP in the industry?
→Yes, …. but▪ Realistic expectation about the achievable COP▪ COP between 2-3▪ SEC of the system must be evaluated▪ Realistic expectation about the TRL → technical risk
▪ MVR-technology available for large capacities (>5 MW)▪ Integration with the onsite excess heat source is challenging → high temperature lift
▪ Do we really need 150-180°C process heat?
▪ What is a realistic product temperture?
▪ Is it possible to develop "low-temperature" processes?
▪ Is it possible to have high humidity exhaust air?

Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

Technology for abetter society

Steam producing air source heatpump (Research Centre HighEFF)

Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

Cofficient of Performance of HTHP
"Ruled" by thermodynamic!
→High temperature lift
→Low COP→High CAPEX→High system complexity
Where is the technoeconomic sweet-spot?

Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

How could such a steam producing heatpump for pulp and paper industry look like?
• Combination of different
heat pump cycles• Bottom cycle lifts close to
100°C• Top cycle operates withsteam compression (R718)
Source:https://www.sciencedirect.com/science/article/pii/S2590
174519300091?via%3Dihub

Michael Bantle (PhD), SINTEF Energy Research, 30.03.2022

Case study - HighEFF
Closed MVR-HP circuit
Energy source:

Water, 110’C, 425m3/h

Water, 80’C, 425m3/h

Energy sink:

Water, 110’C, 500m3/h

Water, 140’C, 500m3/h

COP:
17.5MW supplied heat by
3.2MW electrical cons.
=
COP 5.5

55

Background

Wolf, S., et al. (2014). Analyse desPotenzials von Industriewärmepumen in
Deutschland (in German)
Forschungsbericht. Universität Stuttgart,
Institut für Energiewirtschaft undRationelle Energieanwendung

SINTEF Energi AS, Michael BantlePerformance: Agrana

17/05/2022

56

Performance: Wienerberger

17/05/202257