Why generate new energy when much of the heat you need is already present in your process? In many industrial installations, valuable residual heat still goes to waste, even though the right technology can put it back to work.
With compression heat pumps, you can recover that residual heat and upgrade it to usable process heat. That way, you cut your fossil fuel consumption, boost the energy efficiency of your installation, and lower your CO2 emissions.
The Callens Group designs, builds, and integrates compression heat pumps that are fully tailored to your heat demand, available residual heat, and production process.
Compression heat pumps are ideal when valuable residual heat still goes to waste. Think of heat from cooling installations, process water, condensate streams, exhaust gas streams, or humid process air.
Through a mechanical compression process, this heat is raised to a higher temperature, so that it can be reused for process heating or other industrial applications.
Reasons to choose a compression heat pump:
You are losing heat in your processes.
You want to reduce your natural gas consumption.
You want to lower your CO2 emissions.
You are looking for an energy-efficient process heat solution.
Refrigerants
Ammonia
Output temperature
Max 110°C
Thermal output
10 MW
Technical specifications of industrial compression heat pumps
At the Callens Group, we build every installation to measure, and compression heat pump systems are no exception. Our engineers analyze the temperature of the heat source, the available flow rate, the required temperature lift, the operating hours, and the options for integrating the installation seamlessly into your existing energy supply.
Based on this analysis, we design a heat pump system that combines maximum efficiency with high operational reliability and an optimal payback time.
Benefits
Compression heat pumps
Today, compression heat pumps rank among the most energy-efficient technologies for repurposing industrial residual heat.
Maximum use of residual heat
Low-grade heat is upgraded and reused within your production process.
High energy efficiency
Thanks to a high COP, compression heat pumps produce several units of usable heat for every unit of electricity consumed.
Lower CO2 emissions
By partially replacing fossil fuels, you reduce the climate impact of your heat supply.
Lower energy costs
Because a large share of the heat comes from available residual heat, your primary energy consumption drops.
Fully tailored
The compression heat pump is tailored to your existing production environment and energy supply.
Ready for electrification
Compression heat pumps are a key building block in the electrification of industrial process heat.
How do you integrate a compression heat pump into your existing production process?
A compression heat pump delivers the highest efficiency when it is part of your site’s overall energy balance. That is why the specialists at the Callens Group not only look at the available residual heat, but also at your existing heat consumers, piping networks, process installations, and future expansion plans.
Based on this analysis, we determine where the heat pump creates the greatest added value and how the installation can work best alongside your existing steam, hot water, thermal oil, or cooling installations.
Play it safe. Work with the Callens Group.
Outsource complex questions to the Callens Group experts. They develop safe systems that can also be built and maintained safely.
Maximizing energy efficiency does not start with choosing a technology. It starts with mapping out your specific environment and goals.
Questions? We have the answers.
A compression heat pump uses a refrigerant circuit to upgrade low-grade residual heat to a usable temperature level. With the help of an electrically driven compressor, both the temperature and the energy value of the heat increase, so that it can be reused for industrial processes. This makes the most of available residual heat and lowers fossil fuel consumption.
Compression heat pumps can recover heat from a wide range of residual heat streams, such as process water, cooling water, condensate streams, exhaust gas streams, and humid process air. Which heat source is most suitable will depend on factors such as temperature, flow rate, availability, and operating hours. The Callens Group analyzes these parameters and determines which configuration delivers the highest efficiency. Discuss your project with our specialists.
Modern industrial compression heat pumps can upgrade residual heat to temperatures above 100°C, depending on the chosen technology, the refrigerant, and the process conditions. This makes them suitable for a wide range of industrial applications that require hot water or process heat.
Yes. The Callens Group handles the entire process: from analyzing the exhaust gas streams and running a feasibility study to engineering, construction, installation, and commissioning. Our specialists not only consider the compression heat pump itself, but also the extraction, ventilation, piping networks, heat recovery, and integration within your existing production process. That gives you a single point of contact for your entire emission reduction project.
You can find more information about the different steps in our workflow here.
For a building materials manufacturer, the Callens Group delivered a heat pump installation that recovers residual heat from humid drying air and reuses it within the production process. Three industrial heat pumps with a combined thermal output of 4.2 MW upgrade water from 33°C to 80°C. The installation runs entirely on green electricity and replaces most of the existing gas-fired heating, resulting in a significant reduction in energy consumption and CO2 emissions.
