Heat Pumps for Process Heating Applications

Industrial process heating is commonly achieved using fossil fuel boilers, electric resistance heating, steam systems and industrial heat pumps. While each has its place, industrial heat pumps stand out by capturing and upgrading existing thermal energy rather than generating heat through combustion. The result is significantly greater efficiency, lower operating costs and reduced carbon emissions.

• Fossil fuel boilers – Proven technology with fuel costs and direct emissions
• Electric resistance heating – Simple design but limited to a COP of approximately 1.0
• Steam systems – Effective but often energy-intensive
• Industrial heat pumps – Deliver three to six units of heat for every unit of electricity consumed

An industrial heat pump captures low-grade heat from sources such as waste heat, water or air, upgrades it through a refrigeration cycle and delivers it back to your process at a higher, usable temperature. Because it transfers existing thermal energy rather than generating heat through combustion, it can deliver three to six units of thermal energy for every unit of electricity consumed.

Vilter process heating solutions combine proven single-screw and reciprocating compressor technologies with ammonia (NH₃), CO₂ (R744), hydrocarbons and hydrofluorocarbons refrigerants to deliver reliable, energy-efficient performance across a wide range of industrial heating applications.

Industrial heat pumps can deliver process heat across a wide range of operating temperatures. Vilter VQ Series heat pumps are engineered to supply hot water between 60°C and 180°C, covering many industrial heating applications, including:

• Pasteurization
• Sterilization
• Drying
• Evaporation
• Process washing
• Industrial space and water heating

For applications requiring higher temperatures, Vilter application engineers can evaluate alternative system configurations.

Every industrial heating application is different. Vilter application engineers begin by evaluating your process heat requirements, available heat sources, operating temperatures and site conditions to configure the right solution.

Typical design considerations include:

• Required process temperature
• Available waste heat or other heat source
• Required heating capacity
• Refrigerant selection
• Heat exchanger sizing
• Site layout and operating conditions

The result is a system configured to maximize efficiency, reliability and long-term operating performance.

Payback depends on factors including energy prices, operating hours, available incentives and the equipment being replaced. Many industrial facilities realize payback within several years through lower energy consumption, reduced maintenance costs and improved operating efficiency.

Vilter application engineers can provide a site-specific lifecycle cost analysis to estimate expected savings and return on investment.

Industrial heat pumps are best suited for applications requiring consistent heating between 60°C and 180°C, particularly when waste heat can be recovered and reused.

Common applications include:

• Food and beverage processing
• Pulp and paper
• Chemical processing
• Automotive manufacturing
• Metal processing

Vilter application engineers can help determine whether your process is a good candidate for heat pump technology.

Vilter process heating solutions utilize proven compressor technologies selected to match application requirements. Depending on the system, Vilter offers both single-screw and reciprocating compressors, delivering reliable performance, high efficiency and long equipment life.

Benefits include:

• Proven industrial reliability
• Excellent part-load efficiency
• Reduced vibration
• Wide operating flexibility
• Long service life

Vilter VQ Series industrial heat pumps can support water heating, thermal oil heating, and steam generation, depending on the required temperature and the selected model.
VQ95 is ideal for hot water heating up to 95°C. Water-based systems typically provide the simplest installation and operation, although the VQ95 can also be configured for other heat transfer media upon request.

VQ145 can provide hot water or thermal oil heating up to 145°C. It can also facilitate steam generation up to 117°C (1.8 barA). For steam applications, additional equipment is required to manage the expansion and flashing of the hot pressurized water used to generate steam.

VQ180 offers the greatest flexibility and can be configured for liquid heating of either water or thermal oil up to 180°C, or for direct steam generation up to 175°C (8.9 barA), making it suitable for a wide range of high-temperature industrial process applications.
In short, the VQ Series industrial heat pumps can do it all. Whether your process requires hot water, thermal oil, or steam, Vilter offers a solution tailored to the temperature, pressure, and integration requirements of your application.

Yes. Vilter VQ Series heat pumps are designed for compact installation in industrial facilities. Modular skid-mounted construction simplifies installation, minimizes site work and makes it easier to integrate into existing plants.

During the quotation phase, Vilter provides detailed layout drawings to confirm system fit before installation begins.

Vilter supports your equipment throughout its lifecycle with comprehensive aftermarket services, including:

• Genuine OEM Parts
• Factory Remanufacturing
• Preventive maintenance
• Technical training
• Service and technical support

These services help maximize uptime, extend equipment life and keep your system operating at peak performance.

The total cost of ownership includes the purchase price, installation, energy consumption, maintenance and operating costs over the life of the equipment.

Because industrial heat pumps use significantly less energy than traditional heating systems, many facilities realize lower lifecycle costs while also reducing emissions and regulatory risk. Vilter application engineers can provide a customized lifecycle cost analysis for your operation.

The Vilter VQ Series heat pump combines a proven single-screw compressor, plate heat exchangers, controls and supporting components into a compact skid-mounted package designed for reliable industrial operation.

Core components include:

• Single-screw and reciprocating compressors: At the heart of Vilter process heating solutions, these proven compressor technologies drive the refrigeration cycle while delivering reliable performance, high efficiency and application-specific flexibility.
• Evaporator (plate heat exchanger): Extracts heat from the source fluid and transfers it to the refrigerant
• Condenser (plate heat exchanger): Releases heat from the refrigerant to the process water circuit
• Expansion valve: Reduces refrigerant pressure between condenser and evaporator, controlling the thermodynamic cycle
• Electric motor and drive: Powers the compressor, with variable speed drive (VSD) enabling capacity modulation and efficiency optimization
• Controls platform: Monitors and manages system operation, COP, alarms and remote connectivity
• Skid frame: Pre-assembled structural base integrating all components for simplified site installation

All components are specified to meet the demands of continuous industrial operation and are supported by Vilter's global spare parts network.

Refrigerant selection determines the heat pump's efficiency, operating temperature range, environmental impact and long-term regulatory compliance. Refrigerant selection affects system efficiency, operating temperature, environmental impact and long-term operating costs.

Key reasons refrigerant choice matters:

• Efficiency: Different refrigerants carry different thermodynamic properties that directly affect achievable COP at your specific operating temperatures
• Temperature capability: The refrigerant must remain stable and efficient across your required evaporating and condensing temperature range
• Environmental impact: Global Warming Potential (GWP) determines regulatory exposure as EU F-Gas regulations tighten
• Long-term availability: Synthetic high-GWP refrigerants face accelerating phase-down schedules, creating supply and cost risk
• Safety classification: Refrigerants carry flammability and toxicity classifications that affect site permitting and handling requirements

Vilter VQ Series heat pumps use ammonia (NH3), CO₂ (R744), hydrocarbons and hydrofluorocarbons refrigerants, delivering best-in-class thermodynamic performance for industrial process heating.

Vilter VQ Series heat pumps use ammonia, CO₂ (R744), hydrocarbons and hydrofluorocarbons refrigerants. Choosing natural refrigerants today eliminates the risk of future refrigerant phase-outs disrupting your operations.

Installing a Vilter VQ Series heat pump using ammonia refrigerant requires a structured safety assessment, but with proper engineering and compliance measures, plant safety is fully manageable and well understood across European industrial facilities. Ammonia has been safely used in industrial refrigeration for over 150 years.

Safety considerations and mitigations include:

• Ammonia detection: Fixed gas detection systems with audible and visual alarms are standard practice and required by EU safety regulations
• Ventilation design: Adequate mechanical ventilation in the plant room ensures safe dispersal of any minor leak
• Pressure relief systems: Properly sized relief valves and emergency systems are integrated into VQ Series skid designs
• Operator training: Vilter provides comprehensive training on safe ammonia handling, emergency procedures and routine maintenance protocols
• Regulatory compliance: Systems are designed to comply with EN 378, the Pressure Equipment Directive (PED) and relevant ATEX requirements where applicable
• Minimal charge volume: The compact VQ Series design minimizes refrigerant charge, reducing overall risk inventory

Our Vilter engineers work with your team to help select and apply the right heat pump solution for your facility, taking into account refrigerant requirements, equipment location, ventilation, ammonia detection and applicable safety standards. With proven industrial heat pump technology and built-in safety considerations, Vilter can help you integrate a solution that supports your performance and decarbonization goals while maintaining plant safety.

Installing a Vilter VQ Series heat pump using flammable refrigerants (HC) requires a structured safety assessment, but with proper engineering and compliance measures, plant safety is fully manageable and well understood across European industrial facilities.

Safety considerations and mitigations include:

• Gas detection: Appropriate refrigerant detection systems provide early warning of a leak, allowing ventilation, alarms or other safety measures to be activated as required.
• Ventilation design: Adequate mechanical ventilation in the plant room ensures safe dispersal of any minor leak
• Pressure relief systems: Properly sized relief valves and emergency systems are integrated into VQ Series skid designs
• Operator training: Vilter provides comprehensive training on safe refrigerant handling, emergency procedures and routine maintenance protocols
• Regulatory compliance: Systems are designed to comply with EN 378, the Pressure Equipment Directive (PED) and relevant ATEX requirements where applicable
• Minimal charge volume: The compact VQ Series design minimizes refrigerant charge, reducing overall risk inventory

Our Vilter engineers work with your team to help select and apply the right heat pump solution for your facility, taking into account refrigerant requirements, equipment location, ventilation, gas detection and applicable safety standards. With proven industrial heat pump technology and built-in safety considerations, Vilter can help you integrate a solution that supports your performance and decarbonization goals while maintaining plant safety.

Electrical requirements depend on system capacity, operating conditions and desired efficiency. Vilter application engineers provide complete electrical load information during system design to support facility planning.

For practical reference:

• A 1,000 kW heat pump operating at a COP of 4.0 requires approximately 250 kW of electrical input
• A 3,000 kW system at COP 5.0 requires approximately 600 kW of electrical input

Key electrical supply considerations include:

• Supply voltage: Vilter VQ Series units are configured for standard European industrial supply voltages (typically 400V or 690V, 3-phase, 50 Hz)
• Soft-start or variable speed drive: VSD integration reduces peak inrush current and enables capacity modulation, reducing grid impact
• Power quality: Stable supply voltage improves compressor motor performance and longevity
• Grid connection capacity: Existing electrical infrastructure should be assessed during the system design phase to confirm adequate capacity

Vilter engineers provide full electrical load data during the specification process to support site electrical planning.

To develop an accurate VQ Series heat pump configuration, Vilter's engineering team requires a defined set of process and site parameters. Providing complete and precise data at the outset enables faster, more accurate system sizing and avoids costly redesign during project execution.

Required information includes:

• Process heat demand: Total thermal load in kW and the load profile over time (steady-state or variable)
• Process delivery temperature: The temperature at which heat must be supplied to your process
• Heat source details: Type of source (waste heat stream, cooling water, ambient air), available temperature and flow rate
• Site location: Geographic location to assess ambient conditions and regulatory context
• Available utilities: Electrical supply capacity, voltage, water supply and drainage
• Space constraints: Available floor area, ceiling height and any equipment access restrictions
• Operating hours: Annual hours of operation and any seasonal variation in load or source conditions
• Refrigerant preferences: Any site-specific constraints on refrigerant type

With this data, Vilter engineers can deliver a full system configuration, COP estimate, dimensional drawing and lifecycle cost analysis.

In heat pump terminology, the "source" is the low-temperature medium from which the system extracts heat, and the "sink" is the higher-temperature medium to which heat is delivered. Understanding this relationship is fundamental to system design and performance optimization.

Applied to the Vilter VQ Series:

• Source examples: Industrial waste heat streams, process cooling water, groundwater or air. A higher source temperature reduces compressor workload and improves COP.
• Sink examples: Process hot water circuits, space heating systems or any industrial process requiring heat at 60 °C to 180°C. A lower sink temperature requirement reduces the temperature lift the compressor must achieve.

The temperature difference between source and sink is called the "temperature lift." Minimizing this lift is the single most effective lever for maximizing COP and reducing operating costs. Vilter engineers assess both source and sink conditions in detail during system design to ensure the VQ Series operates at peak efficiency for your specific application.