Industrial park heat network up to 120 °C
How an industrial park can run a pressurised hot-water network at up to 110–120 °C from heat pumps using a 55 °C waste heat stream, and what it saves against furnace-oil boilers in each factory.
▶Video: Waste-heat recovery heat pumps
V10 · 2–2.5 minLifting warm water from condensers, effluent and process cooling to useful heat
Video coming soon01Problem statement
- Many small boilers. Each factory runs its own small boiler with its own fuel store, operator and emissions, often at low part-load efficiency.
- Waste heat next door. The anchor factory dumps 55–60 °C water to cooling towers while neighbours burn fuel for heat at 80–110 °C.
- Steam distribution losses. Steam networks lose heat through traps, flash and condensate that is never returned.
- Losses between fuel and process. Burning furnace oil in a boiler or heater and distributing the heat loses a quarter or more of the fuel's energy before it reaches the process.
- Compliance, safety and handling. Fired equipment brings boiler inspections, fuel storage and unloading, flue emissions and an attendant on every shift.
02Use case
The reference network serves a small industrial park with a dye house, a food plant and a staff campus. An anchor factory rejects 55–60 °C water from gas-engine jackets and process coolers, and the park lays an insulated pressurised loop with a 110 °C supply and 70 °C return.
| Heat user | Process temp. | Basis | Heat, kWh/day |
|---|---|---|---|
| Dye house substation | Network 110 → 70 °C | 2 m³/h × 12 h, 70 → 110 °C | 1,115 |
| Food plant substation | Network 110 → 70 °C | 1.5 m³/h × 10 h, 70 → 110 °C | 697 |
| Staff campus hot water and heating | Network 100 → 70 °C | 1 m³/h × 8 h, 70 → 100 °C, 10% pipe losses | 307 |
| Storage and pipework standing losses | – | about 5% | 106 |
| Total useful heat | 2,224 | ||
Averaged over 20 running hours, the heat pumps need about 111 kW.
03P&ID
Tags: HP heat pump, TK tank, SG steam generator, P pump, PHE plate heat exchanger, TCV temperature control valve, TIC temperature indicating controller (panel), TT temperature transmitter, MT moisture transmitter, PT pressure transmitter, LT level transmitter, FS flow switch, NC normally closed. Process fluids are heated through their own exchanger, coil or jacket.
04Solution
System description
- 5 × SE-WWUHT-27 (135 kW total) (SE-WWUHT water-source, R245fa) delivering 120 °C, covering the day's 2,224 kWh in about 16.5 running hours.
- A 4,500 L insulated storage tank decouples the heat pumps from the process peaks.
- Heat source: engine jacket and process cooling water at about 55 °C. Cooling the anchor factory's 55–60 °C water reduces its cooling tower load.
- The furnace-oil fired boilers in each factory stays connected behind a normally closed valve as standby.
- Waste water from the anchor factory at 55–60 °C feeds the heat pump evaporators in a central energy centre and returns to its cooling circuit at about 45 °C.
- The heat pumps lift the network water from 70 °C return to 110–120 °C into a pressurised buffer tank.
- Each customer takes heat through its own substation PHE with a heat meter, so network water never enters a process.
- Existing boilers stay connected at each site as standby until the network has proven itself.
Selected equipment
| Model | SE-WWUHT-27 × 5 |
|---|---|
| Heating capacity | 27 kW each, 135 kW total |
| COP | 2.93 at the data sheet's rated condition (60/55 °C source water) |
| Power input | about 46.0 kW total at rated conditions |
| Rating | water or steam to 120 °C, R245fa |
| Supply temperature | 120 °C |
| Storage | 4,500 L insulated tank |
Ratings from the Sunniva TDS 2026 data sheets.
Control philosophy
TT-101 at the top of the buffer tank stages the heat pumps to hold 110 °C and allows up to 120 °C when demand is high. A differential pressure controller on the network sets pump speed. TIC-201 to TIC-203 at each substation control the secondary side, and the network return temperature is monitored to keep it near 70 °C.
05Energy saving and ROI
Change any input to match a customer's site. Defaults are typical Indian prices for October 2026. The installed cost is a placeholder; replace it with the actual quotation.
| Existing | Heat pump | |
|---|---|---|
| Daily consumption | – | – |
| Annual energy cost | – | – |
| CO₂ per year | – | – |
06Benefits
One energy centre
A single plant room replaces several small boilers, with one maintenance team and one set of records.
Waste heat finds a buyer
The anchor factory earns from heat it now rejects, and its cooling towers run lighter.
Billing by heat meter
Each customer pays for measured kWh, which makes costs transparent.
Lower energy cost
Each kWh of electricity delivers about 2.9 kWh of heat at the required temperature, against well under one kWh of useful heat per kWh of fuel burnt.
No flame on site
No burner, flue or fuel tank for this duty, and no fuel deliveries to schedule.
Built-in redundancy
Several machines share the load. If one is serviced, the others and the storage carry most of the day, with the existing heater in reserve.
07Engineering pointers
Site data to collect
- Waste heat stream flow, temperature and hours
- Each customer's heat demand, temperature and hours
- Network route and length
- Existing boiler fuel use at each site
- Space for the energy centre
- Present fuel or electricity use and monthly bill
- Sanctioned electrical load and spare capacity
- Space for the heat pumps and storage, with service access
Design notes
- Pressurisation. Water at 120 °C must be kept at about 3 bar or more to prevent flashing. Use a pressurisation unit and rate all pipework and PHEs accordingly.
- Low return temperature. Network efficiency depends on a cold return. Specify substations for a 70 °C or lower return and penalise high returns in the heat contract.
- Buried pipe losses. Use pre-insulated pipe and keep the network compact. Losses above 10% of heat sold usually mean the network is too long for the load.
- Electrical. About 46 kW of heat pump input at rated conditions, plus pumps and fans. Check spare sanctioned load before ordering.
- Source stream. The source must give up roughly two-thirds of the heat delivered. Confirm its flow and temperature over a full production day, and filter it before the evaporator.
- Water quality. Scale forms quickly above 60 °C. Use softened make-up and keep the heat pump loop closed, with process fluids on the far side of an exchanger or coil.
Service and warranty
Sunniva has supplied 5,000+ heat pumps since 2012, with nine service technicians across India, including remote sites such as Leh. All components carry a one-year warranty.
Talk to us
Industrial park heat network up to 120 °C
How an industrial park can run a pressurised hot-water network at up to 110–120 °C from heat pumps using a 55 °C waste heat stream, and what it saves against furnace-oil boilers in each factory.
▶Video: Waste-heat recovery heat pumps
V10 · 2–2.5 minLifting warm water from condensers, effluent and process cooling to useful heat
Video coming soon01Problem statement
- Many small boilers. Each factory runs its own small boiler with its own fuel store, operator and emissions, often at low part-load efficiency.
- Waste heat next door. The anchor factory dumps 55–60 °C water to cooling towers while neighbours burn fuel for heat at 80–110 °C.
- Steam distribution losses. Steam networks lose heat through traps, flash and condensate that is never returned.
- Losses between fuel and process. Burning furnace oil in a boiler or heater and distributing the heat loses a quarter or more of the fuel's energy before it reaches the process.
- Compliance, safety and handling. Fired equipment brings boiler inspections, fuel storage and unloading, flue emissions and an attendant on every shift.
02Use case
The reference network serves a small industrial park with a dye house, a food plant and a staff campus. An anchor factory rejects 55–60 °C water from gas-engine jackets and process coolers, and the park lays an insulated pressurised loop with a 110 °C supply and 70 °C return.
| Heat user | Process temp. | Basis | Heat, kWh/day |
|---|---|---|---|
| Dye house substation | Network 110 → 70 °C | 2 m³/h × 12 h, 70 → 110 °C | 1,115 |
| Food plant substation | Network 110 → 70 °C | 1.5 m³/h × 10 h, 70 → 110 °C | 697 |
| Staff campus hot water and heating | Network 100 → 70 °C | 1 m³/h × 8 h, 70 → 100 °C, 10% pipe losses | 307 |
| Storage and pipework standing losses | – | about 5% | 106 |
| Total useful heat | 2,224 | ||
Averaged over 20 running hours, the heat pumps need about 111 kW.
03P&ID
Tags: HP heat pump, TK tank, SG steam generator, P pump, PHE plate heat exchanger, TCV temperature control valve, TIC temperature indicating controller (panel), TT temperature transmitter, MT moisture transmitter, PT pressure transmitter, LT level transmitter, FS flow switch, NC normally closed. Process fluids are heated through their own exchanger, coil or jacket.
04Solution
System description
- 5 × SE-WWUHT-27 (135 kW total) (SE-WWUHT water-source, R245fa) delivering 120 °C, covering the day's 2,224 kWh in about 16.5 running hours.
- A 4,500 L insulated storage tank decouples the heat pumps from the process peaks.
- Heat source: engine jacket and process cooling water at about 55 °C. Cooling the anchor factory's 55–60 °C water reduces its cooling tower load.
- The furnace-oil fired boilers in each factory stays connected behind a normally closed valve as standby.
- Waste water from the anchor factory at 55–60 °C feeds the heat pump evaporators in a central energy centre and returns to its cooling circuit at about 45 °C.
- The heat pumps lift the network water from 70 °C return to 110–120 °C into a pressurised buffer tank.
- Each customer takes heat through its own substation PHE with a heat meter, so network water never enters a process.
- Existing boilers stay connected at each site as standby until the network has proven itself.
Selected equipment
| Model | SE-WWUHT-27 × 5 |
|---|---|
| Heating capacity | 27 kW each, 135 kW total |
| COP | 2.93 at the data sheet's rated condition (60/55 °C source water) |
| Power input | about 46.0 kW total at rated conditions |
| Rating | water or steam to 120 °C, R245fa |
| Supply temperature | 120 °C |
| Storage | 4,500 L insulated tank |
Ratings from the Sunniva TDS 2026 data sheets.
Control philosophy
TT-101 at the top of the buffer tank stages the heat pumps to hold 110 °C and allows up to 120 °C when demand is high. A differential pressure controller on the network sets pump speed. TIC-201 to TIC-203 at each substation control the secondary side, and the network return temperature is monitored to keep it near 70 °C.
05Energy saving and ROI
Change any input to match a customer's site. Defaults are typical Indian prices for October 2026. The installed cost is a placeholder; replace it with the actual quotation.
| Existing | Heat pump | |
|---|---|---|
| Daily consumption | – | – |
| Annual energy cost | – | – |
| CO₂ per year | – | – |
06Benefits
One energy centre
A single plant room replaces several small boilers, with one maintenance team and one set of records.
Waste heat finds a buyer
The anchor factory earns from heat it now rejects, and its cooling towers run lighter.
Billing by heat meter
Each customer pays for measured kWh, which makes costs transparent.
Lower energy cost
Each kWh of electricity delivers about 2.9 kWh of heat at the required temperature, against well under one kWh of useful heat per kWh of fuel burnt.
No flame on site
No burner, flue or fuel tank for this duty, and no fuel deliveries to schedule.
Built-in redundancy
Several machines share the load. If one is serviced, the others and the storage carry most of the day, with the existing heater in reserve.
07Engineering pointers
Site data to collect
- Waste heat stream flow, temperature and hours
- Each customer's heat demand, temperature and hours
- Network route and length
- Existing boiler fuel use at each site
- Space for the energy centre
- Present fuel or electricity use and monthly bill
- Sanctioned electrical load and spare capacity
- Space for the heat pumps and storage, with service access
Design notes
- Pressurisation. Water at 120 °C must be kept at about 3 bar or more to prevent flashing. Use a pressurisation unit and rate all pipework and PHEs accordingly.
- Low return temperature. Network efficiency depends on a cold return. Specify substations for a 70 °C or lower return and penalise high returns in the heat contract.
- Buried pipe losses. Use pre-insulated pipe and keep the network compact. Losses above 10% of heat sold usually mean the network is too long for the load.
- Electrical. About 46 kW of heat pump input at rated conditions, plus pumps and fans. Check spare sanctioned load before ordering.
- Source stream. The source must give up roughly two-thirds of the heat delivered. Confirm its flow and temperature over a full production day, and filter it before the evaporator.
- Water quality. Scale forms quickly above 60 °C. Use softened make-up and keep the heat pump loop closed, with process fluids on the far side of an exchanger or coil.
Service and warranty
Sunniva has supplied 5,000+ heat pumps since 2012, with nine service technicians across India, including remote sites such as Leh. All components carry a one-year warranty.