Fermenter warm water from fermenter cooling heat
How a biotech plant can warm its fermenters, media and downstream water to 30–45 °C with a heat pump on fermenter cooling-water return, in place of electric heaters.
▶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
- Heating and cooling at the same time. Fermenters reject heat to cooling water during growth, while media, seed and buffer water are heated electrically next door.
- Tight temperature windows. Cultures need 30 to 40 °C within ±0.5 K. Electric heaters cycle on and off and can overshoot.
- Power cost. Resistance heating of large water volumes is expensive per unit of heat.
- Electric heating is expensive heat. Resistance heaters turn one kWh of electricity into one kWh of heat, at the full commercial tariff. A heat pump moves two to four kWh of heat for the same unit.
- Large connected load. Heater banks take a big share of the sanctioned load and push up maximum-demand charges.
02Use case
The reference plant makes enzymes and probiotic cultures in three 10 m³ production fermenters with seed vessels. It runs batch fermentations around the clock with media preparation and downstream recovery on two shifts.
| Heat user | Process temp. | Basis | Heat, kWh/day |
|---|---|---|---|
| Production fermenter warm-up | 25 → 37 °C | 2 batches × 10,000 L | 279 |
| Media and seed water | 25 → 40 °C | 10,000 L/day | 174 |
| Downstream wash and buffer water | 25 → 45 °C | 8,000 L/day | 186 |
| Storage and pipework standing losses | – | about 5% | 32 |
| Total useful heat | 671 | ||
Averaged over 20 running hours, the heat pumps need about 34 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
- 1 × SE-WW-55V (55 kW) (SE-WW water-source heat pump) delivering 55 °C, covering the day's 671 kWh in about 12.2 running hours.
- A 2,000 L insulated storage tank decouples the heat pumps from the process peaks.
- Heat source: fermenter cooling-water return at about 32 °C. Cooling the fermenter return water reduces chiller or cooling tower load during the exothermic growth phase.
- The electric immersion heaters stays connected behind a normally closed valve as standby.
- Fermenter cooling-water return at about 32 °C passes through the heat pump evaporator and goes back to the fermenters colder.
- The heat pump charges a warm-water tank at 50–55 °C that serves fermenter jackets, media preparation and downstream heaters.
- The tank evens out the mismatch between batch warm-up demand and the cooling heat available during growth.
Selected equipment
| Model | SE-WW-55V × 1 |
|---|---|
| Heating capacity | 55 kW each, 55 kW total |
| COP | 4.7 at the data sheet's rated condition (55 °C outlet) |
| Power input | about 11.6 kW total at rated conditions |
| Rating | hot and chilled water at the same time, to 60 °C |
| Supply temperature | 55 °C |
| Storage | 2,000 L insulated tank |
Ratings from the Sunniva TDS 2026 data sheets.
Control philosophy
TT-101 holds the warm-water tank between 50 and 55 °C, with the heat pump enabled while cooling-water return is above 28 °C. TIC-201 controls each fermenter jacket in split range between warm and cooling water. Electric heaters stay as standby when the source runs short.
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 | – | – |
| Cost per fermentation batch | – | – |
| CO₂ per year | – | – |
06Benefits
Cooling and heating together
One machine cools the fermenters and heats the media.
Steady culture temperature
Modulating warm-water control holds the broth within tight limits without overshoot.
Much lower power
The heat pump delivers several units of heat per unit of power at this small temperature lift.
Lower energy cost
Each kWh of electricity delivers about 4.7 kWh of heat at the required temperature, against well under one kWh of useful heat per kWh of fuel burnt.
Smaller electrical load
The heat pump draws roughly 1/4.7 of the power of the heaters it replaces, which frees sanctioned load and cuts demand charges.
Solar-ready
Running hours can be placed in daylight so rooftop solar supplies much of the electricity, which also cuts CO₂ further.
07Engineering pointers
Site data to collect
- Fermenter volumes and batches per day
- Culture temperature set-points
- Cooling-water flow and temperatures during growth
- Media and buffer water volumes
- Present electric heater ratings
- 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
- Sterility. Keep warm water in jackets and coils only. Media and broth are heated through closed surfaces.
- Source timing. Cooling heat peaks mid-fermentation and warm-up demand peaks at batch start. Stagger batches and size the tank to bridge the gap.
- Sterilisation stays on steam. Media and fermenter sterilisation need steam above the heat pump range. This note covers temperature control only.
- Electrical. About 12 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.
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
Fermenter warm water from fermenter cooling heat
How a biotech plant can warm its fermenters, media and downstream water to 30–45 °C with a heat pump on fermenter cooling-water return, in place of electric heaters.
▶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
- Heating and cooling at the same time. Fermenters reject heat to cooling water during growth, while media, seed and buffer water are heated electrically next door.
- Tight temperature windows. Cultures need 30 to 40 °C within ±0.5 K. Electric heaters cycle on and off and can overshoot.
- Power cost. Resistance heating of large water volumes is expensive per unit of heat.
- Electric heating is expensive heat. Resistance heaters turn one kWh of electricity into one kWh of heat, at the full commercial tariff. A heat pump moves two to four kWh of heat for the same unit.
- Large connected load. Heater banks take a big share of the sanctioned load and push up maximum-demand charges.
02Use case
The reference plant makes enzymes and probiotic cultures in three 10 m³ production fermenters with seed vessels. It runs batch fermentations around the clock with media preparation and downstream recovery on two shifts.
| Heat user | Process temp. | Basis | Heat, kWh/day |
|---|---|---|---|
| Production fermenter warm-up | 25 → 37 °C | 2 batches × 10,000 L | 279 |
| Media and seed water | 25 → 40 °C | 10,000 L/day | 174 |
| Downstream wash and buffer water | 25 → 45 °C | 8,000 L/day | 186 |
| Storage and pipework standing losses | – | about 5% | 32 |
| Total useful heat | 671 | ||
Averaged over 20 running hours, the heat pumps need about 34 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
- 1 × SE-WW-55V (55 kW) (SE-WW water-source heat pump) delivering 55 °C, covering the day's 671 kWh in about 12.2 running hours.
- A 2,000 L insulated storage tank decouples the heat pumps from the process peaks.
- Heat source: fermenter cooling-water return at about 32 °C. Cooling the fermenter return water reduces chiller or cooling tower load during the exothermic growth phase.
- The electric immersion heaters stays connected behind a normally closed valve as standby.
- Fermenter cooling-water return at about 32 °C passes through the heat pump evaporator and goes back to the fermenters colder.
- The heat pump charges a warm-water tank at 50–55 °C that serves fermenter jackets, media preparation and downstream heaters.
- The tank evens out the mismatch between batch warm-up demand and the cooling heat available during growth.
Selected equipment
| Model | SE-WW-55V × 1 |
|---|---|
| Heating capacity | 55 kW each, 55 kW total |
| COP | 4.7 at the data sheet's rated condition (55 °C outlet) |
| Power input | about 11.6 kW total at rated conditions |
| Rating | hot and chilled water at the same time, to 60 °C |
| Supply temperature | 55 °C |
| Storage | 2,000 L insulated tank |
Ratings from the Sunniva TDS 2026 data sheets.
Control philosophy
TT-101 holds the warm-water tank between 50 and 55 °C, with the heat pump enabled while cooling-water return is above 28 °C. TIC-201 controls each fermenter jacket in split range between warm and cooling water. Electric heaters stay as standby when the source runs short.
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 | – | – |
| Cost per fermentation batch | – | – |
| CO₂ per year | – | – |
06Benefits
Cooling and heating together
One machine cools the fermenters and heats the media.
Steady culture temperature
Modulating warm-water control holds the broth within tight limits without overshoot.
Much lower power
The heat pump delivers several units of heat per unit of power at this small temperature lift.
Lower energy cost
Each kWh of electricity delivers about 4.7 kWh of heat at the required temperature, against well under one kWh of useful heat per kWh of fuel burnt.
Smaller electrical load
The heat pump draws roughly 1/4.7 of the power of the heaters it replaces, which frees sanctioned load and cuts demand charges.
Solar-ready
Running hours can be placed in daylight so rooftop solar supplies much of the electricity, which also cuts CO₂ further.
07Engineering pointers
Site data to collect
- Fermenter volumes and batches per day
- Culture temperature set-points
- Cooling-water flow and temperatures during growth
- Media and buffer water volumes
- Present electric heater ratings
- 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
- Sterility. Keep warm water in jackets and coils only. Media and broth are heated through closed surfaces.
- Source timing. Cooling heat peaks mid-fermentation and warm-up demand peaks at batch start. Stagger batches and size the tank to bridge the gap.
- Sterilisation stays on steam. Media and fermenter sterilisation need steam above the heat pump range. This note covers temperature control only.
- Electrical. About 12 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.
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.