Improving energy efficiency of industrial heating systems through the use of heat pumps

Maksym Tkachenko
Received 22.05.2025, Revised 30.10.2025, Accepted 24.12.2025, Published 28.12.2025
Abstract

The study aimed to justify a computational approach to improving the energy efficiency of industrial heat supply systems through the integration of heat pumps into circuits utilising low-grade and waste heat. As a result, a calculation framework was developed that integrates the waste heat source, heat exchanger, heat pump, industrial consumer and backup source into an energy balance based on indicators of heat load, electricity consumption, residual load, substitution rate and reduction in energy consumption. A systematic analysis of waste heat sources showed that flows with a regular supply and the technical capability for heat exchange have the highest calculated suitability for heat pump integration, in particular return water, cooling circuits, refrigeration machines and compressor units. Scenario modelling, assuming a constant useful heat load of 1,000 MWh, showed an increase in heat pump coverage from 250 MWh in the second scenario to 700 MWh in the fifth scenario, corresponding to an increase in the substitution rate from 0.25 to 0.7. Total energy consumption decreased from 1,000 MWh in the baseline scenario to 809.5 MWh in the second scenario, 705.3 MWh in the third scenario, 646.4 MWh in the fourth scenario and 500 MWh in the fifth scenario. The relative reduction in energy consumption increased from 19% in the preheating scenario to 50% in the combined system featuring a heat pump, a backup source and thermal storage. The study determined that an increase in thermal energy from the heat pump does not provide a proportional effect without incorporating the temperature head: in the fourth scenario, with a coefficient of performance of 2.8, electricity consumption amounted to 196.4 MWh, whereas in the fifth scenario, with a coefficient of performance of 3.5, a residual load of 300 MWh and a substitution ratio of 0.7, the lowest total energy consumption of the modernised system was obtained. The practical significance of the study is determined using the calculation framework for the preliminary engineering assessment of industrial heat pump systems

Keywords:
temperature head; backup source; coefficient of performance; cooling circuits; compressor units; refrigeration units

Retrieved from Volume 23, No. 2, 2025

Pages 144–161

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Tkachenko, M. (2025). Improving energy efficiency of industrial heating systems through the use of heat pumps. Journal of Kryvyi Rih National University, 23(2), 144-161. https://doi.org/10.31721/2306-5451-2025-2-23-144-161
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