Integrating Heat Pumps as part of your Sustainable Energy Strategy

The transition to sustainable energy represents one of the most significant challenges facing industrial and commercial businesses today. While heat pumps offer an impressive solution for reducing carbon emissions in heating and cooling, typically they cannot address all high-temperature requirements – there may be spikes in demand, or seasonal differences which need to be considered. A decarbonisation strategy works best when heat pumps are brought in alongside other technologies, despite those alternatives being less efficient. This combined approach improves overall system capability and helps reach carbon reduction goals faster.

Beyond Standalone Solutions

Heat pumps are becoming more and more popular, not least because they are so much more efficient than ‘old-fashioned’ heating mechanisms such as boilers. However, treating them as standalone units rather than as part of a complete energy system is shortsighted. Our experience working with manufacturing clients has demonstrated that the most successful implementations take the following factors into consideration:

• How to integrate heat pumps with existing infrastructure
• Opportunities for heat recovery and redistribution, as well as identifying suitable heat sources for water-source heat pumps
• Complementary renewable power sources, such as biofuels for any remaining boiler units, or buying Green Electricity Power Purchase Agreements (PPAs)
• Energy storage capabilities that enhance system flexibility

Water Source Heat Pump Considerations for Sustainable Operation

In order to install a water-to-water heat pump with its excellent COP (Coefficient of Performance), the heat source and its grade has to be a primary consideration.

Some sustainable approaches:

• Recovering waste heat from your factory operations to maximise efficiency and reduce the need for additional heat sources such as an air source heat pump
• Using heat from the surrounding air or from equipment that generates heat as a by-product of normal operations

The choice will be guided by your specific operational context. Local regulations such as the EU Water Framework Directive, the U.S. Clean Water Act, and regional groundwater policies may constrain your options. Additionally, local water availability will significantly impact which solution is most sustainable and cost-effective for your facility. A site-specific assessment is recommended to determine the optimal system configuration.

Phased Implementation for Manageable Decarbonisation

Sometimes aiming for 100% decarbonisation is going to hurt financially, both in terms of CapEx and OpEx – a huge initial investment and then higher operating costs every year. A holistic approach, where we look at ‘reverse engineering’ can result in a much more sensible strategy where there could even be financial savings. Assessing how much electricity a site has and how much it needs, we can work backwards from there. There may be spikes in energy usage, but perhaps they are only 8% of the overall year – so let’s look at the other 92% first!

While complete decarbonisation may still remain the ultimate goal, a step-by-step approach aiming for >80-90% reduction often makes more sense financially and practically. There are several benefits of following this approach:

• Avoids disproportionate costs associated with the final percentage points of carbon reduction
• Allows organisations to build internal expertise through progressive implementation
• Creates opportunities to incorporate emerging technologies as they mature
• Maintains focus on business continuity during the transition

Measurement and Verification for Optimal Performance

As with all energy systems, comprehensive monitoring and verification protocols are essential for heat pump integration. A few effective approaches include:

• Real-time performance monitoring to ensure optimal operation
• Continuous commissioning to maintain efficiency as seasonal conditions change
• Regular comparison of actual performance against projected savings
• Documentation of carbon reduction achievements for regulatory compliance and stakeholder reporting

These measurement best practices not only validate the effectiveness of heat pump systems, but also identify opportunities for on-going optimisation and improvement.

Emerging Integration Opportunities

The landscape of sustainable energy continues to evolve, with several promising developments on the horizon.

• Advanced heat pump technologies capable of generating higher temperatures for industrial processes
• Smart grid integration enabling demand-response participation while maintaining operational requirements
• Hydrogen integration opportunities as the technology becomes available
• Sector coupling approaches that optimise energy flows between electrical, thermal and transportation networks

Organisations that establish robust measurement and control capabilities today can position themselves to capitalise on these emerging opportunities as they mature.

Avoiding Greenwashing

Sometimes the best approaches are not all ‘bells and whistles’, but big changes being made in the background, deep inside the boiler houses and basements of manufacturing premises – not on show to the public.

We have been to a potential client’s main factory where there is a huge array of solar panels on the roof, very visible to passers-by. It looks like this company is being very ‘green’, very hot on their eco-credentials. The sad truth is that they aren’t even plugged in. They are doing nothing. This is the kind of showy stuff we want to avoid.

Of course, solar panels can be a great idea and can supplement and support other energy initiatives. An array of solar panels on a car port could allow you to provide EV charging stations – but unless you have acres and acres of land to devote to solar, you will not be able to generate enough power to have any significant impact on your regular consumption requirements – at least not in the manufacturing industry.

An Integrated Approach to Decarbonisation

Heat pumps represent a powerful tool in the decarbonisation toolkit, but their effectiveness ultimately depends on proper integration within a comprehensive energy strategy. By adopting a holistic approach that considers the interplay between generation, storage, distribution and consumption, organisations can maximise both environmental and economic benefits.

As manufacturing businesses continue their sustainability journeys, success will increasingly belong to those who view energy technologies not as isolated solutions, but as components of integrated systems designed to meet that business’s specific operational needs while advancing their ambitious carbon reduction goals.

Our team of experts can help you integrate heat pumps effectively, optimise their performance and align them with your sustainability goals. If you’re looking for guidance, reach out to our global team through our Contact Form or connect directly to our offices in Ireland, the UK, Spain or the USA.