Giant heat pump turns paper mill waste heat into 248°F steam with less fossil fuel

Key TakeawaysThe 1.2 MW heat pump can convert waste heat from paper production into industrial steam at 248 degrees Fahrenheit.The system could cut CO2 emissions by up to 600 tons annually and reduce the reliance on natural gas.The technology could also be used in the chemical, food, and pharmaceutical industries. Engineers have just unveiled a powerful 1.2-megawatt (MW) heat pump that can convert waste heat from paper production into industrial steam at temperatures of around 248 degrees Fahrenheit (120 degrees Celsius). The heat pump was made by a research team involving the Fraunhofer Institution for Energy Infrastructures and Geotechnologies (IEG) in Germany. It was tested at a paper mill run by Felix Schoeller GmbH & Co. KG in Weißenborn, Hesse. The trial was conducted under the EU-funded PUSH2HEAT project. The system uses otherwise wasted heat to produce steam for industrial processes. According to the institute, it could reduce carbon dioxide (CO2) emissions by up to 600 tons annually. This means it could also lower natural gas reliance. “Industrial companies need solutions that combine climate protection, energy supply security, and competitiveness,” Reuven Paitazoglou, the project’s manager, said. “High-temperature heat pumps make it possible to economically harness previously unused energy sources for production.” From waste heat to steam Industrial processes operate steam systems well above atmospheric pressure at temperatures exceeding 212 degrees Fahrenheit (100 degrees Celsius). In most cases, producing this steam involves burning fossil fuels, especially natural gas. On the other hand, fossil fuel combustion releases CO2 and other greenhouse gases that drive climate change and air pollution. To address this challenge, the team developed a two-stage heat pump capable of upgrading low-temperature waste heat into usable industrial steam. The system captures excess heat from paper production at temperatures ranging from 86 to 158 degrees Fahrenheit (30 to 70 degrees Celsius). It then raises the temperature to approximately 248 degrees Fahrenheit. During its first approximately 300 operating hours in 2026, the pump achieved an average steam output of around 700 kilowatts (kW). It also produced roughly 1.2 tons of steam per hour at a pressure of around 2.3 bar. The researchers reported a performance factor of 2.30. In simple terms the system delivered more than twice as much useful heat as the electrical energy required to operate it. The installation could prevent up to 600 tons of CO2 emissions a year if operated for 4,000 to 5,000 hours. That could cut CO2 emissions by around 220 lbs (100 kilograms) per megawatt-hour (MWh) of heat compared to natural gas steam production. Wider industrial potential The demo was part of the EU-funded PUSH2HEAT project, which explores ways to reuse industrial waste heat. Although it primarily focuses on paper and chemical production, the technology could also find applications in the pharmaceutical and food industries. Fraunhofer IEG coordinated the scientific aspects of the tests and came up with a monitoring system to assess its performance. The team examined how the pump could be integrated into existing production processes and steam networks. Paitazoglou emphasized the importance of expanding the technology’s use. “The demonstration plant in Weißenborn lays important groundwork for the future use of this technology in other industrial applications,” he disclosed in a press release. Full-load tests began in September 2026. The team plans to evaluate the system under real industrial conditions for one year. Further improvements are expected before the project ends in 2027. Get the latest in engineering, tech, space & science - delivered daily to your inbox.Based in Skopje, North Macedonia. Her work has appeared in Daily Mail, Mirror, Daily Star, Yahoo, NationalWorld, Newsweek, Press Gazette and others. She covers stories on batteries, wind energy, sustainable shipping and new discoveries. When she's not chasing the next big science story, she's traveling, exploring new cultures, or enjoying good food with even better wine.