German 1.2 MW heat pump turns waste heat to steam

October 31, 2026

German researchers have demonstrated a 1.2-megawatt (MW) industrial heat pump capable of transforming waste heat from paper manufacturing into steam at temperatures reaching 120°C (248°F). The technology could help energy-intensive industries reduce natural gas consumption, lower operating emissions, and improve energy efficiency.

Developed through a research collaboration involving the Fraunhofer Institution for Energy Infrastructures and Geotechnologies (Fraunhofer IEG), the high-temperature heat pump was tested at a paper manufacturing facility operated by Felix Schoeller GmbH & Co. KG in Weißenborn, Germany.

The demonstration forms part of the EU-funded PUSH2HEAT project, which focuses on recovering industrial waste heat and converting it into valuable energy for manufacturing processes.

According to the researchers, the system could prevent up to 600 metric tons of carbon dioxide emissions annually, offering manufacturers a potential alternative to conventional fossil fuel-based steam generation.

How the high-temperature heat pump converts waste heat into steam

Industrial steam plays an essential role in manufacturing, particularly in industries such as paper production, chemicals, food processing, and pharmaceuticals. However, generating steam at temperatures above 100°C typically requires significant energy, often supplied by natural gas boilers.

The new heat pump offers a different approach by recovering thermal energy that would otherwise be released into the environment.

Using a two-stage heating process, the system extracts waste heat from paper manufacturing operations at temperatures between 30°C and 70°C (86°F–158°F).

It then increases the temperature to approximately 120°C, producing steam suitable for industrial applications.

Unlike traditional boilers that generate heat through fuel combustion, the heat pump uses electricity to upgrade existing thermal energy. This allows manufacturers to recover valuable heat while reducing their dependence on fossil fuels.

The technology also provides an opportunity to improve overall industrial energy efficiency by integrating waste heat recovery directly into existing production infrastructure.

Industrial heat pump achieves promising efficiency results

Initial operational data from the Weißenborn demonstration facility indicate that the technology can deliver substantial thermal output under real manufacturing conditions.

During approximately 300 operating hours in 2026, the installation recorded several important performance results:

• Installed heat pump capacity: 1.2 MW

• Average steam output: Approximately 700 kW

• Steam production: Around 1.2 metric tons per hour

• Operating steam pressure: Approximately 2.3 bar

• Steam temperature: Around 120°C

• Coefficient of performance (COP): 2.30

A COP of 2.30 indicates that the heat pump supplies approximately 2.3 units of useful thermal energy for every unit of electricity consumed.

This performance demonstrates the potential of high-temperature heat pumps to recover industrial waste heat more efficiently than systems that rely exclusively on direct electric heating.

The researchers estimate that operating the installation for 4,000–5,000 hours annually could avoid up to 600 metric tons of CO2 emissions compared with conventional natural gas steam production.

That represents an estimated reduction of approximately 100 kilograms of CO2 per megawatt-hour of delivered heat.

Actual environmental benefits will depend on operating conditions, the electricity supply, and the fossil fuel system being replaced.

Reducing natural gas dependence in energy-intensive industries

Industrial heat generation remains a major challenge for decarbonization because many manufacturing facilities depend on fossil fuels to provide continuous high-temperature energy.

Paper mills, for example, require large quantities of steam for drying and other production processes. Much of the thermal energy used during manufacturing can be lost through exhaust streams, cooling systems, and other equipment.

Recovering this energy creates opportunities to reduce fuel consumption without completely redesigning industrial production lines.

The Fraunhofer demonstration illustrates how industrial waste heat recovery and electrification can work together to support cleaner manufacturing.

Beyond reducing greenhouse gas emissions, the technology could help companies diversify their energy supplies and reduce exposure to fluctuations in natural gas prices.

Project manager Reuven Paitazoglou highlighted the importance of developing industrial solutions that support climate goals while maintaining energy security and economic competitiveness.

High-temperature heat pumps could contribute to these objectives by transforming previously unused thermal energy into a reliable resource for manufacturing.

Potential applications beyond the paper industry

Although the demonstration was conducted at a paper mill, the technology could eventually support decarbonization across several industrial sectors.

The PUSH2HEAT initiative is investigating opportunities to recover and reuse waste heat, particularly in paper manufacturing and chemical processing.

Other potential applications include pharmaceutical production and food manufacturing, where steam and process heat are essential for daily operations.

Fraunhofer IEG led the scientific coordination of the demonstration and developed a monitoring system to evaluate technical performance.

Researchers also investigated how the heat pump could be connected to existing steam distribution networks and integrated into established manufacturing processes.

Successful integration is particularly important because industrial facilities often operate complex thermal systems that must maintain stable temperatures and pressures.

The Weißenborn project therefore provides practical information about the technical requirements and operational challenges involved in adopting large-scale heat pump technology.

One-year testing program to assess long-term performance

Following the initial demonstration, full-load testing began in September 2026.

The research team intends to monitor the heat pump for approximately one year under actual industrial operating conditions.

The extended evaluation will help determine its long-term reliability, energy performance, and suitability for continuous manufacturing operations.

Researchers are also expected to identify opportunities for technical improvements before the PUSH2HEAT project concludes in 2027.

The findings could provide valuable guidance for industrial companies considering investments in high-temperature heat pumps and waste heat recovery systems.

High-temperature heat pumps could accelerate industrial decarbonization

The German demonstration highlights the growing potential of large-scale industrial heat pumps as a practical technology for reducing fossil fuel use in manufacturing.

By converting low-temperature waste heat into usable steam, the 1.2 MW system demonstrates how factories could improve energy efficiency while lowering carbon emissions.

Although further testing is necessary to establish long-term performance and commercial viability, the project represents an important development in industrial heat electrification.

If successfully deployed across additional manufacturing sectors, similar systems could contribute to lower industrial emissions, reduced natural gas consumption, and more efficient use of existing energy resources.