The metalworking company Nesper GmbH in Ispringen has opted for a sustainable and climate-friendly system solution from Dimplex as part of the modernisation of its heating system. The aim was to completely replace the existing oil-fired central heating system (three large boilers) and, in line with the company’s own sustainability strategy, convert the system to an energy-efficient, renewable heating supply.

The challenge: a complex industrial site comprising production halls, office and residential buildings stretching along an entire street – with a heated area of around 4,500 m², a calculated heating load of 205 kW and a process cooling capacity of 70 kW.

“Our aim is to become independent of fossil fuels for heating and to achieve a significant reduction in annual CO2 emissions.”

nesper.com

Project facts

  • Completion in 2025: Expansion planned
  • Heat supply during refurbishment
  • Sustainability through the use of production waste heat
  • Heating and cooling solution for an industrial site
  • Project: Renewable heating system for a complex industrial site comprising several buildings (production halls, office and residential buildings, etc. along an entire street), existing structures and new builds
  • New heating technology: 1x SI 75TU brine/water heat pump, 2000-litre buffer tank; planned expansion to include 1x SI 130TU brine/water heat pump
  • Special features: Waste heat from process cooling is used for heating and hot water production

Efficient all-in-one solution with brine/water heat pumps from Dimplex


To achieve the ambitious efficiency and sustainability targets, a comprehensive all-in-one solution was implemented, consisting of:

  • Installation of an SI 75TU brine/water heat pump, with a subsequent upgrade to an SI 130TU
  • Utilisation of waste heat from process cooling for building heating and domestic hot water production
  • 17 geothermal boreholes, each 95 m deep
  • Plug-and-play hydraulic modules for rapid installation
  • Integration of custom-developed project software via Siemens SIMATIC S7
  • Planning for fully monovalent-regenerative operation (Expansion under construction)

The system will initially operate in bivalent mode, with the already installed brine/water heat pump replacing one of the three oil boilers; as part of the planned expansion, the two remaining oil boilers will also be replaced by a further brine/water heat pump, so that the entire heating system is subsequently converted entirely to a monovalent-renewable solution. In addition, Dimplex supplied a complete all-in-one solution comprising engineering, a heat pump, plug-and-play hydraulics and a customised control system based on specially developed project software via Siemens SIMATIC S7.

Advantages of the Dimplex solution

  • Significant CO₂ reduction through the use of existing process waste heat
  • Highly efficient heat supply thanks to brine/water technology
  • Scalable system – ideal for industrial applications and complex building structures
  • Future-proof thanks to modular expansion and a flexible control platform
  • All-in-one solution from a single source: engineering, heat pump technology, hydraulics and control systems

Technical specifications of the Dimplex SI 75TU (excerpt)

  • Max. flow temperature: 62 °C
  • Operating range for heat source (heating mode): –5 to +25 °C
  • Energy efficiency class: A+++ / A++
  • Heating capacity B0/W35: 37.9 kW, COP: 5.0
  • Max. heating capacity A–2/W35: 73.5 kW, COP: 4.8
  • Sound power level: 46 dB(A)

Result: A sustainable flagship project for industrial energy efficiency

 

With its new heat pump solution, Nesper demonstrates how industrial waste heat can be put to good use to efficiently heat an entire industrial plant. The Dimplex system solution combines renewable energy generation, innovative control technology and high cost-effectiveness – and serves as a blueprint for numerous similar industrial applications.

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