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Process heat (< 200 degree )
India’s industrial sector consumes large amounts of heat—estimates suggest 40–60% of industrial heat requirements are below 200°C. Traditionally, this heat has been generated by burning fossil fuels (coal, natural gas, fuel oil, etc.) in boilers or furnaces. The resulting steam or hot fluid is then used in applications like distillation, drying, sterilization, cooking, and reactor heating.
With increasing sustainability targets and the rising importance of controlling energy costs, Indian industry needs to turn to electrification to reduce carbon footprints, improve process efficiency, and sometimes tap into cheaper or more stable electricity (particularly if renewable sources are available
Electric heating vs Coal
Below is an updated comparison table for a distillation column heat supply scenario (20 kW of heat output for 1 hour, i.e. 20 kWh or 7.2×107 Joules
- Coal-fired heating (30% efficiency)
- Electric resistive heating (90% efficiency)
- Electric heat pump (effective COP≈3\text{COP} \approx 3, or ~300% “efficiency”)
I have added a final column (highlighted in green) showing approximate cost for the input energy per hour as requested: Coal = INR 60, Electric Resistive = INR 100, Electric Heat Pump = INR 35.
| Heating Method | Input Energy Needed per Hour (kWh, J) | Heat Output per Hour (kWh, J) | Overall Efficiency / COP | Notes | Cost for Input Energy per Hour (INR) |
|---|---|---|---|---|---|
| Coal (30% efficient) | - 66.7 kWh (coal energy)- ~2.40×108 J2.40 \times 10^8\,\text{J} | - 20 kWh- ~7.2×107 J7.2 \times 10^7\,\text{J} | ~30% | Requires solid fuel handling, high CO₂ emissions | 60 |
| Electric Resistive (90%) | - 22.2 kWh (electrical)- ~8.0×107 J8.0 \times 10^7\,\text{J} | - 20 kWh- ~7.2×107 J7.2 \times 10^7\,\text{J} | ~90% | Simple equipment, easier to control, depends on electricity source | 100 |
| Electric Heat Pump (COP ~ 3) | - 6.7 kWh (electrical)- ~2.4×107 J2.4 \times 10^7\,\text{J} | - 20 kWh- ~7.2×107 J7.2 \times 10^7\,\text{J} | ~300% | Most efficient; moves heat from environment, higher installation cost | 35 |
Key Points
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Input Energy vs. Output Heat
- At 30% efficiency, burning coal requires roughly 66.7 kWh of coal to deliver 20 kWh of heat.
- With 90% efficiency, electric resistive heating needs 22.2 kWh of electricity for the same heat output.
- A heat pump with a COP of ~3 only needs about 6.7 kWh of electricity for 20 kWh of delivered heat.
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Costs
- Based on the provided (approximate) cost figures, coal costs INR 60, resistive electric costs INR 100, and heat pump operation costs INR 35 per hour for these energy inputs.
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Overall Efficiency
- The heat pump is most efficient in terms of energy consumption.
- Coal has the lowest efficiency and highest greenhouse gas emissions.
- Electric resistance is simpler than a heat pump but less efficient than moving heat via a heat pump.
Electric heat pumps 20-30kW
High-temperature heat pumps are currently only available for large-scale systems, and the few small-scale systems available are not suited for industrial applications.
There is a need for smaller, industrial-grade solutions that can be used in energy-intensive processes like electroplating.
By electroplating, small manufacturers can create more durable, long lasting goods that protect metal parts from corrosion often caused by heat and/or humidity, a common challenge in the Global South.
Thouth international development solutions we build on your energy and economic growth capabilities.
India’s market is a strong incubator for prototypes with diverse manufacturing base and healthy financing opportunities for proven technologies that can support users in India and across the South Asia region.
Commercial and industrial consumers will start using small-scale (20 kW - 30 kW) high-temperature heat pump capable of reaching 90°C (194 °F) for applications like electroplating and surface treatment.
These heat pumps will be cheaper than fossil fuel based heating and Path To Green Homes can support you develop prototype / pilots to demonstrate the efficiency of these heat pumps in India.
The solution will be either air-sourced or water-sourced, providing the flexibility to operate in different conditions and a clean alternative to traditional processes.
A monitoring infrastructure will track the heat pump’s performance, energy consumption, and efficiency.
Next Step : Pilots/protypes
We can support you in pilots for heat pumps for your industrial application
1. Prototype of a small-scale high-temperature heat pump with us
2. Data on energy savings and performance in real industrial settings.
3. Determine if there is a solution that can be scaled to small industries across multiple sectors with further testing.