MVR4DRY - Integrated MVR heat pump system for drying plasterboard

Brief summary of the project

Drying is among the most energy-intensive industrial processes with 13–35TWh annually in Sweden. One standard gypsum board (3m² area) requires 24kWh energy, with 67% (16kWh/m²) used for drying. This energy could heat a Swedish home for 6–9 hrs in winter. The MVR4DRY solution aims to recycle 50% of drying energy and proves its efficiency through commercial validation. It utilizes water/steam as an eco-friendly refrigerant and integrates an additional n-pentane heat pump to boost heat recovery efficiency. With an IP protected technology, the solution offers a MVR HP as an sustainable alternative by replacing the conventional gas-fired boilers, cutting 16000 tons of CO₂ emissions annually. This transition saves SEK 1,450 per ton under Sweden’s 2024 Carbon Tax and contributes 0.45% toward Sweden's 2030 emission reduction targets. By adopting this solution, Sweden will strengthen its position as a leader in sustainability, advancing its goal of net-zero emissions by 2045.

MVR HP details and specifications

The MVR HP system has a capacity of 10.5 MWth, comprising seven advanced steam compressors and delivering seven temperature levels with a maximum of 210 °C with a lift of 160 °C. Typical industrial MVR HP systems offer temperature ranges from 140 °C to 180 °C with a boost of 40–100 °C, as noted in the case studies published by the IEA Annex 58 project “High-temperature HP”. Achieving 210 °C places this solution among the high-performance models, suitable for energy-intensive drying processes. Based on the results of Annex 58, it was found that the manufacturing of a 1.0 MWth MVR HP could cost between 0.8 and 1.0 million euros, excluding installation, commissioning and grid connection costs. This corresponds to 50% to 60% of the total project cost, excluding the costs of the dryer and other equipment. The MVR HP system will achieve a total coefficient of performance (COP) of at least 2.0, outperforming fossil fuel boilers (efficiency: 0.95–0.97) and electric boilers (efficiency: 0.99–1), and reduce specific energy consumption.

Project objectives

• Design, optimize, and deliver a fully integrated MVR HP system for installation, verification, and testing at the industrial site in Åhus.
• Advance the MVR4DRY system from TRL6 to TRL8. This progression ensures the system is ready for full-scale deployment and commercial use.
• Implement a real-time monitoring system to track key performance indicators, such as 50% energy savings and carbon footprint reduction.
• Use environmentally friendly fluids (water and n-pentane) and promote non-PFAS working fluids.
• Disseminate the result internationally among a wide range of industries, stakeholders, researchers, professionals, and heat pump manufacturers.
• Collaborate with industry associations such as the Swedish Industry Council (Industrirådet) among others, and Swedish HP partners to showcase how the MVR HP systems address key challenges, including rising energy costs and sustainability mandates, both locally and internationally.