integration of solar process heat systems - hogrefe...

Joint Saudi-German CSP Workshop

Integration of Solar Process Heat Systems

19th - 20th November 2013

§  systems are smaller compared to utility scale CSP collectors e.g. Eurotrough

§  Modular collectors, scalable layout §  construction of plants without on-site

preassembly, turn-key §  ground – or roof installation possible §  typical temperature range from 70°C to

320°C up to today §  proven systems to deliver hot water,

steam or saturated steam §  capable to be integrated into existing

conventional boiler systems §  integration of thermal storages allow

24/7 operation

2 Integration of Solar Process Heat Systems Martin Scheuerer 20.11.2013

Solar process heat collectors

Characteristics of concentrating solar process heat systems:


Solar process heat collectors

Examples of parabolic trough and fresnel collectors for process heat

PT-1: 6m x 2.3m

LF-11: 7.5m x 4m

PTC1800: 5m x 1.8m

Solar PolyTrough1200 CF100: 12m x 3m

EST 6000: 8.3m x 6m


Industrial applications for process heat

Food and beverage industry Drying, cleaning, cooking, baking, pasteurization

Wineries and distilleries Steam juicing, sterilization of wine making + bottling

Textile and leather industry Dying, shaping, ironing, tanning

Hotel and tourism Laundry, heating, cooling

Paper industry Bleaching, thermo mechanical pulping, drying

Pharmaceutical + chemical industry Process specific applications, distillation

Mining and oil industry Undeveloped oil recovery, cleaning, oil distillation

Plastics and rubber industry Heating, cooling, vulcanization

Water treatment Desalination and water purification projects

Slaughter houses Cooling and refrigeration of meat and meat products

Industry Applications and processes

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Realized solar process heat projects

Solar process heat for water desalination

I.  Port Augusta, Australia

§  Parabolic trough §  Heat storage tank §  MED (Multi Effect Desalination) 10m3/day

§  ORC Turbine

II.  Um Saied (Qafco), Qatar

§  Parabolic trough §  Heat storage tank §  MED (Multi Effect Desalination) 10m3/day §  Greenhouse heating


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Realized process heat projects

Solar process heat for cooling applications

§  Solar cooling project at a holiday resort in Turkey

§  Cooling provided with double effect absorption chiller


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Solar process heat plant with thermo oil

Frito Lay (PepsiCo) California, USA §  Heating of oil used for

cooking corn and potatoe chips

§  5.068 m² §  250°C, 41bar §  Indirect steam

generation §  Back-up by natural gas

fired steam generators


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Solar process heat plant with direct steam

§  Direct steam generation plant at aluminium anodising factory §  Saturated steam delivered by solar plant at 143°C and 4 bar


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Solar process heat plant with indirect steam generation

Switzerland, milk processing plant §  Indirect supply of heat to

4-6 bar steam network §  Thermal oil circuit,

180-200°C §  116m² collector surface §  Indirect steam

generation in tube-and-shell steam generator


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Solar Process Heat

Project Study I: Integration of CSP power plant for Desalination, Greenhouse, Sludge drying and Biomass

Fresh water

Waste water

Electricity

Heating

Cooling

Housing estate Greenhouse Chicken farm

Waste water treatment plant Sludge drying

CSP Biomass Solid Fuel Desalination Power plant

Solid fuel

Nutrients Fertilizer

Food

Local industry -  Oil/Steal -  Medical -  Food

Sea water


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Solar Process Heat

CSP Greenhouse project §  A typical decentralised

greenhouse needs fresh ground water, fossil fuels, nutrients and sunlight

§  In a CSP driven greenhouse system external fresh water is not longer required. The system requires only sea or salty ground water.


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Benefits of CSP driven greenhouses

§  Land use close to the coast and regions (arid zones) which you never can use for traditional greenhouse concepts

§  Highest food production, e.g. 60 [kg]/[sqm][year] §  Decentralized, high quality food production and reduction of transportation

and CO2 reduction §  Food production independent from seasons (365 days) §  Implemented MED desalination system can handle high salinity sea/

groundwater in comparison to Reverse Osmosis (RO) §  Own electricity production, absorption chiller cooled warehouse §  Independence from price trends and availability of water, fuel, and

electricity §  Local green jobs in every region


Solar Process Heat

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Engineering for a 200.000m2 greenhouse project / serial connection of components in a chain / 60.000m2 solar field CSP

Steam turbine

Desalination

Absoption chiller

Greenhouse heating

Heat storage

Electricity

Water

Cooling heating

Note: Erfis/Sunlis complex basic engineering (CSP, steam, Multi Effect Desalination, fresh water, cooling)


Solar Process Heat

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Solar Process Heat

Project Study II: Solar sludge drying concept study (decentral)

§  Volume reduction up to 40% §  Humidity reduction up to

90% §  Solid fuel production for

cement industry or coal power plants

§  Disinfection of sludge §  Nutrients production for

agriculture industry §  Significant fuel savings §  Neutralization of smell

Note: Sheme from Buss-SMS-Canzler


15 Präsentationstitel Referent Datum

Solar Process Heat

Project Study III: CSP for Enhanced Oil Recovery (EOR) EOR Process Characteristics §  High steam consumption

– injection into wells §  Low electricity §  High reliability of operations (24/7) §  Operational flexibility of plant

Typical plant §  Fossil fired boilers and gen-sets §  Desalination (MED) to generate feed-water

Economics §  Low Investment (CAPEX) §  High Fuel consumption (OPEX)

Boiler 1

Boiler 2 MED

Tank

Deaerator

steam supply oil wells for EOR

brackish water (from well) (feed)

brine (to disposal well)

diesel fuel

diesel fuel G

G

electricity to oil field

Engine

Engine

other

power plant own consumption

16 Präsentationstitel Referent Datum

Solar Process Heat

CSP can contribute 40%-80% solar steam to EOR at competitive rates §  Solar share can reach 40-50% (up to

80% with thermal storage)

§  On 25 year project life time, solar steam is at half of cost of diesel steam, still below LSFO steam

§  Payback period can be as low as 8 years

§  Solar steam also is competitive against LSFO, but with reduced advantage

§  Fuel price increase lifts benefit

⇒  CSP can provide a very attractive commercial option for EOR

Note: * Source: Suntrace internal study

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Solar Process Heat

Project Study IV: Oil Industry 10 MW Solar Crude Oil Pre-Heater

§  In an oil exploration camp in Yemen, 400 oil quells are powered with diesel generators with a total capacity of 250 MW!

§  The diesel is produced in an on-site distillation facility.

§  The required heat energy to process the crude oil into diesel, is powered with diesel


§  By installing a solar crude oil pre-heater the current diesel consumption in the topping plant will be reduced by 34%

§  Leading to a reduction in fuel consumption of 3.2 Million litre per year §  Return on investment 3-4 years [based on a diesel price of 1$/litre]

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Solar Process Heat


Project Study V: Process Steam Supply of a Bakery in Jeddah §  2.5 MW solar boiler to supply process

steam directly in the production process of the bakery

§  The producing requires 4 tones of steam per hour that is currently produced by 3 oil boilers

§  Installing a solar steam boiler will reduce the fuel consumption of light fuel oil (LFO) of 630.000 litre p.a.

§  Return on investment 3 years based on a diesel price of 1 $/litre

§  Current fuel price: 0,07 $/litre

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Challenges in system integration

The solar process heat technology is developed and proven, what are the hurdles to integrate the systems in Saudi Arabia?

System Integration

Project preparation: Project Execution:

Successful system integration by joining competences of Saudi and German partners

-  Knowledge of the local conditions?

-  Solar resources? -  Investment incentives? -  Permissioning? -  Available land?

CSP- Technology

-  Engineering? -  Application? -  Manufacturing? -  Operation? -  PPA? -  Feed-In tariff?


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Solar Process Heat

Why is this topic important for Saudi-Arabia?

§  Preserving oil resources: “sell it, don’t burn it” §  Local content

§  Creation of job §  Local production of components §  Operation & maintenance §  Capacity building

§  Decentralization §  Off-grid solutions (IPP- Independent Power Production) §  Hybrid project design creates flexibility (heating/cooling/electricity)

§  Energy strategy §  Contributing to KSA’s energy targets installing 24GW of CSP till 2032 §  Establishing a Saudi Solar industry by initiating commercial project


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Solar Process Heat

§  What are the specific topics to be addressed?

§  Localisation of potential applications §  Industrial matrix §  Process temperatures §  Project development

§  Pre-feasibility studies §  Evaluation of requirements §  New system or re-fit §  Application – or branch specific system

§  Re-cooling temperatures for solar cooling §  District cooling (system design) §  Acknowledge generation by pilot plants §  Utilisation of local resources (construction, engineering and production) §  Creation of incentive mechanism for the industry


Summary and key take-aways

Key Statements §  CSP = proven technology for process heat §  Solar process heat for local industry (decentralization) §  Substitution of oil is more economical – industrial leadership

Our Proposal §  Project studies for certain applications §  Pilot projects with full system integration §  Technology transfer/capacity building

Opportunities and Benefits for Saudi partners §  Local content §  Developing a Solar Process Heat Industry §  Preserving oil resources for export

Why choosing German Partners §  Global leadership in Concentrated Solar Power (CSP) §  Engineering “Made in Germany” §  Long term commitment in KSA

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