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Solar Heat for Industrial Processes

Interaction Session on Roof Top Solar for Textile Industry, Coimbatore

Abhinav Goyal, ComSolar-IGEN

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Outline

About GIZ

Introduction: GIZ/ComSolar Project

Solar heat potential in textile sector

Scientific monitoring under SoPro India project

Key messages

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About GIZ

Owned by the Federal Republic of Germany

Operations in Germany and in over 130 countries around the

world

Around 17,000 employees

Operates in India since 60 years, currently 250 staff members in

India

GIZ is working in areas where demand in India’s emerging

economy is high and in which Germany is particularly strong

Energy

Environment

Sustainable economic development

Implemented by

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Commercialisation of solar energy in urban and

industrial areas (www.comsolar.in)

Project Duration 2009 - 2016

Commissioning

Ministry

Federal Ministry for the Environment, Nature Conservation,

Building and Nuclear Safety (BMUB) - International Climate

Initiative

Partner Ministry Ministry of New and Renewable Energy (MNRE),

Government of India

Focus sectors Rooftop PV & Solar Thermal in industrial process heat

Project team

(GIZ) Six employed National & International experts

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ComSolar: multi-pronged strategy

DEMO PROJECTS

› Rooftop PV

› CSP Dish power plant with storage

› Solar Air heating

POLICY ADVISORY

› National bodies

› Selected States

› Studies

CAPACITY BUILDING

› Trainings and workshops

› Web based tools (www.SolarGuidelines.in)

› Sector campaigns (www.soproindia.in)

Multi-

Pro

nged

Appro

ach

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»Solar heat potential in textile sector

» Key findings from GIZ sector study

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Solar Thermal Process Heat

14/10/2015

Potential in industries

It is estimated that 15 million tonnes of furnace oil is used in

industrial thermal application below 2500C ~ 10% of total

commercial energy consumed in industries (2011 level)

Technology

Concentrating and Non-concentrating (FPC/ETC)

Solar thermal energy integration

Into the heat distribution network – Pre-heating of boiler feed water

Directly into the process – washing, cleaning

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Source: Aspiration energy

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Identification of Industrial Sectors Promising for the

Commercialisation of Solar Energy

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Objective:

Identify suitable industrial sectors promising for

the Commercialisation of solar energy

Criteria for selection:

1. Energy Consumption in the Sector

2. Heating/Cooling load requirement

3. Power Generation/ DG Sets/ Captive Plants

4. ….

Textile one of the top 5 sectors identified

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Can be downloaded from MNRE website

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Textile Sector ~ 10% energy substitution by solar thermal

14/10/2015

33%

7% 4%

56%

Energy consumption (finishing) (4,460 ktoe)

Coal

Electricity

Petroleum products

Other fuels

16%

43% 17%

24%

Cost-wise distribution (finishing)

Coal

Electricity

Petroleum products

Other fuels

16%

4%

19%

13% 16%

27%

5%

Textile (402 ktoe/ annum)

Desizing

Mercering

Finishing

Scouring

Bleaching

Dyeing

Sizing (spinning &weaving)

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»About SoPro India project

» www.soproindia.in

» Scientific Monitoring of Solar water heating

system

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Solar process heat (SoPro) India

Motivation: promote and deploy SWHS

systems

Partners: GIZ, Fraunhofer ISE, APITCO

With support from: Solar manufacturer,

STFI, MNRE

Duration: Oct 2013 – Dec 2015

Technology: Non-concentrating solar heat

technology for low and medium temp.

ranges (ETC/FPC)

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Objectives: SoPro India

Marketing platform to showcase best practices, case studies, address

performance and quality related issues: http://soproindia.in

Monitor existing installations, disseminate know-how about actual performance

of existing SHIP systems in partnership with the industry

Developing a concept of robust and low cost monitoring concept for SHIP in

collaboration with Fraunhofer ISE

Develop recommendations for MNRE and the industry to promote quality in solar

thermal systems for industries

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Monitoring system at Synthokem Labs, Hyderabad

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Monitoring results at Synthokem Labs, Hyderabad

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Monitoring results at Synthokem Labs, Hyderabad

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Key performance and economic numbers – Synthokem labs

14/10/2015

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Parameter Value

Capacity of the system (LPD/kWth) 10,000LPD/ 87 kWth

Technology and Collector area ETC and 124 sq. meters aperture

Heat demand 1.5 tonnes/hr of steam at 1100C and 6-7

bar for full year Usage Steam Boiler feed water pre-heating

Max. temperature range from solar

collectors on sunny days (0C) ~ 57-65 0C

Investment cost (INR) INR 8.65 Lakhs / INR 7,000 per sq. meters

Year of installation March 2009

Solar thermal energy produced per sunny day in collector loop (kWh thermal)

87 kWh/day

Solar system efficiency (%) ~ 25%

Actual fossil fuel saved through solar

thermal - Fuel oil/day 800 litre/3 winter months

Total savings on Furnace oil (INR) ~ INR 45,000/ 3 winter months

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Case Study Chelsea Textile Mills- Gurgaon

14/10/2015

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Parameter Value

Capacity of the system (LPD/kWth) 50,000 LPD/660kWth

Technology and Collector area FPC and 410 collectors of 2.3 sq. meters

aperture

Heat demand hot water in the temperature range of

55OC to 80OC for washing of apparels in

multiple washing machines.

Usage Steam Boiler feed water pre-heating

Max. temperature range from solar

collectors on sunny days (0C)

~ 57-65 0C

Investment cost (INR) INR 46 Lakhs / INR 5,000 per sq. meters

Solar energy gains ~1600 kWh/day

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»Key messages

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Key messages

14/10/2015

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Solar thermal systems installed across India in many industries

Scientific monitoring proves the solar gains and fuel saved

through Solar thermal systems

10 per cent of heating requirements can be met by solar

thermal systems in textile industries depending on the

processes involved

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As a federal enterprise, GIZ supports the German Government in achieving its objectives in the field of international cooperation for sustainable development.

Published by Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH

Registered offices, Bonn and Eschborn, Germany

Commercialisation of Solar Energy in Urban and Industrial areas (ComSolar)

Indo German Energy Programme

B 5/2, 1st Floor, Safdarjung Enclave, New Delhi 110 029

T +91 11 4949 5353 F +91 11 4603 6690

E Abhinav.goyal@giz.de I www.giz.de, www.comsolar.in

Responsible

Timon Herzog

Author(s)

_____________

Photo credits

© GIZ/ ComSolar

In cooperation with:

Commissioned by: