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Solar Thermal Application in Industry and Commercial Buildings

Pedro Horta Fraunhofer Institute for Solar Energy Systems ISE 24.10.2017, Opportunities for Energy Efficiency in Namibia, Windhoek www.ise.fraunhofer.de

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Solar Process Heat Available technologies, potential and applications

Which technologies are available?

Solar thermal collector technologies

Technology vs. operation temperature

Market penetration

Where and how to use them?

Process heat potential

Suitable sectors and processes

Design questions

Potential for Namibia

Industrial sectors

Energy sources and costs

Solar resource

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Solar thermal technologies Technology vs. Temperature

Solar collector technology vs. required process temperature

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Potential for Namibia Industrial sector and energy sources

Most important Industrial sectors in Namibia [1]:

Food and Beverages T < 250°C (40,5% Manufacturing Composition - MC)

Basic metals (28% MC) T > 400°C

Chemicals and chemical products (7.3% MC) T > 80°C ( T > 250°C)

Textiles (4.9% MC) T < 250°C

Furniture manufacturing (4.8% MC) electricity

Direct impact on ~ 50% MC:

Additional applications in services: hospitals , schools, office buildings

Direct substitution of oil-based products (58% FEC)

safety of supply

[1] Manufacturing Composition (2013). UNIDO Statistics Unit. http://www.unido.org/statistics [2] IEA - International Energy Agency (2014). Statistics: Energy Balance Flows. http://www.iea.org/statistics

Industrial Final Energy Consumption by energy source in Namibia, 2015 [2]

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Solar Process Heat Available technologies, potential and applications

Which technologies are available?

Solar thermal collector technologies

Technology vs. operation temperature

Market penetration

Where and how to use them?

Process heat potential

Suitable sectors and processes

Design questions

Potential for Namibia

Industrial sectors

Energy sources and costs

Solar resource

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Solar thermal technologies Efficiency and temperature

The efficiency of a solar collector depends on incidence dependent optical losses and on operating temperature dependent thermal losses

h

T

LT / s tationary collectors : • Higher optical efficiency • Higher thermal losses

MT / tracking collectors : • Lower optical efficiency • Lower thermal losses

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Solar thermal technologies Stationary collectors: flat-plate

Stationary collectors present lower O&M requirements and system costs. Operation temperature limited to LT (T<150°C)

[3] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region [4] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).

Flat Plate collectors : • common temperature range of 30°C – 100°C • absorber tubes through which working fluid flows

covered by absorber sheet and a transparent cover. • absorber coating converts solar irradiation into heat

transferred to the working fluid in the tubes • usual working fluid is water/glycol mixture • little maintenance and relatively cheap

[3] GAMESA-QUAKER PEPSICO MEXICO Mexico © Modulo Solar

in [4]

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Solar thermal technologies Stationary collectors: evacuated tube

Stationary collectors present lower O&M requirements and system costs. Operation temperature limited to LT (T<150°C)

[3] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region [4] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).

Evacuated Tube collectors : • common temperature range of 50°C – 130°C • row of parallel vacuum glass tubes • absence of air highly reduces convection losses • 2 categories of ETC: • Direct flow principle • Heat pipes principle (as in figure)

[3] Harita Seatings Systems Limited India © @aspirationenergy

in [4]

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Solar thermal technologies Tracking collectors: parabolic trough

Tracking collectors are more demanding in terms of O&M and costs. Yet operation temperatures cover the whole range of MT (T<400°C)

[4] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016). [5] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information

Lesa Dairy Switzerland © ezw

in [4]

[5]

v

Parabolic Trough: • temperature range of 150°C – 400°C • Line-focusing system (one-axis tracking) • Reflector: curved glass mirror or aluminium

sheet • Usual HTF: Water/Steam or thermal oil

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Solar thermal technologies Tracking collectors: linear Fresnel

Tracking collectors are more demanding in terms of O&M and costs. Yet operation temperatures cover the whole range of MT (T<400°C)

[5] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information [6] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/

RAM Pharmaceuticals Jordan © Industrial Solar

[5]

Linear Fresnel: • temperature range of 150°C – 400°C • Line-focusing system (one-axis tracking) • approx. parabolic trough by segmented mirrors:

principle of Fresnel • Easier installation in flat rooftops (weight distrib.,

lower aerodyn. loads) • Reflector: curved glass mirror or aluminium sheet • Usual HTF: Water/Steam or thermal oil

in [5]

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Solar thermal technologies Tracking collectors: parabolic dish

Tracking collectors are more demanding in terms of O&M and costs. Yet operation temperatures cover the whole range of MT (T<400°C)

[5] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information

[5]

Parabolic Dish: • common temperature range of 250°C – >400°C • Point-focusing system (2-axis tracking) • Moving (modular) receiver • Potential for higher temperatures

Tirumala Tirupati Devasthanams India © Gadhia Solar Energy Systems

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Solar thermal technologies Technology vs. Temperature

Solar collector technology vs. required process temperature

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SHIP systems database [2]: 213 projects listed, 129 MWth installed capacity (0.18 million m2) < 1% installed solar thermal capacity

Existing projects Market penetration

[7] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016). Accessed February 2017 [8] SOLRICO, Bärbel Epp, 2017. Solar Process Heat: Surprisingly popular. Sun&Wind Energy. http://www.sunwindenergy.com/topic-of-the-month/solar-process-heat-surprisingly-popular (online 14.02.2017)

• Mostly small/medium size systems (<500 m2)

• Largest capacity in large systems (>1000 m2)

• Stationary technologies dominate in nr. systems and capacity

[7]

• Recent survey [6] points out > 500 SHIP systems with total installed capacity > 280 MWth (0.4 million m2)

[8]

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Stationary technologies

Existing projects Examples

[9] Arcon-Sunmark, 2015. http://arcon-sunmark.com/cases/codelco-minera-gaby-chile [10] http://ship-plants.info/solar-thermal-plants/140-jiangsu-printing-and-dyeing-china?collector_type=4&country=China

Textile Jiangsu Yitong, China Evacuated Tube Aperture: 9,000 m2 Application: process pre-heating Oper. Temp.: 50°C Commissioning : 2011

© Sunrain Co. Ltd [10]

Copper mine “Gabriela Mistral”, Chile Flat Plate Aperture: 43,920 m2 Application/End Use: Process water and electrolyte heating Oper. Temp.: 50°C Commissioning : 2015

© Arcon-Sunmark [9]

Currently largest plant in the world

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Tracking technologies

Existing projects Examples

[11] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/ [12] http://ship-plants.info/solar-thermal-plants/155-dairy-plant-el-indio-mexico?collector_type=5

Dairy El Indio, Mexico Parabolic Trough Aperture: 132 m2 Application: Make-up water pre-heating Oper. Temp.: 95°C Commissioning : 2012

© Inventive Power S.A. de C.V. [12]

RAM Pharmaceuticals , Jordan Linear Fresnel Aperture: 396 m2 Application/End Use: Process Steam Oper. Temp.: 160°C Commissioning : 2015

© Industrial Solar [11]

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Upcoming

Existing projects Examples

[13] MIT, 2016. Technology Review, Arab Edition. http://technologyreview.me/en/energy/oman-explores-solar-powered-oil-recovery/

Amal Solar EOR Pilot Project, Oman Parabolic Trough in greenhouse Thermal Power: 1 GWth Production (pilot): 6 ton steam / day

© Industrial Solar [13] © Petroleum Development Oman.

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Solar Process Heat Available technologies, potential and applications

Which technologies are available?

Solar thermal collector technologies

Technology vs. operation temperature

Market penetration

Where and how to use them?

Process heat potential

Suitable sectors and processes

Design questions

Potential for Namibia

Industrial sectors

Energy sources and costs

Solar resource

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Potential Heat for Industrial Processes

Thermally driven processes present the largest share of final energy use in Industry: Worldwide, 45% of heat is used in Industry [10]

[10] Energy Technology Perspectives 2012 - Pathways to a Clean Energy System, Int. Energy Agency (2012)

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Sectors Heat for Industrial Processes

Heat related Final Energy Consumption (FEC) in Industry [14] comparable to Transport or Building sectors. Distribution: EI 54%, Non-EI 46%

[14] Adapted from IEA - International Energy Agency (2014). Statistics: Energy Balance Flows. http://www.iea.org/statistics/

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Temperature levels Heat for Industrial Processes

Heat requirements in Industry occur at different temperature levels in different sectors [15]: ~ 50% HT; ~ 50% MT + LT

[15] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [2] (2014)

EI sectors

HT (>400°C) 42,5 EJ

MT (150°c-400°C) 18,1 EJ

LT (<150°C) 24,5 EJ

EI

Non-EI

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Suitable processes Heat for Industrial Processes

Suitable industrial processes

Drying and dehydration

Preheating (input or raw material)

Pasteurization and Sterilization

Washing and cleaning

Chemical reactions

Surface treatment

Space heating

Supply of hot water of steam

Main industrial sectors

Chemicals

Food & Beverages

Paper

Fabricated metal

Rubber & Plastic

Machinery & Equipment

Textiles

Wood

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Suitable processes Heat for Service and Commercial Buildings

Besides dwelling hot water (DHW), two particular applications might be considered in Service and Commercial Buildings

Sterilization and laundry in Hospitals

Thermal-driven cooling for space cooling in Offices

[16] Adapted from Solar Cooling Position Paper, IEA/SHC Task 38 Solar Air-Conditioning and Refrigeration (2011)

[16]

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Solar cooling applications

Existing projects Examples

[17] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/ [18] http://ship-plants.info/solar-thermal-plants/63-gicb-wine-cellars-france?unit_operation=12

GICB Wine Cellars , France Evacuated tube collector Aperture: 130 m2 Application: Cooling of wine cellar (absorption chiller 52kW capacity) Oper. Temp.: 75°C - 95°C Commissioning : 1991

© Tecsol [18]

Services MTN Johanesburg, S .Africa Linear Fresnel Aperture: 396 m2 Application/End Use: Air conditioning Oper. Temp.: 180°C Commissioning : 2014

© Industrial Solar [17]

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Solar cooling applications

Existing projects Examples

[18] http://ship-plants.info/solar-thermal-plants/256-canels-s-a-de-c-v-mexico?unit_operation=12 [19] http://ship-plants.info/solar-thermal-plants/251-gerhard-rauch-ges-mbh-austria?unit_operation=12

Gerhard RAUCH Ges.mbH , Austria Flat plate collector Aperture: 264 m2 Application: Process cooling Oper. Temp.: not available Commissioning : 2009

© GASOKOL GmbH [19]

Canels S .A. de C.V., Mexico Parabolic Trough Aperture: 264 m2 Application/End Use: Process cooling Oper. Temp.: not avauilable Commissioning : 2015

© Inventive Power SAPI de CV [18]

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Design procedures EE potential

EE regarded as the first step towards a reduction of energy intensity in Industry

improving industrial energy efficiency by implementing best practice technologies (BPT) could reduce total final industrial energy demand more than 25% [20]

Pinch analysis enables an overview of cross-process heat exchange possibilities [21]

Quantification of maximum heat recovery and effective heating and cooling requirements (efficient energy supply)

visualized via hot and cold composite curves (CCs)

Requires a detailed knowledge of the heating and cooling requirements

Each stream is defined by mass flow, specific heat and inlet and target temperatures

[20] Saygin, D., Patel, M.K. and Gielen, D.J. (2010). Global Industrial Energy Efficiency Benchmarking: An Energy Policy Tool, Working Paper, November 2010. United Nations Industrial Development Organization (UNIDO), Vienna. [21] Muster, Bettina et al., 2015. Guideline for solar planners, energy consultants and process engineers giving a general procedure to integrate solar heat into industrial processes by identifying and ranking suitable integration points and solar thermal system concepts. IEA/SHC Task 49/IV, Subtask B, Deliverable B2

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Dilemma: less resistance to integration at supply level vs. lower temperatures in integration at process level

Design procedures Solar integration

80°C-120°C

15°C-30°C

P1 160°C

P2 80°C

P3 50°C

50°C-90°C

160°C-180°C

11

0°C

-130

°C

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Dilemma: less resistance to integration at supply level vs. lower temperatures in integration at process level

Design procedures Solar integration

80°C-120°C

15°C-30°C

P1 160°C

P2 80°C

P3 50°C

50°C-90°C

160°C-180°C

11

0°C

-130

°C

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Design procedures Pre- and feasibility studies

Holistic planning approach

Pre-analysis: boundary conditions

Checklists, phone calls

motivation of the company?

Analysis of process characteristics and heat distribution network

Site visit with technician, sketch of the building

Temperature levels, condition of heat distribution network

Open / closed processes, heat integration at process level or supply level (heat network)

Process-schemes, load profiles, installation of measuring equipment

Process optimization and EE measures [23]

Processes state-of-the-art? Future plans?

Heat exchanger optimization (pinch analysis)

[22] www.solar-process-heat.eu/checklist [23] C. Brunner et al. 2010: IEE-Project Einstein: www.iee-einstein.org

[22]

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Solar Process Heat Available technologies, potential and applications

Which technologies are available?

Solar thermal collector technologies

Technology vs. operation temperature

Market penetration

Where and how to use them?

Process heat potential

Suitable sectors and processes

Design questions

Potential for Namibia

Industrial sectors

Energy sources and costs

Solar resource

© Fraunhofer ISE

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Potential for Namibia Industrial sector and energy sources

Most important Industrial sectors in Namibia [1]:

Food and Beverages T < 250°C (40,5% Manufacturing Composition - MC)

Basic metals (28% MC) T > 400°C

Chemicals and chemical products (7.3% MC) T > 80°C ( T > 250°C)

Textiles (4.9% MC) T < 250°C

Furniture manufacturing (4.8% MC) electricity

Direct impact on ~ 50% MC:

Additional applications in services: hospitals , schools, office buildings

Direct substitution of oil-based products (58% FEC)

safety of supply

[1] Manufacturing Composition (2013). UNIDO Statistics Unit. http://www.unido.org/statistics [2] IEA - International Energy Agency (2014). Statistics: Energy Balance Flows. http://www.iea.org/statistics

Industrial Final Energy Consumption by energy source in Namibia, 2015 [2]

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Potential for Namibia Solar resource

Very favourable solar resource conditions

stationary technologies (T < 100°C) Global Horizontal Irradiation (GHI)

2100 – 2500 kWh/m2

[24]

[24] solargis. http://solargis.com/

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Potential for Namibia Solar resource

Very favourable solar resource conditions

tracking technologies (100 °C < T < 250 °C) Direct Normal Irradiation (DNI)

2000 – 3000 kWh/m2

[24]

[24] solargis. http://solargis.com/

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Potential for Namibia Technology vs. energy costs

Current technology costs [19]:

220 – 620 €/m2

For average system cost 450 €/m2 (7220 NAD/m2)

Critical LCOH 2,8 €cent/kWh (4,5 NAD/kWh)

[21]

[25]

[25] adapted from Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).

h = 50% GHI, DNI = 2200 kWh/m2

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Solar Process Heat Available technologies, potential and applications

Which technologies are available?

stationary technologies (T < 100°C) Global Horizontal Irradiation (GHI)

tracking technologies (100 °C < T < 250 °C) Direct Normal Irradiation (DNI)

Where and how to use them?

Food and beverage, checmicals, textiles

Hospitals (steam), schools (hot water), commercial buildings (cooling)

Potential for Namibia

Very favourable solar resource GHI 2100 – 2500; DNI 2000 – 3000 kWh/m2

Critical LCOH for solar process heat ~ 2,8 €cent/kWhth (4,5 NAD/kWh)

Very important vector of security of supply security of industrial production

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Thank you for your attention!

Fraunhofer Institute for Solar Energy Systems ISE Pedro Horta www.ise.fraunhofer.de Pedro.horta@ise.fraunhofer.de