Findings by analysing case studies of solar heat systems for industrial processes within the project

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1 Findings by analysing case studies of solar heat systems for industrial processes within the project Gerhard Stryi-Hipp Head of Energy Policy Coordinator Smart Energy Cities Fraunhofer Institute for Solar Energy Systems ISE President European Technology Platform on Renewable Heating & Cooling Workshop Solar Process Heat Delhi, 16 October 2014

2 Fraunhofer Institute for Solar Energy Systems ISE n Applied research on Renewable Energies since 1981 n Largest Solar Research Institute in Europe 1300 employees incl. 300 PhD and diploma students n Director: Prof. Eicke R. Weber n Part of the Fraunhofer Society with 60 institutes and employees, largest applied research network n Energy Efficient Buildings n Applied Optics, Functional Surfaces n Solar Thermal Technology n Silicon Photovoltaics n Alternative PV Technologies n Renewable Power Supply n Hydrogen Technology

3 SoPro India - Outline Project of GIZ with Fraunhofer ISE and Apitco Partner: GIZ, Fraunhofer ISE, Apitco Support required by: Solar manufacturer, STFI, MNRE, researcher,... Duration: October 2013 Dec 2014 (monitoring during 2015) Technology: Non-concentrating solar heat technology up to 100 C Motivation: Supporting the promotion and deployment of Solar Water Heating Systems (SWHS) for Industrial Processes in India 1. Increase the awareness 2. Increase the confidence 3. Support the enhancement of quality Measures: 1. Online database on 20 representative SWHS in India and further information on a website 2. Scientific monitoring on 3 SWHS to get reliable data on the solar energy output and fuels savings 3. Recommendations on monitoring of SWHS

4 Motivation for starting SoPro India n GIZ did sector studies, awareness workshops, pre-feasibility studies and demonstration projects in SWHS sector for industrial processes; Fraunhofer ISE compared in a master thesis SWHS technology from Germany and India Findings n The Indian SWHS for IP market is rather small yet, but has a great potential n There are several SWHS for IP already installed in India, but concerns were mentioned that some systems are not or not optimal working n There is a great interest of the industry in India on solar technology to avoid increasing fuel costs, however there are several barriers for the deployment: - Lack of awareness of the SWHS for IP technology SoPro India - Concerns on the reliability of the technology - No reliable data on performance and cost savings of SWHS - Available roof space is limited - Financing - Some industries require a higher temperature level -

5 Work packages 1. Data gathering on 20 case studies 2. Scientific Monitoring of 3 SWHS for industrial processes 3. Preparing basic information on SWHS for industrial processes 4. Publishing information on website 5. Awareness measures (workshops and articles) 6. Recommendations for cheap, robust and reliable monitoring systems for SWHS

6 First findings There are significant differences between SWHS in Europe and India Pressurized* Heat transfer fluid Separation of heat circuits Central / North Europe Only pressurized systems Almost only glycol mixture (anti-freezing) Solar circuit is separated from other circuits by heat exchangers India Almost only non-pressurized systems Almost only water without freezing protection (Often demineralized / reversed osmosis water used DM/RO) Often one circuit only, water used in the process flows through collectors Control Only automatically controlled Often manually operated»philosophyheat generation oriented«è system is defined by collector area (solar yield increases with size)»hot water supply oriented«è The system is designed to deliver a specific amount of water with a specific temperature a day (storage is sized with this volume SWHS sized with LPD = Litre per day) *A solar water heating system is called»pressurized«, if the collector or other hydraulic circuits are closed and an additional pressure of for typically 1 to 3 bars (100 to 300 kpa or 1.02 to 3.06 kg/sq. cm) is added to the static pressure. If the system pressure is only created by statics e.g. by a make-up water tank, it is defined as»non-pressurized«.

7 Typical European Large SWHS Collector Loop freeze protected Solar Heat Store buffer water Hot Water Demand supply Collector inlet temperature must be as low as possible (store stratification!) to achieve high collector efficiency Charge and discharge devices and strategy must lead to a good temperature stratification Cold water supply must cool down the bottom of the buffer store via heat exchanger for a high solar collector efficiency

8 Synthokem Labs, Hyderabad T1 T2 P2 Hot water tank ltr Filled in the morning P1 RO water storage tank Pumped in the evening T3 Hot water tank ltr Filled in the morning Refilled by demand W1 P5 P4 Steam boiler generating 7x24h C ltr per day feeding water needed P3 Operation: RO (Reverse Osmosis) water prepared by the company is pumped by P1 to tank 1 in the morning and is circulation through the collector field (1) during the day by switching on P2 at 9 am and off at 5 pm manually. Tank 2 is filled with RO water in the morning by P1 and heated during the day by collector field (2). The RO water of tank 2 is continuously used as feeding water for the steam boiler and for this purposed pumped by the pumps P4 and P5 to the steam boiler. The water level of tank 2 varies during the day and is refilled manually by P1 if it falls under a specific level. P1 P3 are operated manually, only P4 and P5 are automatically controlled. Temperature T1 T3 and water volume W1 is measured, but not used for automatic control. W Water meter T Temperature sensor Pump Water level Gate valve

9 Hydraulics of coll fields at Synthokem Labs Collector field 2: 2x4 ETCs in parallel and 1x2 ETCs in parallel connected in series Collector field 1: 5x2 ETCs in parallel

10 Pictures Synthokem Labs

11 Himachal Pradesh Dairy Milk plant Du7nagar, Tehsil- Rampur Bushar, District Shimla Make up water tank Steam boiler 1.5 tons capacity Controller T3 Boiler feeding water tank P4 Solar hot water tank 6000 ltr T4 P6 P5 P2 T1 P3 T2 P1 Type: Non- pressurized solar hea3ng system separated from the feeding water circuit by a plate heat exchanger OperaAon: If the temperature difference between T3 (collector outlet) and T2 (tank bocom) is higher than a defined temperature, the controller starts the pumps P3 / P4 and the collector circuit is hea3ng up the solar tank. If the temperature difference between T4 (tank top) and T1 (cold water inlet) is higher than a defined temperature the controller starts the pumps P1 / P2 and P5 / P6 and the boiler feeding water tank is heated. The open make up water tank refills the closed heat exchanger solar hot water tank collector circuit if needed and provides a sta3c pressure to the circuit. The boiler feeding water tank is filled manually by switching on the pump P7 un3l the maximum level is reached defined by the overflow pipe. T Temperature sensor Pump Plate heat exchanger Manual ball valve Floa3ng valve

12 Conclusions n n Gathering detailed and reliable data of SWHS for industrial processes installed in India is a challenge European and Indian SWHS are very different in several aspects è The Indian concept and design of SWHS must be understood for comparison è It needs detailed analysis to identify, which technology is worthful to be transfered and adapted to Indian market è Monitoring is needed to understand Indian SWHS technology and their potential for optimization

13 Thank you very much for your attention! Fraunhofer Institute for Solar Energy Systems ISE Gerhard Stryi-Hipp