SEMINARIO SOLAR FRAUNHOFER CHILE - CSET

Transcription

1 SEMINARIO SOLAR FRAUNHOFER CHILE - CSET CALOR SOLAR PARA PROCESOS Solar Thermal Technologies for Process Heat Applications: available solutions and process temperature suitability Peter Nitz Pedro Horta 20 th April 2016 Fraunhofer Institute for Solar Energy Systems ISE Freiburg, Germany

2 Introduction Energy use in Industry Heat for Industrial Processes Thermally driven processes present the largest share of final energy use in Industry electricity stands for 31% of final energy consumption in Industry [1] Electricity driven processes include Surface deposition processes (electroplating, anodization, etc) Melting processes in Electric Arc Furnaces Cooling and vacuum Motor driven systems (compressed air, pumping) lighting Share of different energy sources in final energy consumptions on the Industrial Sector, 2012 (adapted from [1]) 2 [1] Final energy consumption by sector and fuel, European Environment Agency. (2015)

3 Introduction Heat Generation by Sector 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 [2] 3 [2] Energy Technology Perspectives Pathways to a Clean Energy System, Int. Energy Agency (2012)

4 Introduction Generation of Heat Heat for Industrial Processes Worldwide 66% of heat is generated by fossil fuels [2] 79% 59% 60% 88% 61% 100% 91% 21% Heat generation by region for different fuel types (2009) [2] 4 [2] Energy Technology Perspectives Pathways to a Clean Energy System, Int. Energy Agency (2012)

5 Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability Solar collectors Overview Stationary collectors Flat Plate collectors and variants Evacuated collectors and variants Tracking collectors Parabolic Trough Linear Fresnel other concepts Process Heat: sectors and processes, examples in Chile Summary 5

6 Overview Solar thermal collector heat exchanger converting the solar radiation into heat transfers this heat to a working fluid (e.g. air, water, thermal oil) circulating through the system solar energy collected is carried from the working fluid to the load/use or to energy storage tank to be used later different technologies for different operating temperature levels 6

7 Collector Efficiency Overview The efficiency of a solar collector depends on incidence angle dependent optical losses and on operating temperature dependent thermal losses Temp. Difference 0 40K 80K G=800 W/m² 7

8 Operating Temperatures Overview Thus the selection of a specific solar collector technology is intrinsically related to the required temperature at the heat delivery point 8

9 Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability Solar collectors Overview Stationary collectors Flat Plate collectors and variants Evacuated collectors and variants Tracking collectors Parabolic Trough Linear Fresnel other concepts Process Heat: sectors and processes, examples in Chile Summary 11

10 Stationary Collectors Flat Plate Collectors (FPC) and Variants Commonly used for temperatures in the range of 30 C to 100 C Comprise of absorber tubes through which working fluid flows and is covered by absorber sheet and a transparent cover. Coating on the absorber converts the solar irradiation to heat which is transferred to the working fluid in the tubes. Usual fluid is water/glycol mixture (with some additives) in order to avoid corrosion and frost damages Simple to use as there is little maintenance and relatively cheap. 12 Source: gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region

11 Stationary Collectors Flat Plate Collectors (FPC) and Variants Examples Electro Winning in Copper Mine Copper mine Gabriela Mistral, Chile m2 FPC Non pressurized water storage (4300 m3) % solar fraction electro winning of copper electrolyte kept at 50 C cleaning processes 13 Source:

12 Stationary Collectors Flat Plate Collectors (FPC) and Variants Improved Medium Temperature Flat-Plate Collectors Reduced heat losses 14 double glazed, AR coatings CPC flat plate honeycomb collector Operation temperature up to 80 C for flat-plate up to 100 C-120 C for honeycomb and double glazing Improvement of optical efficiency difficult Can heat loss be further reduced? Other possibilities? Efficiency [%] 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% FPC Standard FPC with double glazing FPC Honeycomb FPC with CPC internally Temperature diff. T op -T a [K] Efficiency for Irradiation 850 W/m 2, IAM=1

13 Stationary Collectors Evacuated Tube Collectors (ETC) and Variants Can achieve higher temperature than FPC ranging from 50 to 130 C Consists of a row of parallel vacuum glass tubes. Absence of air highly reduces convection and conduction thermal losses. 2 categories of ETC: Direct flow principle: the heat transfer fluid of the collector loop flows directly through the absorber via a coaxial tube Heat pipes principle: the heat of the absorber is transferred to the heat transfer fluid of the collector loop via a heat pipe system (Figure 5 right). 19 Source: gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region

14 Stationary Collectors Evacuated Tube Collectors (ETC) and Variants Compound Parabolic Concentrator ETC (RPC) Low concentration CPC (C < 2) Evacuated tubes CPC collectors which can deliver up to 200 C; Stationary collector CPC is designed in a way that all solar positions during a year a accepted by the concentrator Bridges the gap between the lower temperature application FPC (<80 C) to the higher temp. applications of concentrators (T>200 C) 20 Source: Linuo Solar, :

15 Stationary Collectors Evacuated Tube Collectors and Variants Evacuated Flat Plate: Thermal Vacuum Power Charged (I) advantage of high vacuum insulation in a planar layout Flat plate vacuum collector TVP MT-Power 3rd prize INTERSOLAR 2012 operation temperatures up to 160 C 200 C 21 Efficiency [%] FPC Standard 100% FPC Vacuum 90% VTC process heat 80% VTC Standard 70% 60% 50% 40% 30% 20% 10% 0% Temperature diff. T op -T a [K]

16 Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability Solar collectors Overview Stationary collectors Flat Plate collectors and variants Evacuated collectors and variants Tracking collectors Parabolic Trough Linear Fresnel other concepts Process Heat: sectors and processes, examples in Chile Summary 22

17 Parabolic Trough Collectors (PTC) Tracking Collectors Parabolic mirror focuses only direct sun-light onto an absorber tube Designed to track the sun along one axis oriented in the northsouth or east-west direction. Reflecting surface normally a curved glass mirror or an aluminium sheet Water or thermal oil usually used as working fluid Receptor consists of an absorber tube of an area usually 25 to 35 times smaller than the aperture 23 Source: gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region

18 Parabolic Trough Collectors (PTC) Tracking Collectors PolyTrough 1200 and 1800 NEP Solar (AUS/CH) Width: 1.2 or 1.8 m Oper. Temp. 250 C 24m long and 1.6m high (standard 1200 collector) Various receiver options Shopping Center Newcastle, Australia Aperture: 345m2 (PolyTrough 1200) Peak Thermal Power: 200kW Outlet Temperature: 180 C HTF: Water Application/End Use: Air conditioning Commissioning : April 2011 NEP Solar NEP Solar 24 Source:

19 Parabolic Trough Collectors (PTC) Tracking Collectors Soltigua (I) - PTM parabolic trough collector Surface = 13.5 sqm/module Length = 6.2 mt/module Peak power = 570 W/m2 (7.7 of 1000 W/m2, Tamb= 30 C, Tout = 200 C) 25 mt long / 54 sqm / 31 kwpeak first collector tested under the new European standard for concentrating collectors up to 250 C Installation in Gambettola (I), a solar cooling systems with concentrating collectors and double effect absorptions chiller TECHNOLOGICAL EXCELLENCE In 2010 PTM has been awarded the Towards the A-class building prize at the at MCE2010, Europe s largest trade fair for heating and air conditioning. The prize was given to the best innovations for building energy systems. 25

20 Parabolic Trough Collectors (PTC) Tracking Collectors Solarlite (D) Production of PTC collectors 2300 and 4600 for: process heat concentrated solar thermal power 2.3 m and 4.6 m aperture operation up to 400 C / 55 bar 12m segment variable size of plant Solar Lite Costs comparable with larger CSP collectors instead of small plant size 26

21 Tracking: Parabolic Trough collectors Sopogy (USA) SopoNova 4.0 Geometrical features Length: 3.66 m Width: 1.52 m Center to Center Spacing: 2.59 m Reflector Aperture Area: 5.07 m2 Reference installation Masdar cooling project 27

22 Linear Fresnel Reflector (LFR / LFC) Tracking Collectors Many nearly flat mirror facets instead of one parabolic mirror Receiver/Absorber is above mirror rows, which track the sun High concentration ratio and temperatures up to 400 C Thermal capacity from 50 kw up to several MW. Easy to mount on flat roofs as a result of good weight distribution and low wind resistance. Water/steam or thermal oil usually used as working fluid High surface coverage 28 Source: Industrial Solar Gmbh

23 Linear Fresnel Reflector (LFR / LFC) Tracking Collectors Industrial Solar GmbH (Freiburg, Germany) Geometrical features Length: modular in steps of 4 m Total width: 7.5 m Aperture width: 5.5 m Height: 4 m Weight: 27 kg/m² Peak power: 560 W/m² Max. temp. : 400 C MTN Johanesburg, South Africa Aperture: 396 m2 Application/End Use: Air conditioning Commissioning :

24 Linear Fresnel Reflector (LFR / LFC) Tracking Collectors New developments Further development: Soltigua (I), Solar Euromed (F), Thermax (IND), Lotus (EGY), KG Group (IND), others DSG Pilot Plant in La Seyne Sur Mer, France DSG Pilot Plant in Sicily, Italy Fera CNIM 30

25 Tracking Collectors Other Concepts Point Focusing Collectors Parabolic dish focuses only direct sun-light onto a central receiver (point focus) Designed to track the sun along two axes Potential to high (overheated steam) and very high temperatures (chemical reactions, fusion of materials, etc) ( Fresnel approach to the parabolic dish? The central receiver - Tower) Central receiver Tracker Concentrator Thermal load + - Electric load 31

26 Tracking Collectors Other Concepts Scheffler Dish Reflector Gadhia Solar Energy Systems (In) (Scheffler Reflector) Solar Steam Cooking System for people (worlds largest) Tirumala Tirupati Devasthanams (TTD) 32

27 Other Concepts Tracking Collectors Chromasun (USA) low profile, lightweight, no external moving parts Simple to mount and to maintain 20x25x Fresnel reflector optic Output temperatures up to 220 C Chromasun 33

28 Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability Solar collectors Overview Stationary collectors Flat Plate collectors and variants Evacuated collectors and variants Tracking collectors Parabolic Trough Linear Fresnel Other concepts Process Heat: sectors and processes, examples in Chile Summary 36

29 Process Heat Sectors and processes Heat is required at different temperature levels, whose distribution depends on the specific industrial sector [3] 100% 80% 60% 40% 20% Above 400 C C Below 100 C 0% Mining and Quarrying Food and Tobacco Pulp & paper Chemical Non-Metallic Minerals Basic Metals Machinery Transport Equipment Others Heat consumption distribution by temperature level in different industrial sectors [3] 37 [3] ECOHEATCOOL The European Heat Market, EU IEE co-fund, (2006)

30 With Solar?! Solar Heat for Industrial Processes (SHIP) Suitable industrial sectors and processes [4] 38 [4] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012

31 With Solar?! Solar Heat for Industrial Processes (SHIP) Suitable industrial sectors and processes [4] 39 [4] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012

32 With Solar?! Solar Heat for Industrial Processes (SHIP) Suitable industrial sectors and processes [4] 40 [4] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012

33 Process Heat Sectors and processes Suitable industrial processes Drying and dehydration (Concentration) Preheating (input or raw material) Pasteurization and Sterilization Washing and cleaning Chemical reactions Surface treatment Space heating Supply of hot water or steam Main industrial sectors Chemicals Agriculture / Food & Beverages Paper Fabricated metal (/ Mining) Rubber & Plastic Machinery & Equipment Textiles Wood 41

34 Process Heat Main Applications for Chile Sectors and processes Suitable industrial processes Drying and dehydration (Concentration) Preheating (input or raw material) Pasteurization and Sterilization Washing and cleaning Chemical reactions Surface treatment Space heating Supply of hot water or steam Main industrial sectors Chemicals Agriculture / Food & Beverages Paper Fabricated metal (/ Mining) Rubber & Plastic Machinery & Equipment Textiles Wood 42

35 Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability Process Heat: sectors and processes Solar collectors Overview Stationary collectors Flat Plate collectors and variants Evacuated collectors and variants Tracking collectors Parabolic Trough Linear Fresnel other concepts Summary 43

36 Summary Classification - Technology Readiness Level TRL TRL level* (in SHIP applications) 9. System operation 8. System Qualif. 7. Oper. demo 6. Relev. Envir. demo 5. Relev. Envir. Val. 4. Lab. validation 3. Exp. Proof 2. Tech. Concept 1. Basic principles 44 * Source:

37 Summary 155 operational SHIP systems reported worldwide [5] Underestimated m2 [5] 20 plants > 1000 m2 Largest: m2 Codelco Gabriela Mistral Copper Mining, Chile Tracking Reported SHIP systems: ship-plants.info [2] 45 [5] Database for applications of solar heat integration in industrial processes, AEE-INTEC. (online 06,2015)

38 Technology status Summary Although the market for SPH is still small, many companies have developed new collector products suitable for a medium temperature range 100 C 250 C or even higher Non-concentrating standard collectors are suitable for temperatures below 80 C (flat-plate) / 150 C (evacuated tube collectors with CPC) Concentrating collectors PTC, LFR and other concepts, cover the remaining medium temperature range Very High temperature applications (EI sectors) still lack technology developments Standardization and Product certification is in place Systems and component development and testing is a important task for R&D organizations 46

39 Technology application in SHIP Obstacles Factors impairing higher technology penetration Highly diversified Applications and Technologies Integration in steam networks (BoP) Available area restrictions (calling for lower LOF / building integration) Low cost of conventional heat sources (even lower in industry ) FINANCING! Industrial end-users expect VERY SHORT pay-back periods (1 to 2 years ) IRR > 40% 47

40 Technology application in SHIP New Financing Schemes to Support Industry Obstacles Someone else deciding on investment? Atract 3 rd party investors w/ lower IRR expectation (7%) Lower risk perception (optimal design, GRA, PPA) 48

41 Technology application in SHIP Obstacles First Results IEA SHC Task 49 Data base [3] 49

42 Technology application in SHIP Learning Curve and Economy of Scale Obstacles The successful story of PV [5] Each doubled installed capacity stood for 20 % technology cost reduction SHIP STE A factor 10 in 25 years! 50 [5] Navigant Consulting; EUPD PV module prices (since 2006), Graph: ISE 2014

43 Thank you for your attention! Fraunhofer Institute for Solar Energy Systems ISE Peter Nitz / Pedro Horta pedro.horta@ise.fraunhofer.de 51