Solar Thermal Application in Industry and Commercial Buildings

Transcription

1 Solar Thermal Application in Industry and Commercial Buildings Pedro Horta Fraunhofer Institute for Solar Energy Systems ISE , Opportunities for Energy Efficiency in Namibia, Windhoek

2 Solar Process Heat Available technologies, potential and applications Which technologies are available? 2 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

3 Solar thermal technologies Technology vs. Temperature Solar collector technology vs. required process temperature 3

4 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 Industrial Final Energy Consumption by energy source in Namibia, 2015 [2] 4 [1] Manufacturing Composition (2013). UNIDO Statistics Unit. [2] IEA - International Energy Agency (2014). Statistics: Energy Balance Flows.

5 Solar Process Heat Available technologies, potential and applications Which technologies are available? 5 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

6 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 LT / stationary collectors: Higher optical efficiency Higher thermal losses MT / tracking collectors: Lower optical efficiency Lower thermal losses T 6

7 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] GAMESA-QUAKER PEPSICO MEXICO Mexico Modulo Solar in [4] 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 7 [3] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region [4] AEE-INTEC, Database for applications of solar heat integration in industrial processes. ( ).

8 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] Harita Seatings Systems Limited in [4] 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) 8 [3] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region [4] AEE-INTEC, Database for applications of solar heat integration in industrial processes. ( ).

9 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) [5] Lesa Dairy Switzerland ezw v in [4] 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 9 [4] AEE-INTEC, Database for applications of solar heat integration in industrial processes. ( ). [5] Adapted from SolarPaces.org, 2016),

10 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] RAM Pharmaceuticals Jordan Industrial Solar in [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 10 [5] Adapted from SolarPaces.org, 2016), [6]

11 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] Tirumala Tirupati Devasthanams India Gadhia Solar Energy Systems Parabolic Dish: common temperature range of 250 C >400 C Point-focusing system (2-axis tracking) Moving (modular) receiver Potential for higher temperatures 11 [5] Adapted from SolarPaces.org, 2016),

12 Solar thermal technologies Technology vs. Temperature Solar collector technology vs. required process temperature 12

13 Existing projects Market penetration SHIP systems database [2]: 213 projects listed, 129 MWth installed capacity (0.18 million m 2 ) < 1% installed solar thermal capacity [7] [8] Mostly small/medium size systems (<500 m 2 ) Largest capacity in large systems (>1000 m 2 ) Stationary technologies dominate in nr. systems and capacity Recent survey [6] points out > 500 SHIP systems with total installed capacity > 280 MWth (0.4 million m2) 13 [7] AEE-INTEC, Database for applications of solar heat integration in industrial processes. ( ). Accessed February 2017 Fraunhofer [8] SOLRICO, ISE Bärbel Epp, Solar Process Heat: Surprisingly popular. Sun&Wind Energy. (online )

14 Existing projects Examples Stationary technologies 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 Textile Jiangsu Yitong, China Evacuated Tube Aperture: 9,000 m2 Application: process pre-heating Oper. Temp.: 50 C Commissioning : 2011 Arcon-Sunmark [9] Sunrain Co. Ltd [10] Currently largest plant in the world 14 [9] Arcon-Sunmark, [10]

15 Existing projects Examples Tracking technologies RAM Pharmaceuticals, Jordan Linear Fresnel Aperture: 396 m2 Application/End Use: Process Steam Oper. Temp.: 160 C Commissioning : 2015 Dairy El Indio, Mexico Parabolic Trough Aperture: 132 m2 Application: Make-up water pre-heating Oper. Temp.: 95 C Commissioning : 2012 Industrial Solar [11] Inventive Power S.A. de C.V. [12] 15 [11] [12]

16 Existing projects Examples Upcoming 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. 16 [13] MIT, Technology Review, Arab Edition.

17 Solar Process Heat Available technologies, potential and applications Which technologies are available? 17 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

18 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] 18 [10] Energy Technology Perspectives Pathways to a Clean Energy System, Int. Energy Agency (2012)

19 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% 19 [14] Adapted from IEA - International Energy Agency (2014). Statistics: Energy Balance Flows.

20 Temperature levels Heat for Industrial Processes Heat requirements in Industry occur at different temperature levels in different sectors [15]: ~ 50% HT; ~ 50% MT + LT EI sectors HT (>400 C) 42,5 EJ LT (<150 C) 24,5 EJ Non-EI EI MT (150 c-400 C) 18,1 EJ 20 [15] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [2] (2014)

21 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 21

22 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] 22 [16] Adapted from Solar Cooling Position Paper, IEA/SHC Task 38 Solar Air-Conditioning and Refrigeration (2011)

23 Existing projects Examples Solar cooling applications Services MTN Johanesburg, S.Africa Linear Fresnel Aperture: 396 m2 Application/End Use: Air conditioning Oper. Temp.: 180 C Commissioning : 2014 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 Industrial Solar [17] Tecsol [18] 23 [17] [18]

24 Existing projects Examples Solar cooling applications Canels S.A. de C.V., Mexico Parabolic Trough Aperture: 264 m2 Application/End Use: Process cooling Oper. Temp.: not avauilable Commissioning : 2015 Gerhard RAUCH Ges.mbH, Austria Flat plate collector Aperture: 264 m2 Application: Process cooling Oper. Temp.: not available Commissioning : 2009 Inventive Power SAPI de CV [18] GASOKOL GmbH [19] 24 [18] [19]

25 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 25 Paper, November United Nations Industrial Development Organization (UNIDO), Vienna. [21] Muster, Bettina et al., Guideline for solar planners, energy consultants and process engineers giving a general procedure to Fraunhofer integrate ISE 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

26 110 C-130 C Design procedures Solar integration Dilemma: less resistance to integration at supply level vs. lower temperatures in integration at process level 50 C-90 C P3 50 C 15 C-30 C 80 C-120 C 160 C-180 C P2 80 C P1 160 C 26

27 110 C-130 C Design procedures Solar integration Dilemma: less resistance to integration at supply level vs. lower temperatures in integration at process level 50 C-90 C P3 50 C 15 C-30 C 80 C-120 C 160 C-180 C P2 80 C P1 160 C 27

28 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 [22] 28 Process optimization and EE measures [23] Processes state-of-the-art? Future plans? Heat exchanger optimization (pinch analysis) [22] [23] C. Brunner et al. 2010: IEE-Project Einstein:

29 Solar Process Heat Available technologies, potential and applications Which technologies are available? 29 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

30 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 Industrial Final Energy Consumption by energy source in Namibia, 2015 [2] 30 [1] Manufacturing Composition (2013). UNIDO Statistics Unit. [2] IEA - International Energy Agency (2014). Statistics: Energy Balance Flows.

31 Potential for Namibia Solar resource Very favourable solar resource conditions stationary technologies (T < 100 C) Global Horizontal Irradiation (GHI) kwh/m 2 [24] 31 [24] solargis.

32 Potential for Namibia Solar resource Very favourable solar resource conditions tracking technologies (100 C < T < 250 C) Direct Normal Irradiation (DNI) kwh/m 2 [24] 32 [24] solargis.

33 Potential for Namibia Technology vs. energy costs Current technology costs [19]: /m 2 [25] For average system cost 450 /m 2 (7220 NAD/m 2 ) Critical LCOH 2,8 cent/kwh (4,5 NAD/kWh) h = 50% GHI, DNI = 2200 kwh/m 2 [21] 33 [25] adapted from Database for applications of solar heat integration in industrial processes. ( ).

34 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 34 Very favourable solar resource GHI ; DNI kwh/m 2 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

35 Thank you for your attention! Fraunhofer Institute for Solar Energy Systems ISE Pedro Horta 35