Case studies & Opportunities: Clean Process Heat

Transcription

1 Case studies & Opportunities: Clean Process Heat Jeremy Osborne Director Cases studies & Opportunites: Clean Process Heat. J. Osborne 1

2 Enabling innovation for sustainable future Research and Development Expertise Services Consulting Software sales and training Project development & implementation Solar thermal / PV Storage Building energy Heat pumps Numerical Modelling System Design Project Management Technical advisory 2

3 Our Team Dr Fiona McClure Jeremy Osborne Alastair McDowell Erika Degoute Dr Mike Dennis Australian Distributor for TRNSYS software Training in TRNSYS: 3

4 Case studies 1. Atacama Desert, Chile Copper Processing with Solar Thermal 2. UK - Chocolate factory with a Heat Pump 3. Paris Creek, South Australia Dairy with Solar Thermal 4. Griffith, NSW Winery with Solar Thermal 5. Colignan, Victoria - Tartaric plant with Biomass 5

5 Case study Location Industry Technology Design concept Cost Performance 6

6 Chile - Copper Processing Location: Minera Gabriela Mistral copper mine and processing site 100 km south of Calama, in the Atacama Desert Source: ARCON SUNMARK, Google 7

7 Source: ARCON SUNMARK 8

8 Chile - Copper Processing Technology: Flat Plate Solar Thermal Turnkey supplier: Energia Llaima and Arcon-Sunmark Customer: Codelco mining company Size: 27MW, 39,000m 2 solar field Industry: Mineral processing, Copper, Electrowinning process Capital Cost: $0 to the customer Sales model: 10 year Energy Service Contract Start-up: August Source: ARCON SUNMARK 9

9 Solar Thermal - Chile Copper 4300mMine 3 Storage 2013 Tank Source: ARCON SUNMARK 10

10 2620 panels, 15m 2 each Source: ARCON SUNMARK 11

11 Process Integration Supply 50 C hot water for electrowinning Source: ARCON SUNMARK 12

12 Performance Performance Heat production: 51,800 MWh per year Solar fraction: 85% Fuel saving per year: 6,500 tons of diesel 250 truck travels per year Source: ARCON SUNMARK 13

13 UK- Chocolate factory with HP Location: Halifax, UK Source: Google 14

14 Replaces an old Coal Boiler Source: Star Refrigeration Ltd. 15

15 UK- Chocolate factory with HP Technology: Ammonia Heat Pump Supplier: Star refrigeration, Vilter/Emerson, Cool Partners Customer: Nestle Size: 1.25MW Heating,3.2MW Cooling Design concept: Provide cooling or heating and cooling at the same time. Heat Pump supply 60 C, + 90 C boost with gas Refrigeration from 5 C to 0 C simultaneously. Industry: Chocolate factory Capital Cost: 4,200,000 Start-up: 2010 Source: Star Refrigeration Ltd. 16

16 Elec Process Q Cooling Only mode 0degC Rejects heat to atmosphere to town heating supply Provide cooling 4.0MW Q Evaporator Q Heat pump Q Condenser 3.2MW 5degC Estimated COP COP cooling = = 4 0.8MW Source: Star Refrigeration Ltd. 17

17 Elec Process Q Heat and Cooling Mode 0degC Rejects heat to atmosphere to town heating supply 10 degc Provide cooling 2.8 MW Q 3.2MW Evaporator Q Heat pump Q Condenser Q 1.2MW 5degC Estimated COP 0.8MW COP cooling+heating = = Star Ref. provides the COP c+h = 6.38 this is likely due to part load improvements Source: Star Refrigeration Ltd. Provide Heating to process or gas boiler degc

18 Economics Source: Star Refrigeration Ltd 19

19 Paris Creek Dairy Location: Paris Ck Rd, Paris Ck, South Australia Source: Google 20

20 Whole of site energy Source: Clean Technology Food and Foundries Investment Program and Paris Creek Farm interview. Energy Efficiency Power Factor Correction Heat Recovery Soft-start Clean Electricity Solar PV 100kW Clean Heat Solar thermal 150kW 47% reduction in GHG emissions and financial saving $125,000 per year 21

21 Paris Creek Dairy Source: LCi 22

22 Paris Creek Dairy Technology: Evacuated Tube Solar Thermal Supplier: Greenland Systems, LCi Customer: BD farm Paris Creek Size: 140 kw, 169 m 2 solar field Industry: Dairy Processing Capital Cost: $350,000 (not including grants) Sales model: Cash sale with government grants Start-up: August :$2000/m2 for complete project including collector, BOP, integration. 2016: $ /m2 for ground-mount large field Many opportunities for price reductions! Source: BD farms, LCi, ARENA 23

23 Process integration 60 x Greenland Systems GL C SOLAR COLLECTORS 7m3 storage vessel HX To the boiler HX SOLAR STORAGE T1 T2 Pump Return from process T3 Pump Pump Pump Pasteurizer Heat Source: EnergyAE and LCi 24

24 De Bortoli Winery Location: Griffith NSW Source: Google 25

25 De Bortoli Winery Technology: Evacuated tube Solar Thermal Supplier: Apricus, The Solar Project, Fletchers Plumbing Customer: De Bortoli Winery Size: 200 kw Heating, 280 m 2 solar field Design concept: Provide pre-heating to a condensing gas boiler Industry: Winery Start-up: May 2013 Source: Apricus, ITPower

26 De Bortoli Winery 100x AP30 Apricus Collectors 280m 2 solar field 12 m 3 storage at 95 C Source: Apricus Australia, ITPower

27 Australian Tartaric Products - Colignan Location: Colignan, Victoria Source: ITPower 2015, Australian Tartaric Products 28

28 Australian Tartaric Products - Colignan Technology: Biomass boiler, Organic Rankin Cycle (ORC) Supplier: Customer: Australian Tartaric Products Size: 8MW th Boiler, 600kW e ORC Design concept: Biomass boiler and ORC 180 C steam and electricity using grape marc biomass Industry: Winery Capital Cost: $7.5M Start-up: May 2013 Source: ITPower

29 More Case Studies All Solar thermal Heat Pumps 30

30 More Case Studies Bioenergy 31

31 Opportunities for Australia How do these case studies apply to the Australian Context? 1. Energy efficiency 1. 7% immediate opportunity for easily implemented changes (source: EEO) 2. Deep savings through process integration and process intensification 2. Renewable Heating 1. Bioenergy 2. Solar thermal 3. Heat pumps (with PV) now low temperature, future - high temperature 4. Electric boilers and furnaces (with PV) High temperature 32

32 Where does each technology work? Solar thermal: 1. Space required for collectors: m2 roof or ground space per GJ heat load / year ** 2. For temperatures of less than 120 C use a good flat plate 3. For less than 160 C, use a good evacuated tube 4. For greater than 160 C, use concentrating collectors ** Assumption update since talk: sun:1600kwh/m2/year, heat load, not purchased gas: multiply bill by efficiency to find heat load typically x0.8, assuming % solar fraction 100% generally difficult, Ratio of collector to roof or ground space: possible if flat on roof, 3 for trough collectors. 33

33 Where does each technology work? Heat Pumps: 1. Where little roof or ground space is available for solar 2. Where grid connection can support extra demand 3. Where temperature is less than 95 C (high temperature on the way) 4. Where a refrigeration is also required for process integration Add PV and thermal/battery storage to remove electricity grid reliance 34

34 Where does each technology work? Bioenergy: 1. Where suitable feedstock is consistent available 2. Where combustion is required 3. Where high temperature is required 4. Where no roof or ground space is available 35

35 BILLIONS Energy Expenditure by Temperature $2.5 $2.0 Low temperature is a great opportunity for solar thermal and heat pumps $1.5 $1.0 $0.5 $- Food, Beverage, Tabacco Textiles Expenditure below 60C Expenditure 100C-150C Paper and printing Chemical, Polymer and Rubber Glass Ceramics Cement, lime, plaster and concrete Expenditure between 60C-100C Expenditure greater than 150C Source: BREE, IEA, Fuller, UNIDO and EnergyAE analysis 36

36 # Sites in Food and Beverage Australia Other Food Product Manufacturing 65 Sugar and Confectionery Manufacturing Bakery Product Manufacturing Grain Mill and Cereal Product Manufacturing Oil and Fat Manufacturing Fruit and Vegetable Processing Great opportunity: Conservative companies look to what others have done in their industry. Focusing one sub-sector at a time is important Dairy Product Manufacturing 53 Seafood Processing 1 Meat and Meat Product Manufacturing

37 # Sites in Chemical Australia Natural Rubber 2 Polymer 97 Other Basic Chemical 30 Cleaning Compound and Toiletry Preparation Pharmaceutical and Medicinal Great opportunity Fertiliser and Pesticide 24 Basic Polymer 8 Basic Chemical

38 Map of Sites for Food, Beverage and Chemical Australia VICTORIA Food sites away from Natural gas Chemical site Food and Beverage site Natural Gas pipeline Food sites are regional, on more expensive LPG Great opportunity Source: EnergyAE 39

39 Government Support Australian Renewable Energy Agency s Advancing Renewables Program Clean Energy Regulator s Small-scale Renewable Energy Scheme (STCs) Victorian Government New Energy Jobs Grants NSW Government Energy Saving Scheme Clean Energy Finance Corporation (finance) 40

40 Clean Energy Regulator s STCs We are expecting changes to the program to make claiming Small-scale Technology Certificates for Large-scale Solar Hot Water easier in The program uses AS/NZS 4234 to calculate the energy savings of solar hot water using the program TRNSYS over a 10 year period. These changes include: Theoretical Heat loss calculation for the storage tank (already changed) Changes to the load profile Call us for help! 41

41 Conclusions 1. There is significant international experience 2. We are developing our Australian experience 3. There is a bright future for renewables in process heating However, 4. We must show leadership to make it happen! 5. Government support is available to make it happen! 42

42 Reference BREE, 2014 Australian energy statistics data available at IEA, 2012 Energy Statistics available at consumption Fuller, JR, 2012 Solar industrial process heating in Australia Past and current status, Renewable Energy UNIDO, 2010 Renewable Energy in Industrial Applications An assessment of the 2050 potential IEA 2008, Potentail for Solar Heat in Industry. s.l. : IEA, SHIP database, ITPower, 2015 Renewable Energy Options For Australian Industrial Gas Users 43

43 Thank you! Jeremy Osborne Cases studies & Opportunites: Clean Process Heat. J. Osborne 44