Contents I INDEX i II FOREWORD iv III AEE INTEC LICENCE AGREEMENT v IV ABOUT THE PRESENTER vi V COURSE OUTLINE viii 1. SECTION A - SOLAR HEATING WORLDWIDE 1 1.1 Main Markets 1 1.2 Total capacity of glazed water collectors in operation 5 1.3 Market development of glazed water collectors between 2000 and 2012 7 1.4 Exceptional markets and applications for solar thermal systems 10 1.5 Market for solar air conditioning and cooling applications 12 2. SECTION B - POTENTIAL FOR SOLAR HEATING IN INDUSTRIAL PROCESSES 13 2.1 Introduction to TASK 33 INDUSTRIAL SOLAR HEATING POTENTIAL 13 2.2 Potential for Solar Heating in Industrial Processes 14 2.3 Industrial heat demand by temperature range 15 2.4 Industrial sectors and processes 17 2.5 The energy potential for solar process heat in the European Union 21 2.6 Design considerations in Solar Thermal commercial systems 25 2.7 Conclusion on Market Potential 26 3. SECTION C - SOLAR THERMAL THEORY 27 3.1 SOLAR RADIATION 27 3.1.1 Global Radiation 28 3.1.2 Direct Radiation 31 3.1.3 Solar Radiation Data 31 3.1.4 Measuring Instruments 33 3.1.5 Solar Radiation on Tilted Surface 35 3.1.6 Conversion of solar radiation energy into other energy forms 36 3.2 SOLAR COLLECTORS 38 3.2.1 Plastic Absorber 38 3.2.2 Flat Plate Collector 38 3.2.3 CPC Collector 42 3.2.4 Evacuated Tube Collector 43 3.2.4.1 Construction and working principle 43 3.2.4.2 Direct flow evacuated tube collector 45 3.2.4.3 Heat pipe evacuated tube collector 47 3.2.5 Concentrating Collectors 48 3.2.5.1 Parabolic trough collector 49 3.2.5.2 Working principle of a Parabolic trough 50 3.3 PHYSICAL PROCESSES INSIDE A FLAT-PLATE COLLECTOR 51 3.4 COLLECTOR MATERIALS 52 3.4.1 Suitable absorber materials for flat-plate collectors 52 3.4.2 Absorber coating 53 3.4.3 Transparent cover materials 55 3.4.4 Insulating materials 55 3.4.5 Casing 56 I
3.5. PERFORMANCE CRITERIA OF SOLAR COLLECTORS 57 3.5.1 Characteristic Values of Flat-plate and Evacuated Tube Collectors 57 3.5.2 Collector Efficiency Curve 57 3.5.3 Area Definitions 59 3.5.4 Possible Improvements 60 3.6 BUILDING INTEGRATION OF COLLECTORS 3.6.1 Roof Integration of Solar Collectors 61 61 3.6.2 Collector Assembly with Frame Structures 62 3.6.3 Facade Integration of Solar Collectors 65 3.7 THERMAL ENERGY STORAGES 67 3.7.1 Storage Tank for Natural Circulation Systems 67 3.7.2 Pressurised Storage Tank 68 3.7.3 Storage Tank Insulation 71 3.7.4 Heat Losses 71 3.8 OTHER COMPONENTS 73 3.8.1 Expansion Vessel 73 3.8.2 Heat Exchanger 74 3.8.2.1 Coil heat exchangers 75 3.8.2.2 Plate Heat Exchanger 79 3.8.3 Hot Water-mixing Valve 80 3.8.4 Gravity Break and Safety Valve 81 3.8.5 Air Elimination 83 3.8.6 Pumps, Safety Valves, Controller 85 3.9 SYSTEM CONCEPTS AND APPLICATIONS 86 3.9.1 Swimming Pool Heating 86 3.9.2 Thermosyphon Systems for Hot Water Preparation 87 3.9.3 Direct System with Open Circulation 87 3.9.4 Indirect Systems with Hydraulic Separation 89 3.9.5 Domestic Hot Water Systems with Forced Circulation 90 3.9.6 Combi-systems for Hot Water Preparation and Space Heating 92 3.10 DISTRICT HEATING 95 3.11 PILOT- AND DEMONSTRATION PLANTS IN PROCESS HEAT 99 3.12 SOLAR COOLING AND AIR CONDITIONING 103 3.12.1 What is Solar Air Conditioning? 103 3.12.2 How does Solar Air Conditioning Work? 104 3.12.3 Absorption Refrigeration Machines 104 3.12.4 Adsorption Refrigeration Machines 104 3.12.5 Sorption-Assisted Air Conditioning 106 3.12.6 How well do Solar-Assisted Air Conditioning Systems Operate? 107 3.12.7 Energy Balance 107 3.12.8 Cost Effectiveness 107 4. SECTION D - SOLAR THERMAL THEORY 110 4.1 IRRADIATION OR AVAILABLE ENERGY 111 4.2 CONSUMPTION OF HOT WATER 112 4.2.1 Measuring actual consumption 112 4.2.2 Using Fuel bills 113 4.2.3 User Profile Consumption Tables 114 4.2.4 Consumption Profiles 114 4.2.5 Water Saving Measures 115 4.3 SOLAR FRACTION OF THE SYSTEM 115 4.4 SYSTEM EFFICIENCY 116 4.5 COLLECTOR AREA SIZING 116 4.6 STORAGE CAPACITY 117 II
4.7 AUXILIARY VOLUME SIZING 117 4.8 COLLECTOR ARRAY CONFIGURATION 119 4.9 FLOW RATE THROUGH THE SYSTEM 122 4.10 PRESSURE LOSSES IN THE SYSTEM 124 4.10.1 Pressure across the collector Array 124 4.10.2 Pressure in the Pipe runs 125 4.10.3 Components ie. pipe fittings and other components 126 4.11 PIPE DIAMETER 127 4.12 CIRCULATION PUMP SIZING 127 4.13 HEAT EXCHANGER 128 4.14 EXPANSION VESSEL 129 4.14.1 Size of the expansion vessel 129 4.14.2 Charging pressure of the expansion vessel 129 4.14.3 Correct installation of the tank 129 5. APPENDIX 131 5.1 COLLECTORS Powerz-on 131 5.1.1 ST-2.5 MSC (Selective Coating) 131 5.1.2 ST-2.5 BSC (Aluminium Solar Absorber Coating) 132 5.2 PUMPS - WILO 133 5.2.1 STAR RS 25/2 133 5.2.2 STAR RS 25/6 RG 134 5.3 HEAT EXCHANGERS - Alpha Laval 135 5.3.1 Brazed plate heat exchanger 135 III
Foreword I have managed to word and channel a passion and love for the Solar Thermal Technology in the pages of this amazing training manual. Under the mentorship and guidance of Werner Weiss who is globally known for his knowledge and insight in Solar Thermal and have been involved in the largest installations globally, I have constructed a 2 day training curriculum that will transform the South African market s insight into solar thermal at a commercial level. South Africa is faced with major energy challenges and the future is going to be very challenging for our children. Our economy is faced with a major challenge of de-coupling economic growth from energy generation. The only way is a major shift towards renewable energy if we wish to stimulate and transform a sustainable environment and economy for our children and their children. I dedicate this book to my family, a mother that taught a young boy all about perseverance. A wife that keeps me grounded and focussed on the end goal with her attention to detail and absolute perfection, and my 2 daughters that remind me every day why I am doing this, how to live with passion and how to laugh Wally Weber IV
SOUTHERN AFRICAN SOLAR THERMAL TRAINING AND DEMONSTRATION INITIATIVE AEE INTEC LICENCE AGREEMENT This training manual includes material that was prepared by AEE Institute for Sustainable Technologies (AEE INTEC) from Austria for training courses of the project SOLTRAIN. The project SOLTRAIN is financed by the Austrian Development Agency (ADA). Implementing organisation: AEE - Institute for Sustainable Technologies from Austria in cooperation with project partners from Lesotho (BBCDC), Mozambique (Eduardo Mondlane University), Namibia (Polytechnic of Namibia), South Africa (Sustainable Energy Society of Southern Africa and Stellenbosch University) and Zimbabwe (Domestic Solar Heating). BLACKDOT Energy was authorised to use this training manual for its solar thermal training courses in South Africa based on the agreement that only qualified trainers may partcipate in these courses. AEE - Institute for Sustainable Technologies A-8200 Gleisdorf, Feldgasse 19, Austria Tel.: +43-3112-5886, Fax: +43-3112-5886-18 E-mail: office@aee.at AEE INTEC AEE, Institute for Sustainable Technologies Feldgasse 19, A-8200 Gleisdorf, Austria, 2014 Reprinting or reproduction, even partial or in modified form, is allowed by permission of AEE INTEC BLACKDOT Energy is a co-operation partner of SOLTRAIN V
About the Presenter - WALLY WEBER: An Industrial Engineer with a Passion for Manufacturing and Renewable Energy with qualifications including B-Tech (Industrial Engineering), BSc (Hons) Business Systems. With more than 14 years in the manufacturing industry as engineer, plant manager, project manager and entrepreneur, his experience includes 8 years as business owner with manufacturing plants in Cape Town, Rosslyn and Garankuwa. In 2006 the company completed the Cape Recovery Program for ESKOM in the Western Cape manufacturing and installing 122,500 Geyser Blankets within eight weeks, saving a massive 5,82 MW. During 2011 a major achievement involved in designing and building a Solar Thermal Flat Plate Panel manufacturing plant for a local solar company in Midrand. With full SABS accreditation on both the product and the manufacturing plant, to be accomplished within eight months. A further highlight in 2011 involved a partnership with Pioneer Plastics to develop a Renewable Energy product division and establishing Pioneer Plastics Energy that has to date launched the Raditherm Roof Insulation range, Plumb-Easy Geyser Blankets, Little Green Monster domestic Biogas tanks and Large Scale Solar Thermal Storage Tanks. In 2013 he started a new manufacturing plant in Rosslyn called ENERGYWEB. Energyweb continued with the Roof Insulation range and the Geyser Blankets. It s a family owned business that lives the passion they have for the Renewables Environment. He also successfully completed the SOLTRAIN solar training and the German RENAC training program in Large Scale Solar Thermal. He presented training programs for Industry on Large Scale Solar Thermal for 3 years and is part of the South African success story of Renewable Energy Technology development. This passion for Solar and training sparked the birth of BLACKDOT Energy in 2014. A training business focussed on the Renewable Technologies in SA. The business core focus is training of professionals and expanding the market awareness in Solar applications. VI
Holms and Friends provide supreme solar solutions for buildings. South Africa has one of the worlds highest solar radiation, we bring you the service and the quality to use it effectively. Our core competencies: Ţ Ţ Ţ Ţ Energy strategies and project management Solar thermal systems Solar Photovoltaic systems Training (Education for Sustainable Development & Continuous Professional Development) Mail & Guardian 2009 eta 2010 Contact us now: Sanea 2011 Eskom eta-awards. Residential category 2013 PO Box 2160 / Xanadu Crossing / 0279 South Africa T: +27 (0)82 809 0190 F: +27(0)86 642 5128 info@holmsandfriends.co.za www.holmsandfriends.co.za Holms and Friends VII
2 DAY COURSE OUTLINE: This unique 2 day course has been designed for engineers, architects, contractors, specifiers, quantity surveyors, project- and construction managers and individuals who are involved with, or who has a keen interest in Solar Thermal technology. Course content is intended to expose candidates to the calculations, components, and design of large scale solar thermal systems. The course is broken down into 6 modules: 1. Solar Radiation & Solar Collectors 2. Collector Materials & Performance 3. Building integration, Thermal storage & System components 4. System Concepts & Applications 5. Dimensioning; Practical challenges & solutions 6. Solar Thermal Process Heat Reference is made to locally installed and operational Large Scale Solar Thermal systems on a Technical level to facilitate understanding in terms of design, optimization, construction and commissioning. The training materials aim to provide a strong theoretical base with information extracted from various recognised institutions including SOLTRAIN (AEE-INTEC). The outcome is a curriculum that provides a realistic and current view on the solar thermal market, capacity and potential of the trading environment in SA; giving attendees an understanding of components, system design and construction parameters, commissioning procedures, project planning and calculations pertaining to Solar Thermal systems. The course participant will be able to design a solar hot-water system with a size ranging from 500 Litres to 50,000 Litres using the RET-Screen software as well as calculate and size the basic components including collectors. VIII
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SECTION A 1 SOLAR HEAT WORLDWIDE 1.1 Preview 2014 The estimated total capacity of solar thermal collectors in operation worldwide by the end of 2014 is 406 GWth, or 580 million squaremeters of collector area. This corresponds to an annual collector yield of 341 TWh, which is equivalent to savings of 36.7million tons of oil and 118.6million tons of CO2. The preview for 2014 is based on latest market data from Austria, Brazil, China, Germany and India, which represented more than 82% of the cumulated installed capacity in operation in the year 2013. The other countries were estimated according to their trend over the past two years. Compared with other forms of renewable energy, solar heating s contribution in meeting global energy demand is, besides the traditional renewable energies like biomass and hydropower, second only to wind power (Figure 1). Considering installed capacity, solar thermal is leading. Total capacity in operation [GWet ], [GWth] and produced energy [TWhet/a], [TWhth/a], 2014 Figure 1: Total capacity in operation [GWel], [GWth] 2014 and annual energy generated [TWhel], [TWhth] (Sources: AEE INTEC,GWEC, EPIA, IEA PVPS, Navigant Research, Ocean Energy Systems, REN21, U.S. Geothermal Energy Association) Table 1: Total capacity in operation by the end of 2012 [MWth] Note: If no data is given: no reliable database for this collector type is available. FPC: flat plate collector; ETC: evacuated tube collector * Total capacity in operation refers to the year 2009 ** Total capacity in operation refers to the year 2011 *** Total capacity in operation is based on estimations for new installations in 2012 # New included countries compared to the 2013 edition of this report + The figures for France relate to mainland France only, overseas territories of France (DOM) are not considered 1