Case studies & Opportunities: Clean Process Heat Jeremy Osborne Director Cases studies & Opportunites: Clean Process Heat. J. Osborne 1
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
Our Team Dr Fiona McClure Jeremy Osborne Alastair McDowell Erika Degoute Dr Mike Dennis Australian Distributor for TRNSYS software www.trnsys.com Training in TRNSYS: https://learn.trnsys.guru/ 3
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
Case study Location Industry Technology Design concept Cost Performance 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
Source: ARCON SUNMARK 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 2013. Source: ARCON SUNMARK 9
Solar Thermal - Chile Copper 4300mMine 3 Storage 2013 Tank Source: ARCON SUNMARK 10
2620 panels, 15m 2 each Source: ARCON SUNMARK 11
Process Integration Supply 50 C hot water for electrowinning Source: ARCON SUNMARK 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
UK- Chocolate factory with HP Location: Halifax, UK Source: Google 14
Replaces an old Coal Boiler Source: Star Refrigeration Ltd. 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
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 = 3.2 0.8 = 4 0.8MW Source: Star Refrigeration Ltd. 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 3.2 + 1.2 COP cooling+heating = = 5.5 0.8 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 18 60 degc
Economics Source: Star Refrigeration Ltd 19
Paris Creek Dairy Location: Paris Ck Rd, Paris Ck, South Australia Source: Google 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
Paris Creek Dairy Source: LCi 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 2014 2014 :$2000/m2 for complete project including collector, BOP, integration. 2016: $300-600/m2 for ground-mount large field Many opportunities for price reductions! Source: BD farms, LCi, ARENA 23
Process integration 60 x Greenland Systems GL100-16 75 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
De Bortoli Winery Location: Griffith NSW Source: Google 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 2015 26
De Bortoli Winery 100x AP30 Apricus Collectors 280m 2 solar field 12 m 3 storage at 95 C Source: Apricus Australia, ITPower 2015 27
Australian Tartaric Products - Colignan Location: Colignan, Victoria Source: ITPower 2015, Australian Tartaric Products 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 2015 29
More Case Studies All https://arena.gov.au/resources/renewable-energy-options-for-australianindustrial-gas-users/ Solar thermal http://ship-plants.info/ Heat Pumps http://heatpumpingtechnologies.org/publications/application-of-industrialheat-pumps-part-1/ 30
More Case Studies Bioenergy http://www.bioenergyaustralia.org/pages/case-studies.html 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
Where does each technology work? Solar thermal: 1. Space required for collectors: 1. 0.35-0.7 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 60-100% solar fraction 100% generally difficult, Ratio of collector to roof or ground space: 2. 1.5 possible if flat on roof, 3 for trough collectors. 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
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
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
# 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 10 15 21 25 36 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 94 0 10 20 30 40 50 60 70 80 90 100 37
# Sites in Chemical Australia Natural Rubber 2 Polymer 97 Other Basic Chemical 30 Cleaning Compound and Toiletry Preparation Pharmaceutical and Medicinal 12 18 Great opportunity Fertiliser and Pesticide 24 Basic Polymer 8 Basic Chemical 102 0 20 40 60 80 100 120 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
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
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 2017. 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
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
Reference BREE, 2014 Australian energy statistics data 2014. available at http://www.bree.gov.au/publications/australian-energy-statistics/2014-australian-energy-statisticsdata IEA, 2012 Energy Statistics available at http://www.iea.org/sankey/#?c=australia&s=final 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. 2010 IEA 2008, Potentail for Solar Heat in Industry. s.l. : IEA, 2008. SHIP database, 2014 http://ship-plants.info/ ITPower, 2015 Renewable Energy Options For Australian Industrial Gas Users 43
Thank you! Jeremy Osborne jeremy.osborne@energyae.com http://energyae.com +61400063327 Cases studies & Opportunites: Clean Process Heat. J. Osborne 44