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© Fraunhofer ISE
Solar Process Heat: Available technologies, potential and applications
Pedro Horta Fraunhofer Institute for Solar Energy Systems ISE 25.09.2017, PENRA Workshop, Ramallah www.ise.fraunhofer.de © Industrial Solar
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Solar Process Heat Available technologies, potential and applications
Which technologies are available?
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 Palestine
Industrial sectors
Energy sources and costs
Solar resource
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Solar thermal technologies Technology vs. Temperature
Solar collector technology vs. required process temperature
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Potential for Palestine Industrial sector and energy sources
Most important Industrial sectors in the State of Palestine [16]:
Food and Beverages T < 250°C (32% Manufacturing Value Added per capita - MVA, 18% Total Manufacturing Employment – TME)
Non-metallic mineral products (18% MVA, 21% TME) T > 400°C
Fabricated metal products (12% MVA, 11% TME) T < 250°C
Furniture manufacturing (9%, 17% TME) electricity
Direct impact on 44% MVA, 29% TME:
Additional applications in services: hospitals , schools
Direct substitution of oil-based products
safety of supply
[16] UNIDO Statistics Unit, 2015. http://www.unido.org/statistics [17] Palestinian Central Bureau of Statistics, State of Palestine, 2015. http://www.pcbs.gov.ps/site/lang__en/886/Default.aspx
Share of Industrial Final Energy Consumption by energy source in the State of Palestine, 2015 [17]
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Solar Process Heat Available technologies, potential and applications
Which technologies are available?
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 Palestine
Industrial sectors
Energy sources and costs
Solar resource
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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
T
LT / s tationary collectors : • Higher optical efficiency • Higher thermal losses
MT / tracking collectors : • Lower optical efficiency • Lower thermal losses
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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)
[1] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region [2] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
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
[1] GAMESA-QUAKER PEPSICO MEXICO Mexico © Modulo Solar
in [2]
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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)
[1] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region [2] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
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)
[2] Harita Seatings Systems Limited India © @aspirationenergy
in [2]
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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)
[2] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016). [3] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information
Lesa Dairy Switzerland © ezw
in [2]
[3]
v
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
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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)
[3] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information
RAM Pharmaceuticals Jordan © Industrial Solar
[3]
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
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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)
[3] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information
[3]
Parabolic Dish: • common temperature range of 250°C – >400°C • Point-focusing system (2-axis tracking) • Moving (modular) receiver • Potential for higher temperatures
Tirumala Tirupati Devasthanams India © Gadhia Solar Energy Systems
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Solar thermal technologies Technology vs. Temperature
Solar collector technology vs. required process temperature
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Stationary technologies
Existing projects Examples
[5] Arcon-Sunmark, 2015. http://arcon-sunmark.com/cases/codelco-minera-gaby-chile [6] http://ship-plants.info/solar-thermal-plants/140-jiangsu-printing-and-dyeing-china?collector_type=4&country=China
Textile Jiangsu Yitong, China Evacuated Tube Aperture: 9,000 m2 Application: process pre-heating Oper. Temp.: 50°C Commissioning : 2011
© Sunrain Co. Ltd [6]
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
© Arcon-Sunmark [5]
Currently largest plant in the world
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Tracking technologies
Existing projects Examples
[7] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/ [8] http://ship-plants.info/solar-thermal-plants/155-dairy-plant-el-indio-mexico?collector_type=5
Dairy El Indio, Mexico Parabolic Trough Aperture: 132 m2 Application: Make-up water pre-heating Oper. Temp.: 95°C Commissioning : 2012
© Inventive Power S.A. de C.V. [8]
Services MTN Johanesburg, S .Africa Linear Fresnel Aperture: 396 m2 Application/End Use: Air conditioning Oper. Temp.: 180°C Commissioning : 2014
© Industrial Solar [7]
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Direct Steam Generation
Saturated Steam 160°C
20 minutes Steam Storage for increased stability
https ://www.youtube.com/ watch?v=ibiUoACea6o
Existing projects A nearby example: RAM Pharmaceuticals, Jordan
[7] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/
RAM Pharmaceuticals Amman, Jordan Linear Fresnel Aperture: 396 m2 Application/End Use: Process Steam Oper. Temp.: 160°C Commissioning : 2015
[7]
© Industrial Solar
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Stable steam pressure under variable solar radiation conditions
Existing projects A nearby example: RAM Pharmaceuticals, Jordan
[7] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/
So
lar
rad
iati
on
(D
NI)
[W
/m2
]
© Industrial Solar [7]
Ste
am
pre
ssu
re [
ba
r]
© Industrial Solar
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Upcoming
Existing projects Examples
[9] MIT, 2016. Technology Review, Arab Edition. http://technologyreview.me/en/energy/oman-explores-solar-powered-oil-recovery/
Amal Solar EOR Pilot Project, Oman Parabolic Trough in greenhouse Thermal Power: 1 GWth Production (pilot): 6 ton steam / day
© Industrial Solar [9] © Petroleum Development Oman.
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Solar Process Heat Available technologies, potential and applications
Which technologies are available?
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 Palestine
Industrial sectors
Energy sources and costs
Solar resource
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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]
[10] Energy Technology Perspectives 2012 - Pathways to a Clean Energy System, Int. Energy Agency (2012)
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Sectors Heat for Industrial Processes
Heat related Final Energy Consumption (FEC) in Industry [11] comparable to Transport or Building sectors. Distribution: EI 54%, Non-EI 46%
[11] Adapted from IEA - International Energy Agency (2014). Statistics: Energy Balance Flows. http://www.iea.org/statistics/
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Temperature levels Heat for Industrial Processes
Heat requirements in Industry occur at different temperature levels in different sectors [12]: ~ 50% HT; ~ 50% MT + LT
[12] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [2] (2014)
EI sectors
HT (>400°C) 42,5 EJ
MT (150°c-400°C) 18,1 EJ
LT (<150°C) 24,5 EJ
EI
Non-EI
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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
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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% [13]
Pinch analysis enables an overview of cross-process heat exchange possibilities [5]
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
[13] Saygin, D., Patel, M.K. and Gielen, D.J. (2010). Global Industrial Energy Efficiency Benchmarking: An Energy Policy Tool, Working Paper, November 2010. United Nations Industrial Development Organization (UNIDO), Vienna. [5] Muster, Bettina et al., 2015. Guideline for solar planners, energy consultants and process engineers giving a general procedure to integrate 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
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Dilemma: less resistance to integration at supply level vs. lower temperatures in integration at process level
Design procedures Solar integration
80°C-120°C
15°C-30°C
P1 160°C
P2 80°C
P3 50°C
50°C-90°C
160°C-180°C
11
0°C
-130
°C
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Dilemma: less resistance to integration at supply level vs. lower temperatures in integration at process level
Design procedures Solar integration
80°C-120°C
15°C-30°C
P1 160°C
P2 80°C
P3 50°C
50°C-90°C
160°C-180°C
11
0°C
-130
°C
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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
Process optimization and EE measures [15]
Processes state-of-the-art? Future plans?
Heat exchanger optimization (pinch analysis)
[14] www.solar-process-heat.eu/checklist [15] C. Brunner et al. 2010: IEE-Project Einstein: www.iee-einstein.org
[14]
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Solar Process Heat Available technologies, potential and applications
Which technologies are available?
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 Palestine
Industrial sectors
Energy sources and costs
Solar resource
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Potential for Palestine Industrial sector and energy sources
Most important Industrial sectors in the State of Palestine [16]:
Food and Beverages T < 250°C (32% Manufacturing Value Added per capita - MVA, 18% Total Manufacturing Employment – TME)
Non-metallic mineral products (18% MVA, 21% TME) T > 400°C
Fabricated metal products (12% MVA, 11% TME) T < 250°C
Furniture manufacturing (9%, 17% TME) electricity
Direct impact on 44% MVA, 29% TME:
Additional applications in services: hospitals , schools
Direct substitution of oil-based products
safety of supply
[16] UNIDO Statistics Unit, 2015. http://www.unido.org/statistics [17] Palestinian Central Bureau of Statistics, State of Palestine, 2015. http://www.pcbs.gov.ps/site/lang__en/886/Default.aspx
Share of Industrial Final Energy Consumption by energy source in the State of Palestine, 2015 [17]
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Potential for Palestine Solar resource
Very favourable solar resource conditions
stationary technologies (T < 100°C) Global Horizontal Irradiation (GHI)
1900 – 2150 kWh/m2
[18]
[18] solargis. http://solargis.com/
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Potential for Palestine Solar resource
Very favourable solar resource conditions
tracking technologies (100 °C < T < 250 °C) Direct Normal Irradiation (DNI)
1900 – 2100 kWh/m2
[18]
[18] solargis. http://solargis.com/
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Potential for Palestine Technology vs. energy costs
Current technology costs [19]:
220 – 620 €/m2
Current average oil products driven heat production costs [20]:
104 – 188 €/MWhth
(0.104 – 0.188 €/kWhth)
[21]
[19]
[19] adapted from Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016). [20] Calculations based on average consumer costs for different energy sources, in [17], and fuel to heat conversion efficiency of 85% [21] adapted from Stryi-Hipp, G. et al., 2012. Strategic Research Priorities for Solar Thermal Technology. Renewable Heating and Cooling – European Technology platform and World Bank, 2016. Commodity Markets, Price forecasts and Annual prices. http://www.worldbank.org/en/research/commodity-markets.print. Online October 2016
h = 50% GHI, DNI = 2000 kWh/m2
(220 – 620 €/m2) / (0.104 – 0.188 €/kWhth)
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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, fabricated metal
Hospitals (steam), schools (hot water)
Potential for Palestine
Very favourable solar resource GHI 1900 – 2150; DNI 1900 – 2100 kWh/m2
Very favourable economic conditions
LCOHcurr ~ 104 – 188 €/MWhth / LCOHsolar ~ 15 – 41 €/ MWhth
Very important vector of security of supply security of industrial production
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Thank you for your attention!
Fraunhofer Institute for Solar Energy Systems ISE Pedro Horta www.ise.fraunhofer.de [email protected]