Case studies & Opportunities: Clean Process Heat · Case study •Location •Industry ... De Bortoli Winery ... Opportunities for Australia How do these case studies apply to the

Case studies & Opportunities: Clean Process HeatJeremy Osborne – Director

12/12/2016Cases studies & Opportunites: Clean Process Heat. J.

Osborne Melbourne1

2

Enabling innovation for sustainable future

Research and Development

Consulting

Software sales and training

Project development & implementation

Solar thermal / PV

Storage

Building energy

Heat pumps

Expertise

Numerical Modelling

System Design

Project Management

Technical advisory

Services

12/12/2016Cases studies & Opportunites: Clean Process Heat. J. Osborne

Melbourne

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Our Team

Australian Distributor for TRNSYS software www.trnsys.com

Training in TRNSYS: https://learn.trnsys.guru/

Dr Fiona McClure Jeremy Osborne Alastair McDowell Erika Degoute Dr Mike Dennis


Melbourne

http://www.trnsys.com/

https://learn.trnsys.guru/

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


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Case study

• Location

• Industry

• Technology

• Design concept

• Cost

• Performance


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Chile - Copper Processing


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Location: Minera Gabriela Mistral copper mine and processing site

100 km south of Calama, in the Atacama Desert

Source: ARCON SUNMARK, Google


Melbourne8Source: ARCON SUNMARK

Chile - Copper Processing

Source: ARCON SUNMARK

• Technology: Flat Plate Solar Thermal• Turnkey supplier: Energia Llaima and Arcon-Sunmark• Customer: Codelco mining company• Size: 27MW, 39,000m2 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.


Melbourne9

Solar Thermal - Chile Copper Mine 20134300m3 Storage Tank



2620 panels, 15m2 each



Process IntegrationSupply 50°C hot water for electrowinning



Performance


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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

UK- Chocolate factory with HP


Melbourne14

Location: Halifax, UK

Source: Google

Replaces an old Coal Boiler


Melbourne15Source: Star Refrigeration Ltd.

UK- Chocolate factory with HP

Source: Star Refrigeration Ltd.

• 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


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Cooling Only mode


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Heat pump CondenserEvaporatorQ

Provide cooling

Q Q

Pro

cess

5degC

0degC

Q

Elec

3.2MW

4.0MW

0.8MW

𝐶𝑂𝑃𝑐𝑜𝑜𝑙𝑖𝑛𝑔 =3.2

0.8= 4

Estimated COP


Rejects heat to atmosphere to town heating supply

Heat and Cooling Mode


Melbourne18

Heat pump CondenserEvaporatorQ

Provide cooling

Q Q

Rejects heat to atmosphere to town heating supply

Pro

cess

5degC

0degC

Q

Elec

3.2MW

2.8 MW

0.8MW

Provide Heating to process or gas boiler

Q

10 degC

60 degC

1.2MW

𝐶𝑂𝑃𝑐𝑜𝑜𝑙𝑖𝑛𝑔+ℎ𝑒𝑎𝑡𝑖𝑛𝑔 =3.2 + 1.2

0.8= 5.5

Estimated COP

Star Ref. provides the COPc+h = 6.38 – this is likely due to part load improvements


Economics


Melbourne19Source: Star Refrigeration Ltd

Paris Creek – Dairy

Location: Paris Ck Rd, Paris Ck, South Australia


Melbourne20Source: Google

Whole of site energy

Energy Efficiency

• Power Factor Correction

• Heat Recovery

• Soft-start

Clean Electricity

• Solar PV – 100kW

Clean Heat

• Solar thermal – 150kW


Melbourne21

47% reduction in GHG emissions and financial saving $125,000 per year

Source: Clean Technology Food and Foundries Investment Program and Paris Creek Farm interview.



Melbourne22Source: LCi


Source: BD farms, LCi, ARENA

• Technology: Evacuated Tube Solar Thermal• Supplier: Greenland Systems, LCi• Customer: BD farm Paris Creek• Size: 140 kW, 169 m2 solar field• Industry: Dairy Processing• Capital Cost: $350,000 (not including grants) • Sales model: Cash sale with government grants• Start-up: August 2014


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2014 :$2000/m2 for complete project including collector, BOP, integration.

2016: $300-600/m2 forground-mount large field

Many opportunities for price reductions!

Process integration


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Source: EnergyAE and LCi

SOLAR

COLLECTORS

SOLAR

STORAGE

T1

T2

T3

HX

Return from

process

To the boiler

Pasteurizer

Heat

HX

75° C

60 x Greenland Systems

GL100-16

7m3 storage vessel

Pump Pump

Pump

Pump

De Bortoli Winery


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Location: Griffith NSW

Source: Google

De Bortoli Winery


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• Technology: Evacuated tube Solar Thermal• Supplier: Apricus, The Solar Project, Fletchers Plumbing• Customer: De Bortoli Winery • Size: 200 kW Heating, 280 m2 solar field• Design concept: Provide pre-heating to a condensing gas boiler• Industry: Winery• Start-up: May 2013

Source: Apricus, ITPower 2015

De Bortoli Winery


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Source: Apricus Australia, ITPower 2015

100x AP30 Apricus Collectors280m2 solar field

12 m3 storage at 95°C

Australian Tartaric Products - Colignan


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Source: ITPower 2015, Australian Tartaric Products

Location: Colignan, Victoria

Australian Tartaric Products - Colignan


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• Technology: Biomass boiler, Organic Rankin Cycle (ORC) • Supplier: • Customer: Australian Tartaric Products• Size: 8MWth Boiler, 600kWe 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

More Case Studies

All

https://arena.gov.au/resources/renewable-energy-options-for-australian-industrial-gas-users/

Solar thermal

http://ship-plants.info/

Heat Pumps

http://heatpumpingtechnologies.org/publications/application-of-industrial-heat-pumps-part-1/


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https://arena.gov.au/resources/renewable-energy-options-for-australian-industrial-gas-users/


http://heatpumpingtechnologies.org/publications/application-of-industrial-heat-pumps-part-1/

More Case Studies

Bioenergy

http://www.bioenergyaustralia.org/pages/case-studies.html


Melbourne31

http://www.bioenergyaustralia.org/pages/case-studies.html

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 Heating1. Bioenergy2. Solar thermal 3. Heat pumps (with PV) – now – low temperature, future - high temperature4. Electric boilers and furnaces (with PV) – High temperature


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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.


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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


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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


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Energy Expenditure by Temperature

$-

$0.5

$1.0

$1.5

$2.0

$2.5

Food, Beverage,Tabacco

Textiles Paper andprinting

Chemical,Polymer and

Rubber

Glass Ceramics Cement, lime,plaster and

concrete

BIL

LIO

NS

Expenditure below 60C Expenditure between 60C-100C

Expenditure 100C-150C Expenditure greater than 150C

Source: BREE, IEA, Fuller, UNIDO and EnergyAE analysis


Melbourne36

Low temperature is a great opportunity for solar thermal and heat pumps

# Sites in Food and Beverage Australia

94

1

53

15

10

21

25

36

65

Meat and Meat Product Manufacturing

Seafood Processing

Dairy Product Manufacturing

Fruit and Vegetable Processing

Oil and Fat Manufacturing

Grain Mill and Cereal Product Manufacturing

Bakery Product Manufacturing

Sugar and Confectionery Manufacturing

Other Food Product Manufacturing

0 10 20 30 40 50 60 70 80 90 100


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Great opportunity: Conservative companies look to what others have done in their industry. Focusing one

sub-sector at a time is important

# Sites in Chemical Australia


Melbourne38

102

8

24

18

12

30

97

2

0 20 40 60 80 100 120

Basic Chemical

Basic Polymer

Fertiliser and Pesticide

Pharmaceutical and Medicinal

Cleaning Compound and Toiletry Preparation

Other Basic Chemical

Polymer

Natural Rubber

Great opportunity

Map of Sites for Food, Beverage and Chemical


Melbourne39

Source: EnergyAE

Chemical site

Food and Beverage site

VICTORIAAustralia

Natural Gas pipeline

Food sites away from Natural gas

Food sites are regional, on more expensive LPG –

Great opportunity

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)


Melbourne40

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


Melbourne41

Call us for help!

http://energyae.com/

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!


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Reference


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• BREE, 2014 Australian energy statistics data 2014. available at http://www.bree.gov.au/publications/australian-energy-statistics/2014-australian-energy-statistics-data

• 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

http://www.bree.gov.au/publications/australian-energy-statistics/2014-australian-energy-statistics-data


Thank you! Jeremy Osborne

[email protected]

http://energyae.com

+61400063327

12/12/2016Cases studies & Opportunites: Clean Process Heat. J.

Osborne Melbourne44

http://energyae.com/

Documents

Case studies & Opportunities: Clean Process Heat · Case study •Location •Industry ... De Bortoli Winery ... Opportunities for Australia How do these case studies apply to the