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© Fraunhofer ISE
SEMINARIO SOLAR FRAUNHOFER CHILE - CSET CALOR SOLAR PARA PROCESOS
Solar Thermal Technologies for Process Heat Applications: available solutions and process temperature suitability
Peter Nitz Pedro Horta 20th April 2016 Fraunhofer Institute for Solar Energy Systems ISE
Freiburg, Germany
www.ise.fraunhofer.de
© Fraunhofer ISE
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Introduction Heat for Industrial Processes Energy use in Industry
Thermally driven processes present the largest share of final energy use in Industry
electricity stands for 31% of final energy consumption in Industry [1]
Electricity driven processes include
Surface deposition processes (electroplating, anodization, etc)
Melting processes in Electric Arc Furnaces
Cooling and vacuum
Motor driven systems (compressed air, pumping)
lighting
[1] Final energy consumption by sector and fuel, European Environment Agency. http://www.eea.europa.eu/data-and-maps/indicators/final-energy-consumption-by-sector-8/assessment-2 (2015)
Share of different energy sources in final energy consumptions on the Industrial Sector, 2012 (adapted from [1])
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Introduction Heat for Industrial Processes Heat Generation by Sector
Thermally driven processes present the largest share of final energy use in Industry: Worldwide, 45% of heat is used in Industry [2]
[2] Energy Technology Perspectives 2012 - Pathways to a Clean Energy System, Int. Energy Agency (2012)
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Introduction Heat for Industrial Processes Generation of Heat
Worldwide 66% of heat is generated by fossil fuels [2]
[2] Energy Technology Perspectives 2012 - Pathways to a Clean Energy System, Int. Energy Agency (2012)
Heat generation by region for different fuel types (2009) [2]
88% 61%
21%
91%
60%
59%
100%
79%
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Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability
Solar collectors
Overview
Stationary collectors
Flat Plate collectors and variants
Evacuated collectors and variants
Tracking collectors
Parabolic Trough
Linear Fresnel
other concepts
Process Heat: sectors and processes, examples in Chile
Summary
© Fraunhofer ISE
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Solar collectors Overview
Solar thermal collector
heat exchanger converting the solar radiation into heat
transfers this heat to a working fluid (e.g. air, water, thermal oil) circulating through the system
solar energy collected is carried from the working fluid to the load/use or to energy storage tank to be used later
different technologies for different operating temperature levels
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Solar collectors Overview Collector Efficiency
The efficiency of a solar collector depends on incidence angle dependent optical losses and on operating temperature dependent thermal losses
Temp. Difference 0 40K 80K 120K @ G=800 W/m²
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Solar collectors Overview Operating Temperatures
Thus the selection of a specific solar collector technology is intrinsically related to the required temperature at the heat delivery point
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Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability
Solar collectors
Overview
Stationary collectors
Flat Plate collectors and variants
Evacuated collectors and variants
Tracking collectors
Parabolic Trough
Linear Fresnel
other concepts
Process Heat: sectors and processes, examples in Chile
Summary
© Fraunhofer ISE
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Solar collectors Stationary Collectors Flat Plate Collectors (FPC) and Variants
Commonly used for temperatures in the range of 30 °C to 100 °C
Source: gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region
Comprise of absorber tubes through which working fluid flows and is covered by absorber sheet and a transparent cover.
Coating on the absorber converts the solar irradiation to heat which is transferred to the working fluid in the tubes.
Usual fluid is water/glycol mixture (with some additives) in order to avoid corrosion and frost damages
Simple to use as there is little maintenance and relatively cheap.
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Solar collectors Stationary Collectors Flat Plate Collectors (FPC) and Variants
Examples – Electro Winning in Copper Mine
Copper mine “Gabriela Mistral”, Chile
39.300 m2 FPC
Non pressurized water storage (4300 m3)
85-100% solar fraction
electro winning of copper
electrolyte kept at 50°C
cleaning processes
Source: http://www.arcon.dk/
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Improved Medium Temperature Flat-Plate Collectors
0%
10%
20%30%
40%
50%
60%
70%80%
90%
100%
0 50 100 150 200 250Temperature diff. Top-Ta [K]
Effic
ienc
y [%
]
FPC Standard
FPC with double glazing
FPC Honeycomb
FPC with CPC internally
Reduced heat losses double glazed, AR coatings
CPC flat plate
honeycomb collector
Operation temperature up to 80°C for flat-plate
up to 100°C-120°C for honeycomb and double glazing
Improvement of optical efficiency difficult
Can heat loss be further reduced? Other possibilities?
Efficiency for Irradiation 850 W/m2, IAM=1
Solar collectors Stationary Collectors Flat Plate Collectors (FPC) and Variants
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Solar collectors Stationary Collectors Evacuated Tube Collectors (ETC) and Variants
Can achieve higher temperature than FPC ranging from 50 to 130°C
Consists of a row of parallel vacuum glass tubes. Absence of air highly reduces convection and conduction thermal losses.
2 categories of ETC: Direct flow principle: the heat transfer
fluid of the collector loop flows directly through the absorber via a co-axial tube
Heat pipes principle: the heat of the absorber is transferred to the heat transfer fluid of the collector loop via a heat pipe system (Figure 5 right).
Source: gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region
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Solar collectors Stationary Collectors Evacuated Tube Collectors (ETC) and Variants
Compound Parabolic Concentrator ETC (RPC)
Low concentration CPC (C < 2) Evacuated tubes CPC collectors
which can deliver up to 200°C;
Stationary collector – CPC is designed in a way that all solar positions during a year a accepted by the concentrator
Bridges the gap between the lower temperature application FPC (<80°C) to the higher temp. applications of concentrators (T>200°C)
Source: Linuo Solar, : http://image.tradevv.com/2010/11/18/linuosolar001_1741789_600/cpc-solar-collector.jpg
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Solar collectors Stationary Collectors Evacuated Tube Collectors and Variants
Evacuated Flat Plate: Thermal Vacuum Power Charged™ (I)
advantage of high vacuum insulation in a planar layout
Flat plate vacuum collector TVP MT-Power 3rd prize INTERSOLAR 2012
operation temperatures up to 160°C – 200°C
0%10%20%30%40%50%60%70%80%90%
100%
0 50 100 150 200 250
Temperature diff. Top-Ta [K]
Effic
ienc
y [%
]
FPC Standard
FPC Vacuum
VTC process heat
VTC Standard
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Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability
Solar collectors
Overview
Stationary collectors
Flat Plate collectors and variants
Evacuated collectors and variants
Tracking collectors
Parabolic Trough
Linear Fresnel
other concepts
Process Heat: sectors and processes, examples in Chile
Summary
© Fraunhofer ISE
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Solar collectors Tracking Collectors Parabolic Trough Collectors (PTC)
Parabolic mirror focuses only direct sun-light onto an absorber tube
Designed to track the sun along one axis oriented in the north-south or east-west direction.
Reflecting surface normally a curved glass mirror or an aluminium sheet
Water or thermal oil usually used as working fluid
Receptor consists of an absorber tube of an area usually 25 to 35 times smaller than the aperture
Source: gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region
© Fraunhofer ISE
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Solar collectors Tracking Collectors Parabolic Trough Collectors (PTC)
PolyTrough 1200 and 1800 – NEP Solar (AUS/CH)
Width: 1.2 or 1.8 m
Oper. Temp. 250°C
24m long and 1.6m high (standard 1200 collector)
Various receiver options
© NEP Solar
Source: http://www.nep-solar.com/
Shopping Center Newcastle, Australia Aperture: 345m2 (PolyTrough 1200) Peak Thermal Power: 200kW Outlet Temperature: 180°C HTF: Water Application/End Use: Air conditioning Commissioning : April 2011
© NEP Solar
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Solar collectors Tracking Collectors Parabolic Trough Collectors (PTC)
Soltigua (I) - PTM parabolic trough collector
TECHNOLOGICAL EXCELLENCE In 2010 PTM has been awarded the “Towards the A-class building” prize at the at MCE2010, Europe’s largest trade fair for heating and air conditioning.
The prize was given to the best innovations for building energy systems.
Surface = 13.5 sqm/module
Length = 6.2 mt/module
Peak power = 570 W/m2 (7.7 kW/module @DNI of 1000 W/m2, Tamb= 30°C, Tout = 200°C)
25 mt –long / 54 sqm / 31 kWpeak
first collector tested under the new European standard for concentrating collectors up to 250°C
Installation in Gambettola (I), a solar cooling systems with concentrating collectors and double effect absorptions chiller
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Solar collectors Tracking Collectors Parabolic Trough Collectors (PTC)
Solarlite (D)
Production of PTC collectors 2300 and 4600 for:
process heat
concentrated solar thermal power
2.3 m and 4.6 m aperture
operation up to 400°C / 55 bar
12m segment
variable size of plant
Costs comparable with larger CSP collectors instead of small plant size
© Solar Lite
© Fraunhofer ISE
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Solar collectors Tracking: Parabolic Trough collectors
Sopogy (USA) – SopoNova 4.0
Geometrical features
Length: 3.66 m
Width: 1.52 m
Center to Center Spacing: 2.59 m
Reflector Aperture Area: 5.07 m2
Reference installation
Masdar cooling project
http://sopogy.com/
© Fraunhofer ISE
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Solar collectors Tracking Collectors Linear Fresnel Reflector (LFR / LFC)
Many nearly flat mirror facets instead of one parabolic mirror
Receiver/Absorber is above mirror rows, which track the sun
High concentration ratio and temperatures up to 400°C
Thermal capacity from 50 kW up to several MW.
Easy to mount on flat roofs as a result of good weight distribution and low wind resistance.
Water/steam or thermal oil usually used as working fluid
High surface coverage
Source: Industrial Solar Gmbh
© Fraunhofer ISE
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Solar collectors Tracking Collectors Linear Fresnel Reflector (LFR / LFC)
Industrial Solar GmbH (Freiburg, Germany)
Geometrical features
Length: modular in steps of 4 m
Total width: 7.5 m
Aperture width: 5.5 m
Height: 4 m
Weight: 27 kg/m²
Peak power: 560 W/m²
Max. temp. : 400 °C
MTN Johanesburg, South Africa Aperture: 396 m2 Application/End Use: Air conditioning Commissioning : 2014
© Fraunhofer ISE
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Solar collectors Tracking Collectors Linear Fresnel Reflector (LFR / LFC)
New developments
Further development: Soltigua (I), Solar Euromed (F), Thermax (IND), Lotus (EGY), KG Group (IND), others…
© CNIM
DSG Pilot Plant in La Seyne Sur Mer, France
© Fera DSG Pilot Plant in Sicily, Italy
© Fraunhofer ISE
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Solar collectors Tracking Collectors Other Concepts – Point Focusing Collectors
Parabolic dish focuses only direct sun-light onto a central receiver (point focus)
Concentrator
Central receiver
Thermal load
Electric load + -
Tracker
Designed to track the sun along two axes
Potential to high (overheated steam) and very high temperatures (chemical reactions, fusion of materials, etc)
(“Fresnel approach” to the parabolic dish? The central receiver - Tower)
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Solar collectors Tracking Collectors Other Concepts – Scheffler Dish Reflector
Gadhia Solar Energy Systems (In) (Scheffler Reflector)
Solar Steam Cooking System for 15’000 people
(worlds largest)
Tirumala Tirupati Devasthanams (TTD)
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Solar collectors Tracking Collectors Other Concepts
Chromasun (USA)
low profile, lightweight, no external moving parts
Simple to mount and to maintain
20x25x Fresnel reflector optic
Output temperatures up to 220°C
© Chromasun http://chromasun.com/
© Fraunhofer ISE
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Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability
Solar collectors
Overview
Stationary collectors
Flat Plate collectors and variants
Evacuated collectors and variants
Tracking collectors
Parabolic Trough
Linear Fresnel
Other concepts
Process Heat: sectors and processes, examples in Chile
Summary
© Fraunhofer ISE
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Process Heat Sectors and processes
Heat is required at different temperature levels, whose distribution depends on the specific industrial sector [3]
[3] “ECOHEATCOOL – The European Heat Market”, EU IEE co-fund, http://www.euroheat.org/ (2006)
Heat consumption distribution by temperature level in different industrial sectors [3]
0%
20%
40%
60%
80%
100%
Mining and Quarrying
Food and Tobacco
Pulp & paper
Chemical
Non-Metallic
Minerals
Basic Metals
Machinery
Transport Equipment
Others
Above 400°C100 - 400°CBelow 100°C
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With Solar?! Solar Heat for Industrial Processes (SHIP)
Suitable industrial sectors and processes [4]
[4] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012
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With Solar?! Solar Heat for Industrial Processes (SHIP)
Suitable industrial sectors and processes [4]
[4] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012
© Fraunhofer ISE
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With Solar?! Solar Heat for Industrial Processes (SHIP)
Suitable industrial sectors and processes [4]
[4] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012
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Process Heat Sectors and processes
Suitable industrial processes
Drying and dehydration (Concentration)
Preheating (input or raw material)
Pasteurization and Sterilization
Washing and cleaning
Chemical reactions
Surface treatment
Space heating
Supply of hot water or steam
Main industrial sectors
Chemicals
Agriculture / Food & Beverages
Paper
Fabricated metal (/ Mining)
Rubber & Plastic
Machinery & Equipment
Textiles
Wood
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Process Heat Sectors and processes Main Applications for Chile
Suitable industrial processes
Drying and dehydration (Concentration)
Preheating (input or raw material)
Pasteurization and Sterilization
Washing and cleaning
Chemical reactions
Surface treatment
Space heating
Supply of hot water or steam
Main industrial sectors
Chemicals
Agriculture / Food & Beverages
Paper
Fabricated metal (/ Mining)
Rubber & Plastic
Machinery & Equipment
Textiles
Wood
© Fraunhofer ISE
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Content - Solar Thermal Technologies for Process Heat: Available Solutions and Process Temperature Suitability
Process Heat: sectors and processes
Solar collectors
Overview
Stationary collectors
Flat Plate collectors and variants
Evacuated collectors and variants
Tracking collectors
Parabolic Trough
Linear Fresnel
other concepts
Summary
© Fraunhofer ISE
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Solar collectors Summary
Classification - Technology Readiness Level TRL
TRL level* (in SHIP applications)
1. Basic principles
2. Tech. Concept
3. Exp. Proof
4. Lab. validation
5. Relev. Envir. Val.
6. Relev. Envir. demo
7. Oper. demo
8. System Qualif.
9. System operation
* Source: http://ec.europa.eu/research/participants/data/ref/h2020/wp/2014_2015/annexes/h2020-wp1415-annex-g-trl_en.pdf
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Solar collectors Summary
155 operational SHIP systems reported worldwide [5]
144 000 m2 [5]
20 plants > 1000 m2
Largest: 39.300 m2 Codelco Gabriela Mistral Copper Mining, Chile
[5] Database for applications of solar heat integration in industrial processes, AEE-INTEC. http://ship-plants.info/ (online 06,2015)
Reported SHIP systems: ship-plants.info [2]
Tracking
Un
der
esti
mat
ed
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Technology status Summary
Although the market for SPH is still small, many companies have developed new collector products suitable for a medium temperature range 100°C – 250°C or even higher
Non-concentrating standard collectors are suitable for temperatures below 80°C (flat-plate) / 150°C (evacuated tube collectors with CPC)
Concentrating collectors – PTC, LFR and other concepts, cover the remaining medium temperature range
Very High temperature applications (EI sectors) still lack technology developments
Standardization and Product certification is in place
Systems and component development and testing is a important task for R&D organizations
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Technology application in SHIP Obstacles
Factors impairing higher technology penetration
Highly diversified Applications and Technologies
Integration in steam networks (BoP)
Available area restrictions (calling for lower LOF / building integration)
Low cost of conventional heat sources (even lower in industry…)
FINANCING! Industrial end-users expect VERY SHORT pay-back periods (1 to 2 years…) IRR > 40%
© Fraunhofer ISE
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Technology application in SHIP Obstacles New Financing Schemes to Support Industry
Someone else deciding on investment?
Atract 3rd party investors w/ lower IRR expectation (7%)
Lower risk perception (optimal design, GRA, PPA)
© Fraunhofer ISE
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Technology application in SHIP Obstacles
First Results – IEA SHC Task 49 Data base [3]
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Technology application in SHIP Obstacles Learning Curve and Economy of Scale
The successful story of PV [5]
[5] Navigant Consulting; EUPD PV module prices (since 2006), Graph: ISE 2014
Each doubled installed capacity stood for
20 % technology cost reduction
A factor 10
in 25 years! STE SHIP
© Fraunhofer ISE
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Thank you for your attention!
Fraunhofer Institute for Solar Energy Systems ISE Peter Nitz / Pedro Horta www.ise.fraunhofer.de [email protected]