EMINARIO SOLAR FRAUNHOFER CHILE - CSET CALOR SOLAR … · Solar collectors Overview Solar thermal collector heat exchanger converting the solar radiation into heat transfers this

© 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

2

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])

http://www.eea.europa.eu/data-and-maps/indicators/final-energy-consumption-by-sector-8/assessment-2


















© Fraunhofer ISE

3

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)

© Fraunhofer ISE

4

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%

© Fraunhofer ISE

5

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

6

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

© Fraunhofer ISE

7

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

© Fraunhofer ISE

8

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

© Fraunhofer ISE

11


Solar collectors

Overview




Tracking collectors

Parabolic Trough

Linear Fresnel

other concepts


Summary

© Fraunhofer ISE

12

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.

© Fraunhofer ISE

13


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/

© Fraunhofer ISE

14

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


© Fraunhofer ISE

19

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).


© Fraunhofer ISE

20

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

© Fraunhofer ISE

21

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

© Fraunhofer ISE

22


Solar collectors

Overview




Tracking collectors

Parabolic Trough

Linear Fresnel

other concepts


Summary

© Fraunhofer ISE

23

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


© Fraunhofer ISE

24


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

© Fraunhofer ISE

25


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

© Fraunhofer ISE

26


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

27

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

28

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

29


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

30


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

31

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)

© Fraunhofer ISE

32

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)

© Fraunhofer ISE

33

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

36


Solar collectors

Overview




Tracking collectors

Parabolic Trough

Linear Fresnel

Other concepts


Summary

© Fraunhofer ISE

37

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

© Fraunhofer ISE

38

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

39




© Fraunhofer ISE

40




© Fraunhofer ISE

41

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

© Fraunhofer ISE

42

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

43


Process Heat: sectors and processes

Solar collectors

Overview




Tracking collectors

Parabolic Trough

Linear Fresnel

other concepts

Summary

© Fraunhofer ISE

44

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

© Fraunhofer ISE

45

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

http://ship-plants.info/




© Fraunhofer ISE

46

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

© Fraunhofer ISE

47

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

48

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

49

Technology application in SHIP Obstacles

First Results – IEA SHC Task 49 Data base [3]

© Fraunhofer ISE

50

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

51

Thank you for your attention!

Fraunhofer Institute for Solar Energy Systems ISE Peter Nitz / Pedro Horta www.ise.fraunhofer.de [email protected]

Documents

EMINARIO SOLAR FRAUNHOFER CHILE - CSET CALOR SOLAR … · Solar collectors Overview Solar thermal collector heat exchanger converting the solar radiation into heat transfers this