India One' Solar Thermal Power Plant

‘India One’ Solar Thermal Power Plant

1 MW (el.) with 16 hrs thermal storage for continuous operation

Applied Solar Energy Research Centre

World Renewal Spiritual Trust, Brahma Kumaris

Shantivan Campus, Abu Road, Rajasthan

BK Jayasimha

[email protected]

R & D Conclave on New and Renewable Energy- Prospects for Cross Cutting Technologies 9-10th August 2012

Venue: Hall No 5, Vigyan Bhawan, New Delhi

Ministry of New & Renewable Energy, Govt. of India

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Content of the presentation

Project specifications

• Unique features

• Design concept

• Deliverables

India One – Project progress

• India One – Milestones achieved

• Future Milestones to achieve

• Progress photos

• Heath, Safety & work environment

• RE awareness

• Project Partners

Combined Heat and Power Generation with CSP

Present scenario & challenges Innovations undertaken R&D executed Solutions

About the Organization

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INDIA ONE – Solar Thermal Power Plant

Key Features:

• CHP Co-gen plant

• Indigineously developed 60 sqm size fixed focus paraboloidal reflector for solar energy

• Static cast Iron cavity shape receivers integrated with thermal storage for continuous 24

Hr. operation

• Direct generation of super heated steam on demand water as HTF

• Co-generation (hot water generation) for efficient usage of thermal energy.

• Two stage twin Turbine and Generator from Siemens

• Generates approx. 24MWH electricity per day and 10 lakh litres of hot water

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Ideal Combined Heat and Power CSP technology for India

Present Scenario and challenges in Solar Reflectors:

• Need for relatively simple modular design / less structural complexities

• Need for Indigenous manufacturing, capacity building and technology transfer to Industry.

• Cost effective technology

• Should be easy in operation/ maintenance by means of readily available spares

• Easy to replicate, decentralized fabrication process to create local employment

• Standardization of the technology

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12.6 SQM Reflector

The Global Hospital and Research Centre Mt Abu

Installed by WRST in 2003

10 paraoboloid reflectors

Total 900 kg steam generation:

• 300 kg steam for sterilizer (2 -3 shifts per day);

• 300 kg steam for laundry

• 300 kg steam for food cooking (600 meals per day);

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12.6 SQM Reflector

Om Shanti Retreat Center, near Delhi



Total 800 kg steam generation for 5000 meals a day

16SQM Paraboloid Reflector

R&D by WRST ,

Abu Rd in 2006

R&D sponsored by MNRE

Innovations undertaken at WRST

Evolution of static focus paraboloidal Reflector at WRST

7.5 SQM Reflector

BK Gyan sarovar, academy for better World Mt Abu



Total 650 kg steam generation: for 2000 meals per day

Oldest system working in this technology

10 SQM Reflector

Brahmakumaris,

Shantivan campus, Abu Road



Total 3500 kg steam generation: for 38000 meals per day

Latest Innovation at WRST: The 60 SQM Paraboloidal Solar Reflector

• 60 sq. meter Parabolidal reflector with space frame design for high concentration Ratio (450:1)

• Optimum steel usage/ Sq. meter. (Approx. 50kg of MS/Sq. meter)

• In built Actuators for Shape change of Reflector (According to Summer, Winter and Equinox)

• Network enabled dual axis tracking system for daily and seasonal changes

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Set up of 60m2 reflector with Static cast iron receiver

3D view of the set up of 60 m2

Paraboloid Reflector with cast Iron

static receiver

Static focus enabling Cast Iron Receiver

to act as a thermal storage medium

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Automated dual axis tracking for solar reflector with remote monitoring

Thermal output of 60m2 reflector

182.41

189.42

157.92

136.71

117.98

83.31

31.49 30.52

77.63

158.88

106.32

160.96

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

200.00

1-Jan-10 1-Feb-10 1-Mar-10 1-Apr-10 1-May-10 1-Jun-10 1-Jul-10 1-Aug-10 1-Sep-10 1-Oct-10 1-Nov-10 1-Dec-10

Monthly avg. Output of standing dish/ day in Kwhrs assuming 60% dish efficiency from DNI (8am to 5 pm) to receiver outlet

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Thermal Storage in Combined Heat and Power CSP technology

Parameters for an Ideal Thermal storage:

• High energy storage density

• Easy and efficient convertibility to the desired energy form

• Efficient, modular methodology for charging and discharging

• Low storage losses

• Easy and reliable operation

• Acceptable capital and O&M cost

• Less parasitic loads

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Present Thermal storage options in Combined Heat and Power CSP technology

• Steam Accumulator – stores heat in tanks as pressurized steam

• Molten salt storage

• Graphite heat storage

• Phase change materials for storage etc

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The static cavity Receiver: Thermal storage option

• Thermal energy storage (250 deg. C to 500 deg. C)

• Direct steam generation of high quality saturated and super heated steam

• Robust , easy to operate Receivers using metal as thermal storage

• Local manufacturing and cost effective design to suit Indian conditions (Approximate 25 USD/KWH thermal)

• Operational flexibility and low maintenance cost

• Low parasitic load due to direct steam generation

• Thermal storage for 24 hours using locally available materials

• Standard components to minimize thermal losses from the Receiver

• Avoids high pressure flexible joints.

• Steam and hot water generation on demand, 24/7 availability

• Antireflection glass at the receiver for minimizing thermal losses

• Long life cycle – Approximate 25 years

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R&D executed at WRST: The measuring system to evaluate the test bed:

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Test results of static cast iron cavity receiver

Observations from the test

results:

• Max. temperature at the receiver block – 450 deg. C

• Max. pressure of steam discharged – 42 bar

• Max. temperature of steam discharged – 430 deg. C

• Discharging 2/3rd of time superheated steam and 1/3rd of time saturated steam before rapid temperature drop.

Thermal behavior simulation of static cast iron cavity receiver

Thermal behavior simulation of static cast iron cavity receiver

Thermal behavior simulation

INDIA ONE – Solar Thermal Power plant Deliverables

• Size of the Paraboloidal Reflectors – 60sqm

• Static cast iron cavity receivers as thermal storage of 100

MWh @ 25 USD/ KWh

• Direct super heated steam generation of 42 bar – up to 400

deg.C, peak output of steam @ 8 tons/hour

• Cogeneration - 1 million ltrs/day hot water at 60 deg.C

• Space utilization 10 acres/MW.

• Anticipated Power generation – 24 MWH / day 17

INDIA ONE Progress photo’s

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Erection of first prototype of parabolic reflector

Installation of cavity receiver


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Dual axis automatic tracking- testing for concentrated focus

Testing of the Prototype unit and data collection for further analysis


20 Construction of foundations and erection of stands on mass scale

INDIA ONE Progress photo’s - 2012

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Arial view of the construction site in May 2012

Fabrication and erection of Rotating supports


22 Localized fabrication & manufacturing of components


23 Quality inspection for Welding works and Painting works

Copper slag blasting and Painting works at site

INDIA ONE – WRST – RE awareness

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Partners of the Project „ India One” is a research project in partnership with:

• Ministry of New and Renewable Energy Sources (MNRE) New Delhi

• German Federal Ministry for the Environment, Nature Conservational and Nuclear Safety (BMU) within the bilateral initiative “ComSolar”

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INDIACARE

About the organization - WRST

• World Renewal Spiritual Trust, a sister organization of BK’s has established the Department of Renewable Energy In 1992.

• First Organization in the World to introduce Solar Steam cooking system up to 15,000 people/day.

• Approx. 700kW Stand alone Solar PV power across India.

• Approx. 50,000 ltrs/day Solar hot water system at HQ’s

Brahmakumaris :

• A Socio-Spiritual Organization estd. in 1936.

• About 9000 meditation centers in India and over 130 countries

• Main Teachings: Spiritual and ethical values, Meditation, Self Management leadership courses, Stress Management etc.

• Affiliated with United Nations and General consultative status with UNICEF.

• Participation with UN peace projects and environmental summits.

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THANK YOU &

OM SHANTI

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www.india-one.net

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India One' Solar Thermal Power Plant