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Solar Thermal Power in India: Experiences and Future

Rangan Banerjee

Forbes Marshall Chair Professor

Dept. of Energy Science and Engineering

IIT Bombay

Invited talk at Renewtech India 2015, April 29, 2015 Mumbai

Solar Power : Potential and Cost

Solar Insolation and area required

= 2500 sq.km

= 625 sq.km Source: World Energy Outlook – 2008, International Energy Agency

2

Solar Concentrators

Arun Technology

CLFR TechnologyParabolic Trough

Scheffler paraboloid dish

Heliostat

3

Solar Thermal Technologies

Companies Operating temp.

Efficiency, η

Remarks

Parabolic Trough

Abener, Thermax, KIE Solatherm

350-400 ͦC Peak 14-20%11-16%Annual

Commercial

Linear Fresnel Reflector

KG Design, Areva 220-250 ͦC Peak 18%Annual 13%

Lower cost

Dish Gadhia Solar, Clique, WRST, Birla Terra Joule, ATE

200 - 700 ͦC Peak 30%Annual 12-25%

Solar heating cooking

HeliostatsSolar Tower

E-Solar (ACME)2.5 MW at Bikaner Sunborne

450-565 ͦC 23-25%7-20%

4

Estimated LCOE for existing and proposed Parabolic Trough and Solar Tower CSP Plants

Source: IRENA 2012

5

KG Design Services Private Limited (KGDS)

Solar thermal research centre in Coimbatore with 1400 m2 of collection area.

45 bar 257 C

Linear Fresnel Reflector

Solar Desalination plant

Solar biomass power plant cum desalination

Source: http://solar.kgisl.com 6

Integration with Heating & Cooling

applications

Boiler

“Built in India” design

Parabolic Concentrators

Agro-waste

Steam Driven Turbine

Completely IndigenousARCI, IIT B, NAL, IIT K, BARC

Agro-waste hybridizationHigh efficient conversion technologies

Project approval received in Dec 2009 with a project completion by June 2011. Total cost of R&D project is 9.11 Cr plus O&M costs

Solar IslandPower Island

Thermal Island

Vapor Absorption Cooling M/C

Organic

Rankine Cycle

Solar Accumulator

256 KW generation

Source: Thermax with permission

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Collaborative DesignBridge Technology Gap Through Collaboration

IIT Bombay

Fraunhofer

IIT Kanpur

DLR

NCL

NAL

ARCI

2Source: Thermax with permission

8

Point focus fixed to the dishMaximized intercept factor

Coiled tube cavity absorberMinimized thermal losses

Automatic two-axes tracking

Facing the Sun, maximum insolation

169m2 or 104m2 Arun dish

Power capacity : 0.5 kWpeak / m2

Operating hours : 8 to 9 hrs / day

Daily output : 4 to 4.5 kWhth/day/m2

Capital cost : Rs. 21,000 / m2

Cost Parameter : Rs. 5,000 /(kWhth/day)Source: Clique Developments Ltd., Mumbai with permission 9

Solar Thermal Concentrator developed at ATE Enterprise

Process heating market for

commercial, small industrial

and rural applications (~10 kWt

at 1000 W/m2 insolation)

medium-scale paraboloid dish

with 15–30 m2 aperture area;

local vendor base and

manufacturing

Direct steam generation using

proprietary receiver

• Characterization of

thermal performance

• Measurement of mirror

reflectivity and effect of

ageing

• Remote monitoring

10

Adhunik Global

• 6kW solar steam power plant• Fresnel type solar concentrators – 3 of 24m2 each -area of 96 sq mt.( Design from http://www.solarfire.org/)• Steam Engine 2 hp to 10 hp

Solar Oven

Source: http://www.tinytechindia.com/solar6kwtp.htm11

India One Dish Project

60m2 parabolic dish with fixed focus

Number of dishes : 770 nos. of 60m2

Electrical output : 1,0 MW el. (net. 22000 kWh/24hrs) Thermal output : 150 MW th. (24hrs) Solar field : 25 Acres Abu Road, RajasthanTotal mirror area : 45.000 m2

Turbine : 1,0 Mw el.

Source: http://www.india-one.net/abouttheproject.html

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Stirling engines seems to be

viable option

Major heat input should be

through gas flame or solar

energy

Choice of Capacity for Stirling

Engine

~ 96,000 villages to be

electrified in India

- For a group of 3-4 households

having enough cattle to supply

bio-gas for gas based systems

or hybrid systems

- Use for small capacity pumps

for irrigation application

Capacity needs to be at least 1.5

kWe

Stirling engines seems to be

viable DECENTRALIZED option

Cylinderhead

Safety valve

Charging line

Crankcase

Heat receiving tube

Tubes for water circulation

Design and development of Stirling engine for net 1.5 kW electrical output

0 200 400 600 800 1000 1200

292

294

296

298

300

302

Cyl

inde

r he

ad t

empe

ratu

re, K

Time, second

Cool down curve

13

Solar TowerE-Solar – Acme partnership

First grid connected plant in India 2011

2.5 MW out of 10 MW installed Bikaner Rajasthan

Double-axis software-mirror tracking system Lightweight, small size 1 m2 flat mirrors

Plant output not stabilised – insolation, auxiliary consumption

http://acme.in/solar/thermal.html 14Non- operational?

Nokh (Godawari): 50 MW

Dhursar 125 MW Reliance/ Areva Megha, AP, 50 MW

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Strategy

16

0% 100 %

Completely

Indigenous

Import Complete plant

Prototype

50 %

National Test Facility

National Testing facility – Facilitate technology

development

Objectives

National Test Facility (for solar thermal applications) • Development of facility for component testing and characterization.

• Scope of experimentation for the continuous development of technologies.

1MW Solar Thermal Power Plant• Design & Development of a 1 MW plant.

• Generation of Electricity for supply to the grid.

• Development of technologies for component and system cost reduction.

Development of Simulation Package• Simulation software for scale-up and testing.

• Compatibility for various solar applications.

17

KG DS

Planned Mode

18

Time Line

Jan. 2010

Nov. 2012

Evaluation Version (v1.0)

Released

Foundation Stone

Preliminary Version (v0.0)

Released

Sep. 2011

Final Version Ready

Aug. 2014

Sep. 7, 2009

Project Start

Jul. 2011

Steam Generation

from LFR

Oct. 2012

Jun. 21, 2013

Mar. 14, 2014

Steam Blowing

Turbine Rolling

Grid Synchronisation

Grid Feeding,Test Rig Ready

May 2014

Mar. 6, 2015

Project End

20

Test Rig

Test Building

Dish Concentrator

User Interface: Main Window

Generation of user defined PFD using Simulator

Typical 50 MWe Solar Thermal Power Plant

Direct Steam Generation Process Heat Application

Simplified Process Flow Diagram

Cooling Water45 bar, 105°C1.09 kg/s

0.1 bar, 45.5°C1.78 kg/s

42 bar, 350°C1.93 kg/s

46.3 bar, 171°C2.22 kg/s

Steam Separator

44 bar, 256.1°C0.84 kg/s (Sat. Steam)

Pump-I

Preheater

Steam Generator

Pump-II

High Temperature Vessel

Low Temperature Vessel

17.5 bar, 232°C8.53 kg/s

13 bar, 393°C8.53 kg/s

PTC Field (8175m2)

Superheater

Pump-III

DeareatorPump-V

Pump-IV

Turbine

1 MWe

LFR Field (7020m2)

Pump-VI

Source: ISES, 2013

8175 m2 area – 3 MWth

Trough Field

LFR Field7020 m2 area – 2 MWth

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Arial view of 1 MWe Solar Thermal Power Plant and Test Facility by IIT Bombay

Plant Performance

0

100

200

300

400

500

600

700

800

10.00 11.00 12.00 13.00 14.00 15.00 16.00

DN

I

Time (h)

4th June 2014

DNI

Minute by minute DNI data for 4th June 2014

0

100

200

300

400

500

600

10.00 11.00 12.00 13.00 14.00 15.00 16.00

Pow

er O

utp

ut (k

W)

Time (h)

4th June 2014

Minute by minute turbine power output data for 4th June 2014

What did we learn?

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Overall

Specialisation- Sub Tasks – Difficult from scratch

1 MW – too small for CSP with present route

Industry interest in CSP research – declined-change in priorities- budgets

Catalysed CSP development – few consortium partners

Testing of one concentrator, new HTF fluid

Simulator – Evaluation licenses- Tata Power, Fichtner 28

Sequence of Commissioning Problems

Kartheek, N G R, et al 2013

Commissioning Experience

30Kartheek, N G R, et al 2013

System Problems

HTF Freezing: Unfreezes only in

summer.

UPS and Tracker failure:

Continuous Power supply

31

9

10

11

12

13

14

15

12:0

0 A

M

12:3

0 A

M

1:0

0 A

M

1:3

0 A

M

2:0

0 A

M

2:3

0 A

M

3:0

0 A

M

3:3

0 A

M

4:0

0 A

M

4:3

0 A

M

5:0

0 A

M

5:3

0 A

M

6:0

0 A

M

6:3

0 A

M

7:0

0 A

M

7:3

0 A

M

8:0

0 A

M

8:3

0 A

M

Am

bie

nt

Tem

per

atu

re (

oC

)

Time (hr: min)

Schematic of Oil System

TG

TG

Kartheek, N G R, et al 2013

Operational Problems

Leakages in

superheater

Receiver tube and

window glass: Spot

Welding, Continuous

power

Water entry in

Instrumented-air line:

NRV

Dry run of the BFP:

Level Switches

32

Receiver Window Glass Breakage

Receiver Tube leakage

Kartheek, N G R, et al 2013

Temperature Transmitters showing Leakages

Leakage

from

Screwed

connection

Pump Seal Failure

33

Equipment problems• NRV selection: Horizontal & Vertical line

• Instrument stub: No threaded parts

• Compressed air line: No threaded joints

• Communication failure

• Steam valves: Control, Manual handle,

Isolation

Control System HierarchyKartheek, N G R, et al 2013

What are the research directions? Gaps?

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Typical loop imbalance problem for 4th June 2014

0

50

100

150

200

250

300

350

400

10.00 11.00 12.00 13.00 14.00 15.00 16.00

Tem

pera

ture

( C

)

Time (h)

Loop 1 Loop 2 Loop 3

4th June 2014343°C

311°C

Castable ceramics storage: The castable ceramic is basedon a binder containing Al2O3.The binder is prepared underambient conditions and reactschemically to form a solid,stable matrix which enclosesthe aggregates iron oxides.

High temperature concrete storage:

In high temperature concrete,blast furnace cement is used asthe binder; iron oxides are usedagain as the main aggregate aswell as flue ash and again asmall amount of auxiliarymaterials.

Two-tank storage: The low vapour pressure of thenitrate salts allows vertical, field-erected tanks to be used. The largetanks, which operate atatmospheric pressure, are similarto commercial oil storage tanks.

Thermocline storage system:

Low-cost filler materials asthe primary thermal storagemedium, and molten nitratesalts as the direct heattransfer fluid.

Phase Change storage:The latent heat of fusion betweenthe liquid and solid states ofmaterials is rather highcompared to the sensible heat,storage systems utilizing phasechange material can be reduced insize compared to single-phasesensible heating systems.

(Brosseau, Hlava, and Kelly, 2004)(Herrmann, Kelly, and Price, 2004)

Steam accumulator storage:

A Steam accumulator is aninsulated steel pressure tankcontaining hot waterand steam under pressure. Itis a type of energy storagedevice.

(Eck, 2012)

(Tamme, Laing and Steinmann, 2004) (Laing, Steinmann, Tamme, and Richter, 2006)

(Michels, and Pitz-Paal, 2007)

Variation of Energy with storage capacity (Nandi, Bandyopadhyay and Banerjee, 2012)

Cost electricity Vs energy requirement for thermal generation(Nandi, Bandyopadhyay and Banerjee, 2012)

Ceramics Concrete

Two Tanks

PCM

Thermocline

5.00

7.00

9.00

11.00

13.00

15.00

1.00 1.02 1.04 1.06 1.08 1.10 1.12 1.14

Energy (MWh)

Cost

(U

S$/M

Wh)

Research Problems

Effect of dust, cleaning schedules

Tracking errors

Flow balancing

Alternative Storage

Control Strategies

Alternative HTF

Alternative mirror materials, vacuum, absorber tube

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Future

Facility – Enabling testing, training , research

Software – free to academic users

Handed over to NISE – March 2015

Limited industry interest

www.solar.energy.gov/sunshot/csp.html

Local Supply Chain – Solar Thermal

ESMAP, 2012, Local Supply Chain

Status Local Capability

ESMAP, 2012, Local Supply Chain

Action Plan

ESMAP, 2012, Local Supply Chain

Vendors – Solar Thermal

ESMAP, 2012, Local Supply Chain

Millman, Pune

Vendors – Power Block/EPC

ESMAP, 2012, Local Supply Chain

EU CSP Technology Roadmap 2014

End-Note

Facility – goal to enable design and development of future indigenous cost effective plants

Facility developed , not sure about future usage,

Attempted to influence/ seed interest –workshops/ training- yet sub-critical technology development efforts

Need for strategic technology development initiative nationally – Industry, researchers, Govt

Potential for cost reduction, integration with storage

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References

IRENA 2012: Renewable Energy Technologies: Cost Analysis Series, Concentrating Solar Power, Vol. 1: Power Sector, issue 2/5, IRENA 2012.

KGDS Renewable Energy Private Limited, http://solar.kgisl.com

Thermax- Sustainable Solutions in Energy and Environment , Pune, http://www.thermaxindia.com/

Clique Developments Pvt. Ltd., Mumbai, http://www.clique.in/

Sunshot Vision Study, U.S. Department of Energy, February 2012, www.solar.energy.gov/sunshot/csp.html

ESMAP, 2012: Development of Local Supply Chain: The Missing Link for Concentrated

Solar Power Projects in India, World Bank.

http://acme.in/solar/thermal.html

Adhunik Global, http://www.tinytechindia.com/solar6kwtp.htm

India One Solar Thermal Power Project, http://www.india-one.net/index.html

Kartheek N G R et al 2013: Experiences in Commissioning of a 1MWe Solar Thermal Power Plant in Gurgaon, Paper No. 339, Proceedings of 4th International Conference on Advances in Energy Research (ICAER 2013), IIT Bombay, Mumbai, December 10-12, 2013.

ISES 2013: Simulation of 1 MWe Solar Thermal Power Plant, Desai N.B., et aL. Proceedings of ISES Solar World Congress, Cancun, Maxico, November 3-7, 2013.

47

References

IEA, 2014: Technology Roadmap – Solar Thermal Electricity, International Energy Agency, 2014 edition.

World Energy Outlook – 2008, International Energy Agency, available online: http://www.worldenergyoutlook.org/media/weowebsite/2008-1994/WEO2008.pdf

Nandi, B.R., Bandyopadhyay, S., Banerjee, R., 2012. Analysis of High Temperature Thermal Energy Storage for Solar Power Plant. 3rd IEEE Int.Conf. Sust. Energy Technologies, Kathmandu, Nepal, 24-27.

Brosseau, D.A., Hlava, P.F., Kelly, M.J., 2004. Testing thermocline filler materials and molten salt heat transfer fluids for thermal energy storage systems used in parabolic trough solar power plants. ASME International Solar Energy Conference, Portland, Oregon, USA, 587-595.

Eck, M., 2012. Thermal Storage for STE Plants. 3rd SFERA Summer School, Almería German Aerospace Center Institute of Technical Thermodynamics

Herrmann, U., Kelly, B., Price, H., 2004. Two-tank molten salt storage for parabolic trough solar power plants. Energy 29, 883–893.

Laing, D., Steinmann, W.D., Tamme, R., Richter, C., 2006. Solid media thermal storage for parabolic trough power plants. Solar Energy 80, 1283–1289.

Michels, H., Pitz-Paal, R., 2007. Cascaded latent heat storage for parabolic trough solar power plants. Solar Energy 81, 829–837.

Tamme, R., Laing D, Steinmann, W.D., 2004. Advanced thermal energy storage technology for parabolic trough. Journal of Solar Energy Engineering ASME 126, 794–800.

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Acknowledgments

IITB Solar Power project team - J. K. Nayak, Santanu B., S. B. Kedare, Suneet Singh, M.Bhushan, S. Bharatiya, S. Doolla, U.N. Gaitonde, U.V. Bhandarkar, S.V. Prabhu, B.P. Puranik, A.K. Sridharan, B.G. Fernandes, K. Chatterjee, A.M. Kulkarni, RajkumarNehra, Kalpesh Karniik, Deepak Yadav, Satish Kumar, VikalpSachan, Pranesh K, Tejas Shinde, Kartheek NGR, Ranjeet Bhalerao, Nishith Desai

R.R. Sonde, Thermax, S.P. Vishwanathan, KGDSL, V. Sardeshpande– ATE, Clique

Bhaskar R Nandi, Balkrishna Surve, IIT Bombay

Thank youEmail: rangan.banerjee@gmail.com

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