SOLAR INDUSTRIAL PROCESS HEAT

Dr. B.F. TCHANCHE Agricultural University of Athens, Greece tfb@aua.gr OR tfb_tchanchef@yahoo.fr

Overview

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Introduction

System components

Solar thermal collectors

Market potential

System design

Examples

System cost

Barriers

African context

Conclusion

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Introduction

Annual solar radiation - © Meteotest, Berne, Switzerland

Batteries, inverter, cables, etc

Electricity

PV panels

Solar thermal collector Heat exchangers,

storage tank, controllers, etc

Heat Electricity

PV-T

System Components

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Solar collector

Storage tank

Control system

End-uses

Flat plates Evacuated tubes Parabolic trough etc

Solar radiation Space heating Domestic hot water Industrial processes (cooling, heating, etc) Power generation

Water Vapor Pressurized water PCM etc

Auxiliary heater/ boiler

Solar thermal collectors

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Global Irradiance Ig 100%

Reflection 8%

Absorption 2%

Heat conduction Usable heat (<60%)

Free convection

Forced convection

radiation

Collector operating principle – flat plate (photo-thermal conversion)

insulation

Glass cover

Solar thermal collectors

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Unglazed flat plate Evacuated tube Double glazed flat plate

single glazed flat plate Hot Air solar collector Parabolic trough

Solar thermal collectors

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CPC collector

heliostat Compact linear fresnel reflector Paraboloidal dish reflector

Maximum reflector collector (mareco)

Combined heat and power solar collector (CHAPS)

Solar thermal collectors

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Type T [C] Concentration ratio

Tracking

Air collector 0-50 1 -

Pool collector 0-50 1 -

Reflector collector 50-90 - -

Solar pond 70 – 90 1 -

Solar chimney 20 – 80 1 -

Flat plate collector 30 – 100 1 -

Advanced Flat Plate collector

80-150 1 -

Combined heat and power solar collector (CHAPS)

80-150 8-80 One-axis

Evacuated tube collector

90 – 200 1 -

Compound Parabolic CPC

70-240 1-5 -

Fresnel reflector technology

100 – 400 8 – 80 One-axis

Parabolic trough 70 – 400 8 – 80 One-axis

Heliostat field + Central receiver

500 – 800 600 – 1000

Two-axis

Dish concentrators 500 - 1200 800 - 8000

Two-axis

Typical operating temperature and concentration ratio for different solar collectors

Efficiency vs temperature ranges (1kW/m2)

Temperature and Applications Low temperature solar collectors (T<80 ºC) Heating (swimming pool, hot water, space) Medium Temperature collectors (80<T<400 ºC) Process industrial heat!! High Temperature collectors (T>400 ºC) Power generation

Market potential

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Electricity

33%

Heat

67%

Final Energy Use of the EU-Industry

ESTIF – European Solar Thermal Industry Federation (www.estif.org)

Industrial sectors

Paper Food & beverage industries Textile industry Metal & plastic Chemical industry

Processes

Drying Washing Cleaning Frying/cooking Liquid/solid heating/cooling Space heating/Cooling Sterilization Distillation etc

Market potential

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Industry Process Temperature (°C)

Food industry Sterilization 60-120

Pasteurization 60-80

Cooking 90-100

Bleaching 60-90

Washing 60-90

Chemical Soaps 200-260

Synthetic rubber 150-200

Processing heat 120-180

Pre-heating water 60-90

Plastics Preparation 120-140

Distillation 140-150

Separation 200-220

Extension 140-160

Textile Bleaching, dyeing 60-90

Drying, degreasing 100-130

Fixing 160-180

Pressing 80-100

Processes and temperature ranges (kalogirou, 2003)

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System design example

Solar collector Buffer solar storage tank

Boiler

Bath

Heater

Heat exchanger

90 ºC

70 ºC

Industrial bath Ref. SOPRO

System design example

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Air pre-heating for an open drying process Ref. SOPRO

Ambient air

Gas/liquid heat exchanger

Fan Fan Air solar collector

Boiler

Hot air for the process

Examples

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Metal processing company Steinbach & Vollman, Germany (2008) Solar coll: vacuum tube, 400 m2, 280 kW Storage: 9 m3 Design: bath heating, heating, domestic hot water Temperature: 60 - 80 ºC

Energy savings: 30-35% (gas reduction) Capital cost: 240,000 € (50% subsidies) Payback period: 7 years (Subs. Incl.)

Brewery, Neumarkteur Lammsbrau Gebr. Ehrensperger e.K., Germany (2000) Solar coll.: single glazed flat plate, 72 m2, 50 kW Design: air preheating (drying process) Storage: no Temperature: up to 60 ºC

System Cost

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53%

14%

14%

11%

6% 3%

Investment Cost Distribution

Collector field

Piping

Planning

Storage & Heat exchangers

Control system

Others

Capital cost location (solar resource, local wages)

Application (temperature, load profile)

System concept

Size of the system

System components

Ref: SOPRO project

In Europe Capital cost: 180-500 €/m2

Heat: 2-8 c€/kWh

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Barriers/Obstacles

Identified obstacles

Awareness (not known by public, decision makers)

Resistance (new tech & “business as usual attitude” of managers)

High investment cost (as most renewable energy technologies)

Lack of standard technology (designs, materials)

Lack of suitable planning guidelines & tools

Lack of training & education

How to overcome the barriers

Information campaign

More demo projects (references)

Subsidies

Training (workshops, seminars,…)

African context

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The solar resource

Industries

- agro-food & beverage - textile - chemical

Conservation of agricultural products - drying - refrigeration

Buildings - Air conditioning (60% of energy consumption)

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African context

Major obstacles

- lack of technology - high upfront cost - lack of subsidies - lack of appropriate energy policy - lack of skilled workers - lack of research facilities

Benefits for countries

- landlocked countries/oil imports (energy security) - development of remote areas (PV + solar thermal) - more jobs - less CO2 emissions

More …

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Potential of Solar Heat in Industrial Processes. – POSHIP - 2001 SO-PRO Project (http://www.solar-process-heat.eu/)- 2009/28 months IEA –SHC (solar cooling & heating): Tasks 33, 38 and Task 49 “Solar Process Heat for Production and Advanced Applications” – begin January 2012. (http://www.iea-shc.org/) MEDISCO project – (Morocco, Tunisia, Egypt) http://www.medisco.org

Conclusion

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Low temperature solar heating (swimming pools, space heating, domestic hot water) well known and mature! High temperature thermal applications are under development for electricity generation since the 1980s(CSP)! Medium temperature solar applications are at the infancy stage (start 2000) despite the huge potential that exist in industries and buildings. Major technology in the coming decades provided the barriers are overcome:

More research Financial support Increase awareness (managers, policy makers)

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