solar thermalfor industrial use(s.b.k)
TRANSCRIPT
Solar Thermal Systems for Industrial Process Applications
Dr. Dr. ShireeshShireesh KedareKedareAdjunct Associate ProfessorAdjunct Associate ProfessorEnergy Systems Engineering, Energy Systems Engineering, IITIIT--BombayBombay
DirectorDirectorClique Developments Pvt. Ltd., MumbaiClique Developments Pvt. Ltd., Mumbai
RENET Workshop, IIT-Bombay September 21-22, 2006
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volume limits for given area Area limits for given
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Maximum temp.constraint (100°C)
Minimum Area
Minimum Volume
Solar Industrial Process Heat 2
Solar Industrial Process Heat Potential: Vast potential exists in industry for application of solar devices for process heatTechnologies: A few solar devices are available for industrial applications
Flat plate water heaters / air heatersEvacuated glass tube collectorsConcentrating solar devices producing higher temperatures (100° to 250° C) are being available
Integration: The basic technology for thermal integration is availableChallenge: Specific applications of solar energy and its optimization is needed
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Collector area,m2
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volume limits for given area Area limits for given
volume
Maximum temp.constraint (100°C)
Minimum Area
Minimum Volume
Solar Industrial Process Heat 3
Why Solar Industrial Process Heat ?
India uses 100 mill tons of oil annually40% of this oil consumption is in industry60 to 70% of industrial energy use is in thermal form70% of industrial thermal energy use in the range below 250°C
15 to 20% of total energy use, say 15 mill tons of oil is used in industry below 250°C.30% of this requirement can be met through solar thermal concentrators, leading to savings of about 4.5 million tons of furnace oil or LDO or Diesel per year
This is 60 to 70% of our oil imports + Reduction in the emission of carbon dioxide as well as other pollutants
Solar Industrial Process Heat 4
Why Solar Industrial Process Heat ?
Solar Energy is Clean, Abundant, available every-where
India has abundant Solar Energy
More than 3000 h/y in Central and Western IndiaAbout 5 to 6 kWh per day on horizontal surface
India has large number of decentralized, small industrial unitsFuel cost is high in IndiaParaboloid Concentrators can be fabricated at lower costs
Solar Industrial Process Heat 5
Challenges:Solar Industrial Process Heat
BUTSolar Energy is diluteSolar Energy is not available at demand
?Can it be concentrated for medium temperature applications ?Can it be stored and delivered at demand ?Can it be integrated with
Other solar technologiesOther renewable technologiesConventional fossil fuel based thermal systems ?
What will be its cost ?
Solar Industrial Process Heat 6
In India, Scheffler dish is available for low temperature steam generation. Solar Bowl at Auroville is also an important effort.
Initially, parabolic trough with line focus and heliostats were pursued for power generation.
Presently, Large Paraboloid Dish Concentrators are being pursued for power generation in US and EU as well as for Industrial Process Heat in EU
ARUN System Has been developed for the purpose
Quest forQuest for
Concentrated Solar EnergyConcentrated Solar Energy
Installation and Focus Tests of ARUN160
Integration and Performance Tests of ARUN160
Solar Industrial Process Heat 7
Solar ConcentratorsSolar Concentrators
Solar Industrial Process Heat 8
Comparison: In a nutComparison: In a nut--shellshellPTC is costly in the present Indian
scenario and has less applicabilityHeliostats with central receiver is
technologically more complicated (especially, thermal energy evacuation)Scheffler dish has a niche near 100 °C
semi-industrial applications and its comparatively much easier to fabricateARUN has high potential in industrial as
well as power generation applications, but its comparatively involved to fabricate
Solar Industrial Process Heat 9
ARUN Solar Concentrator ARUN Solar Concentrator for Industrial Process Heatfor Industrial Process HeatIndustrial Process Heat at 200 to 250°C can be supplied
any time of the day or nightSteam can be generated up to 40 kg/cm2
Thermic oils can be heated to 200 - 250°CAir can be heated for drying
Possibilities of Industrial Process Heat Applications, technical Potential in India and Economics
Solar Industrial Process Heat 10
Cost of Thermal Energy from different solar thermal units (Rs./m2)
6,00010,000
8,000
37,600 36,000
20,000 20,000
11,000
21,429
15,625
0
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15,000
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35,000
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Solar a
ir hea
ter
Solar w
ater h
eater
Evacu
ated t
ube W
ater H
eater
Sandia
, USA
ANU, Aus
tralia
Para
bolic
Trough
Solar B
owl
Schefl
er dish
Arun
70
Arun16
0
Rs.
/m2
Comparison of Solar SystemsComparison of Solar Systems
Solar Industrial Process Heat 11
Comparison of Solar Systems Comparison of Solar Systems Power Cost (Capital cost / Power) (Rs./ kWth)
1476021648
8952485714
60000 59571
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34167
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air h
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ia, U
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ustra
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hefle
r dish
Aru
n70
Aru
n160
Rs./
kWth
Solar Industrial Process Heat 12
Comparison of Solar Systems Comparison of Solar Systems Cost of Thermal Energy from different solar thermal units
(Rs./kWhth)
0.921.35
3.73 3.574.00
4.77
2.202.56
1.42
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ater h
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ustra
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ough
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Arun70
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R
s./ k
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Solar Industrial Process Heat 13
Comparison of Solar Systems Comparison of Solar Systems
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Solar Industrial Process Heat 14
Comparison of Solar Systems Comparison of Solar Systems
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Schefler dish Arun70 Arun160
Solar Industrial Process Heat 15
• Requires ONE-TIME investment• Its running cost is under 2% of its capital
investment. • It saves the costly fuel worth about 20 to 30%
of its capital investment annually for life-time• Its economy depends on the type of fuel saved• The loan instalments are more than
compensated by fuel savings resulting in positive cash flow from the beginning
Solar Concentrator Solar Concentrator ––Economic ViabilityEconomic Viability
Solar Industrial Process Heat 16
Existing government support :12% subsidy available from MNES.80% accelerated depreciationCO2 Emission Reduction can be traded.
This more than covers the O&M cost
Desirable additionally:Soft infrastructure loans @ 5% pa
covering 80% of the capital cost from Banks / FIs to be paid back in 10 years.
Solar Industrial Process Heat 17
Possibilities of Electrical Power Generation
Steam Engine/turbine with oil / gas back-up
As hybrid with Combined Gas Cycle or
Stirling Engine at focus with gas back-up
Suryamukhi – PV on Tracker
Concentrated PV
Solar Industrial Process Heat 18
Conclusions• Concentrators can generate medium temperatures for process heat applications : 100 to 250°C• Heat can be stored and delivered at demand
ARUN at Latur: Unique system • Vast range of Industrial process heat applications • Large potential• Unit can be integrated with
Other solar technologiesOther renewable technologiesConventional fossil fuel based heaters
• Economic today: Positive cash flow from year 1
Dr. Dr. ShireeshShireesh [email protected]@[email protected]@[email protected]@cliquetechnologies.com
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Collector area,m2
stor
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m3
a
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m o
operating region
Load temperature constraint
volume limits for given area Area limits for given
volume
Maximum temp.constraint (100°C)
Minimum Area
Minimum Volume
ARUN 160 at Latur
Optics, Structure, tracking system and integration was designed by Clique Developments Pvt. Ltd.Receiver was designed by Clique Developments Pvt. Ltd., with inputs from IIT-BombayVarious optical, mechanical, electrical, electronic and thermal components were designed by Clique Developments Pvt. Ltd., vendors were developed and the components were sent to LaturThe structure was fabricated at Pune, transported to Latur and erected.
Energy transfer mechanism in the cavity receiver
Experimental set-up of the open mouth cylindrical cavity receiver
Focus Test : ARUN 160 at Latur
Tests for evaluating optical performance of the system were developed at IIT-Bombay.A 3 mm thick MS plate 20% larger than the
receiver diameter fixed with K-type thermocouple was developed.It was fixed near the focus of the dish and
exposed to the concentrated radiation.Temperatures were measured and flux was
calculated using energy balance equation.
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Integration and Performance testing of ARUN160
The thermal components were installed and insulatedInstrumentation and data-logging were
completedPerformance data was collectedSystem was run with water in place of milkSystem was run for milk pasteurizationBoiler is shut-off for Sunny days
Design Space for Optimization of Integration
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Limiting line of 200°C
Design space for 25000 LPD Milk Pasteurization
*
Latur Design Point160 m2, 4.5 m3
y = -1.3336x + 0.5964
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(Tm-Tamb)/Ibn, °C.m2/W
Effic
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Many ARUN™ dishes can be used to generate power by thermal route Using steam engine / turbine with steam from Solar units superheated with oil / gas / biogasIn combined cycle plant with steam in Rankine cycle from Exhaust-Gas-Heat-Recovery-Boiler augmented by Solar unitsStirling engine with gas fired back-up heatingUsing Suryamukhi – PV on TrackerUsing Concentrated PV cells
Solar Thermal Power from Large Solar Thermal Power from Large Solar Concentrator : ARUNSolar Concentrator : ARUN
Thermal Storage
Gas/oil Super-heater
Steam Engine/Turbn
Gen
Condenser and filter
Schematic of Solar Thermal Power using Concentrators :
250 kWe Gas / Oil Hybrid Power Generation System
40 dishes of ARUN160 16 h/d supply for 300-350 d/y
Solar Energy hybrid system with Combined Gas Cycle (CGC)
Large Solar Concentrator Large Solar Concentrator ARUN ARUN with Stirling Enginewith Stirling Engine
ARUN can be fitted with Stirling engine to supply electrical power. Stirling engine will have to be imported presently.The power generated will require 50% to 70% of the capital investment compared to Solar Photo-Voltaic installationsSolar farm for power generation is now
feasible.
Stirling engine for 100 m2 paraboloid dish
ARUN160 as well as ARUN70 may be fitted with Stirling engine
ARUN160 ARUN70
Ap. Area 160 m2 70 m2
Electrical Power 25 kWelect 9.2 kWelect
Operating hours 2500 (6-9 h/day;300-340 day/yr)
Annual Electricity generated, kWh
60,000-75,000 Units / year
20,000-25,000 Units / year
Large Solar Concentrator Large Solar Concentrator ARUN ARUN with Stirling Enginewith Stirling Engine
ParaboloidParaboloid Dishes with Stirling Dishes with Stirling Engine at Point FocusEngine at Point Focus
100 m2 Dishes with Stirling Engine by SES for500 & 800 MW plants at Mojave Dessert, US
SuryamukhiSuryamukhi ™ as PV Trackeras PV Tracker
ARUN may be used as ‘Suryamukhi™’for solar PV on Tracker
Normal PV PV on Suryamukhi
Capacity 22 kWp 22 kWp
PV Cost Rs. 300/W Rs. 300/W
Annual operation 1500 hrs 2000 hrs
Cost of mounting 2% 15%
Cost ratio 100 % 113 %
Output Energy ratio 100 % 125 to 130 %
SuryamukhiSuryamukhi ™ as PV Trackeras PV Tracker
ARUN160 as well as ARUN70 may be fitted with Concentrated PV cellsReceiver can be designed for efficient coolingConcentrated PV cells need to be importedCost of Concentrated PV cells ?
Large Solar Concentrator Large Solar Concentrator ARUN ARUN with Concentrated PV with Concentrated PV
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ParaboloidParaboloid Dish with Dish with Fixed Focus Fixed Focus on groundon ground
7 m2 Scheffler dish for cooking, INDIA
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ParaboloidParaboloid Dish Dish with Fixed Focus on groundwith Fixed Focus on ground
7 m2 Scheffler dish for cooking, INDIA
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ParaboloidParaboloid Dish Dish with Fixed Focus on groundwith Fixed Focus on ground
7 m2 Scheffler dish for cooking, Mt.Abu, India
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SchefflerScheffler ParaboloidParaboloid Dish with Dish with Fixed Focus on groundFixed Focus on ground7 m2 Scheffler dish for cooking, INDIA• Power capacity : 2 kW• Operating hours : 7 hours/day• Daily output : 14 kWhth / day• Capital cost : Rs.60,000
+ Rs.10,000 (Receiver)
+ Rs. 7,000 (Tracking)
• Cost Parameter : Rs. 38,500 /kWth: Rs. 5,500/(kWhth/day)
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Fixed Fixed SpheroidalSpheroidal Dish Dish with Moving Focuswith Moving Focus
176 m2
Solar Bowl at CSR, Auroville, INDIA
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1At Tehachapi, US
Parabolic Trough Collectors Parabolic Trough Collectors with Line Focuswith Line Focus
2At SEC of MNES, New Delhi
Parabolic Trough Collectors Parabolic Trough Collectors with Line Focuswith Line Focus
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Heliostats with Receiver on Heliostats with Receiver on Central TowerCentral Tower
4Solar 2, US
Heliostats with Receiver on Heliostats with Receiver on Central TowerCentral Tower
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Heliostats with Receiver on Heliostats with Receiver on Central TowerCentral Tower
Solar 2, US
At Sandia Lab, US
At Armenia, Spain
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Heliostats with Receiver on Heliostats with Receiver on Central TowerCentral Tower
7Heliostat by SERI
Heliostats with Receiver on Heliostats with Receiver on Central TowerCentral Tower
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ParaboloidParaboloid Dish with Point FocusDish with Point Focus
300 m2 Sandia Dish, US
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
300 m2 Sandia Dish with Cavity Receiver
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
400 m2 ANU Dish with Cavity Receiver,Australia
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
100 m2 Dish with Stirling Engineat Test Field
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
100 m2 Dish with Stirling Engineat Test Field
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
100 m2 Dish with Stirling Engineat Test Field
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
100 m2 SAIC Dish with Stirling Engine, US
ParaboloidParaboloid Dish with Point FocusDish with Point Focus
56 m2 Dish with Stirling Engine at VIT, INDIA
ParaboloidParaboloid Dish Stirling Engine Dish Stirling Engine at Point Focusat Point Focus
100 m2 Dishes with Stirling Engine by SES for 500 & 800 MW plant at Mojave Dessert, US
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Solar Water Heaters
Potential in India : 140 million sq. mInstalled capacity : 1,500,000 sq. mManufacturing capacity : 150,000 sq. m/year
Solar Water HeatersLarge scale operators coming inNew designs coming into the market :
Selective-coated glass tube in evacuated glass tube units being imported from chinaNew synthetic materials by Sintex, India
Other Solar Thermal Systems
Solar air-heaters and dryers
(Design specific to application)
Solar cookers
Wind Energy Conversion Systems
Potential in India : 45,000 MWInstalled capacity : 4,434 MWManufacturing capacity : 1800 to 3000 MW/year
In field since 1970’sInitially 80% subsidy on such machines – misuseProblems in matching the needs
Wind speeds are high in monsoon, but water table is also near surfaceWind pumps are installed near water-wells. But wind speeds is not always high near a water-well.
Multi-bladed water pumping machines
Wind Energy Conversion Systems
Traditional energy sourceAvailability of woody biomass: 1 kg/day/personPotential for power generation:19,500 MWInstalled capacity : • Cogeneration in sugar factories – 358 MW• Biomass gasifier with 20% diesel – 43 MW
Range of gasifiers available – 5 to 200 kWelect
Biomass Energy :Thermo-Chemical Conversion
Biomass Energy :Thermo-Chemical Conversion
Technology development of gasifier run engine since 1980’s in research institutesIndia is a leader in gasifier technology todayAvailability, collection, processing and transport of agricultural biomass is a challenging taskInsistence on Energy Plantation is requiredThermal process applications are also attractive
Bio-gas from cattle dung2 to 5 cu.m plants : 75,000 per yearCommunity plants : 3,500 per year
Waste to energyIndustrial waste processing using bio-route
Few plants of up to 200 kW capacityUrban solid waste processed to get bio-fertilizers
Improved cook-stoves1.5 million per year in 10,000 villagesThrough self-employed workers and entrepreneur
Biomass Energy :Bio-Chemical Conversion
Starch to Natural Gas using Tri-phasicbio-conversion 24 hrs process, compactAny starch can be used !
Spent oil-cakesWaste grainStarchy bio-mass
Applications: Cooking, process heat upto700°C, stationery engines, mobile engines
Biomass Energy :Bio-Chemical Conversion using starch
40 to 50% of liquid fossil fuels go into transport and stationery diesel enginesBio-Diesels can be used: Any oil can be used !
Non-edible oilsWaste cooking oils
Reducing the viscosity Improving the Octane numberAvailability of raw materialBlendingLife of engine
Biomass Energy :Bio-Diesel
Solar Photo-voltaic System
Potential in India : 20 MWp / sq. kmInstalled capacity : 2.74 MWp (Grid) + 1.6 MWp
Exported capacity : 40 MWp
Manufacturing capacity : 60 MWp / year
EconomicsSolar thermal is economic (Re.1/kWhth) when it is compared with thermal systems running on electrical power or liquid fossil fuels in industry
Wind energy is the next (Rs.4 to 5/kWhelect) subject to proper siting and maintenance
Biomass energy is also economic (Rs.3/kWhelect or more) subject to the cost of the biomass available and organizational capability to collect biomass
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