Solar Thermalfor Industrial Use(S.B.K)

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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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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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


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


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 ?


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 ConcentratorsSolar Concentrators


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


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


Cost of Thermal Energy from different solar thermal units (Rs./m2)

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Comparison of Solar SystemsComparison of Solar Systems


Comparison of Solar Systems Comparison of Solar Systems Power Cost (Capital cost / Power) (Rs./ kWth)

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Comparison of Solar Systems Comparison of Solar Systems

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• 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


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.


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


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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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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Energy Systems EngineeringIndian Institute of Technology

Bombay

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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Design space for 25000 LPD Milk Pasteurization

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Latur Design Point160 m2, 4.5 m3

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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

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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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1

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


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Solar 2, US

At Sandia Lab, US

At Armenia, Spain

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7Heliostat by SERI


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ParaboloidParaboloid Dish with Point FocusDish with Point Focus

300 m2 Sandia Dish, US


300 m2 Sandia Dish with Cavity Receiver


400 m2 ANU Dish with Cavity Receiver,Australia


100 m2 Dish with Stirling Engineat Test Field






100 m2 SAIC Dish with Stirling Engine, US


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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Bombay

Solar Thermalfor Industrial Use(S.B.K)

Documents

la rb ow

liquid fossil

positive cash

clique developments

parabolic

solar thermal

solar thermal

combined gas