Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director...
Transcript of Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director...
Elimar Frank
SPF Research Director
Institute for Solar Technology SPF
HSR Univ. for Applied Sciences Rapperswil
Process Heat Collectors and Integration Aspects of Solar Process Heat
RHC Workshop Solar Process Heat - Brussels, March 15 2003 2 Elimar Frank, SPF Research Director
What is «Process Heat»?
Heat that is used for industrial processes:
< 100° C (“low” temperature)
washing, rinsing, drying, food preparation, …
also: space heating and hot water preparation
100° C .. 250° C (“medium” temperature)
evaporation, drying, …
often supplied through steam as a local heat carrier
> 250° C (“high” temperature)
manufacture of metals, ceramics, glass etc.
RHC Workshop Solar Process Heat - Brussels, March 15 2003 3 Elimar Frank, SPF Research Director
Sector, Process and Temperature
Source: Uni Kassel, ISES Solar World
Congress 2011 (adapted)
All solar thermal collectors that supply heat for industrial use…
Nomenclature defined in IEA SHC Task 49 / SolarPaces Annex IV:
Requirement: The collector output exceeds 300 W per m2 gross collector area for the following conditions
- 1000 W/m² hemispherical irradiance
- 15 % diffuse fraction
- 20 °C ambient temperature, respectively
Source: Frank et al. (2012), IEA SHC Task 49 Technical Report
«General Requirements and relevant parameters for Process Heat Collectors»)
RHC Workshop Solar Process Heat - Brussels, March 15 2003 4 Elimar Frank, SPF Research Director
What are «Process Heat Collectors»?
below 100°C 100 °C .. 250 °C above 250 °C
“low” temperature collector or application
“mid” temperature collector or application
“high” temperature collector or application
Principles of system integration
RHC Workshop Solar Process Heat - Brussels, March 15 2003 5 Elimar Frank, SPF Research Director
Source: B. Schmitt, Uni Kassel
Supply level - Hot water systems
Solar heat directly used for heating circuit
Usually less complex to identify suitable system concept
Higher temperatures
Special requirements for collectors and collector loop
RHC Workshop Solar Process Heat - Brussels, March 15 2003 6 Elimar Frank, SPF Research Director
Source: B. Schmitt, Uni Kassel
Integration on Process level
Solar heat is directly used for
one or more processes
More complex to identifiy
suitable point of integration
Various system concepts possible
Variable set temperatures, higher
specific solar yields possible
RHC Workshop Solar Process Heat - Brussels, March 15 2003 7 Elimar Frank, SPF Research Director
Source: B. Schmitt, Uni Kassel
Heat Transfer
Fluid
Heat Demand
Load Profile
System integration in general
Process Boundary Conditions Integration Concept Collector
Open/closed loop
Temperature
Heat Demand
Load Profiles
Process Medium
Existing Storages
Heat recovery
RHC Workshop Solar Process Heat - Brussels, March 15 2003 8 Elimar Frank, SPF Research Director
Source: B. Schmitt, Uni Kassel
RHC Workshop Solar Process Heat - Brussels, March 15 2003 9 Elimar Frank, SPF Research Director
Collectors and Operating Temperatures
< 40 °C
< 80 °C
80-120 °C
120-250 °C
Des
ign
Tem
per
atu
re
«Small» Parabolic Trough and Fresnel Collectors High Vacuum Flat Plate Collectors (Advanced) Evacuated Tube Collectors
Uncovered Collectors
250-450 °C
Concentration Factor
1 2 20 80
Standard Flat Plate Collectors
Evacuated tube Collectors, Advanced Flat Plate Collectors CPC Collectors
«Large» Parabolic Troughs and Fresnel Collectors
Technical aspects
- Thermal Performance (temperature and power)
- Durability and reliability (e.g. mechanical loads)
- Versatility (modularity, HTF options, range of boundary conditions, …)
- …
Economic aspects
- Collector costs
- Transport costs
- Field installation costs (collector mounting and installation , piping and hydraulics, …)
- Maintenance
- …
RHC Workshop Solar Process Heat - Brussels, March 15 2003 10 Elimar Frank, SPF Research Director
Collector Development
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Collectors
www.schueco.com
www.solid.at
80-120 °C
RHC Workshop Solar Process Heat - Brussels, March 15 2003 12 Elimar Frank, SPF Research Director
Collectors
www.ritter-gruppe.com
www.kollektorfabrik.de
80-120 °C 120-250 °C
RHC Workshop Solar Process Heat - Brussels, March 15 2003 13 Elimar Frank, SPF Research Director
Collectors
www.srbenergy.com
www.tvpsolar.com
80-120 °C 120-250 °C
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Collectors
www.itcollect.de www.nep-solar.com
120-250 °C 80-120 °C
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Collectors
www.smirro.de www.solitem.com
120-250 °C
RHC Workshop Solar Process Heat - Brussels, March 15 2003 16 Elimar Frank, SPF Research Director
Collectors
www.soltigua.com
www.absolicon.com
120-250 °C
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Collectors
www.industrial-solar.de
www.chromasun.com
120-250 °C
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Collectors
www.tsc-concentra.com
120-250 °C
… and new test rig specifications
Collector
testing
so far…
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Testing and Certification
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Testing and Certification
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Project example: P3 (Pilot Plant for Process Heat Generation in Parabolic Trough Collectors)
108 m2 Solitem Parabolic
Trough collectors on the roof
of the Alanod production
facility in Ennepetal /
Germany
Direct Steam Generation
Consumer: Steam line
(4 bar, 143°C)
Project Partners: Alanod,
Solitem, DLR, ITW, SIJ, ZFS
Project Report available
Source: Solitem
RHC Workshop Solar Process Heat - Brussels, March 15 2003 22 Elimar Frank, SPF Research Director
Project example: P3 (Pilot Plant for Process Heat Generation in Parabolic Trough Collectors)
108 m2 aperture area
steam line:
4 bar, 143 °C
water supply:
1.5 bar, 102 °C
steam drum
check valve
steam dryer
Source: ITW
Highest-located dairy in Europe (altitude 1800m)
115 m2 Parabolic Trough Collector (NEP 1200)
Indirect Steam Generation
Collector loop operated at approx. 180°C collector outlet temperature
Thermal oil
Energy contracting
Replaces about 70 MWh/a fossile fuels
CO2 reduction of 18 t/a
RHC Workshop Solar Process Heat - Brussels, March 15 2003 23 Elimar Frank, SPF Research Director
Project example: Dairy in Switzerland
Source and Copyright: ewz
RHC Workshop Solar Process Heat - Brussels, March 15 2003 24 Elimar Frank, SPF Research Director
Project example: Dairy in Switzerland
>500 kWh solar heat delivery
Direct Irradiance on one-axis tracked aperture in W/m2
Collector Field outlet temperature in ° C
Two more PTC fields on Swiss Dairies with >1000m2
July 16 2012
RHC Workshop Solar Process Heat - Brussels, March 15 2003 25 Elimar Frank, SPF Research Director
Project example: Swiss Paintshop
Source: www.sunwindenergy.com
400 m2 ETC provide hot water @110° C Up to 200 MWh/a solar gain (160 MWh/a guaranteed) Payback approx. 5a (including subsidies)
Equipment supplier also offers solar process heat plant !!
RHC Workshop Solar Process Heat - Brussels, March 15 2003 26 Elimar Frank, SPF Research Director
Project example: Swiss Paintshop
“Green Alliance” between Eisenmann and Ritter XL
RHC Workshop Solar Process Heat - Brussels, March 15 2003 27 Elimar Frank, SPF Research Director
Project example: InSun - Three Solar Process Heat demonstration plants in the meat/dairy/brick industry
Berger Fleischwaren GmbH Sausage Production in Sieghartskirchen, Austria
Flat plate collector system of SOLID
Planned maximum flat plate collector area: 1489 m²
Hot water storage: 80 m³
Expected total annual solar heating gains: 600 MWh/a
Laterizi Gambettola SRL Brick drying in Gambettola, Italy
Linear Concentrating Fresnel Collector of Soltigua
Direct steam production at 180°C (12 bar)
Fresnel collector model: FTM36 (132 m² /collector)
Solar field size: 2 640 m²
Peak solar field net capacity: 1’264 kW
Lácteas Cobreros Milk powder production in Castrogonzalo-Zamora, Spain
Parabolic trough collectors of Solera Sunpower GmbH
Indirect steam generation 200°C outlet temperature.
Number of Parabolic trough collectors: 600
Total collector area: 2040 m²
Expected heating energy gains: 1 GWh/a
EU FP7 Project «FRESH NRG»
(FREsnel for Solar Heat with New Receiver and Geometry)
Start 01.03.2013, 3 years
Aims: Improved Coatings for Receiver (absorber, glass tube), optimized reflector and collector geometry, cost effective manufacturing and easy installation.
Coordinator: Soltigua (Italy)
SPF Tasks:
Lead of WP «Testing»
Characterization of components
Field Test in Jordan
RHC Workshop Solar Process Heat - Brussels, March 15 2003 28 Elimar Frank, SPF Research Director
Project Example: FRESH NRG
RHC Workshop Solar Process Heat - Brussels, March 15 2003 29 Elimar Frank, SPF Research Director
IEA SHC Task 49 / Solar Paces Annex IV
Subtask A Process heat collectors
Subtask B Process optimization Process integration Process intensification
Subtask C Case studies, Integration tools Design guidelines
Sunmark A/S
GEA brewery systems
PROCESS
INTEGRATION
OPTIMIZATION
RHC Workshop Solar Process Heat - Brussels, March 15 2003 30 Elimar Frank, SPF Research Director
Task 49 Subtask A: Process Heat Collectors
Objectives:
Improving solar process heat collectors
and collector loop components
Providing a basis for the comparison of
collectors with respect to technical and
economical conditions
Recommendations for further improvement
of standardized testing procedures
Source: Industrial Solar Source: Schüco International KG Source: Wagner & Co Solartechnik
Lead country: Switzerland (Elimar Frank – SPF)
Commercial products for temperatures up to 250 °C available
Activities in industry and research for further improvements (efficiency, durability, cost optimization, …)
Some new concepts on the way
Some institutes can test medium collectors based on current standards
Further adaptions of standards (ISO 9806) in preparation
Collector FIELDS: Experiences are being gathered leading to further improvements (including hydraulic parts, control, best practise, …)
RHC Workshop Solar Process Heat - Brussels, March 15 2003 31 Elimar Frank, SPF Research Director
Summary / Conclusion
Is Solar Thermal Process Heat a «Hype»?
Thank you for your attention.
Dr. Elimar Frank [email protected]
RHC Workshop Solar Process Heat - Brussels, March 15 2003 Elimar Frank, SPF Research Director 32
RHC Workshop Solar Process Heat - Brussels, March 15 2003 33 Elimar Frank, SPF Research Director
Collectors
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1.00
0 20 40 60 80 100 120 140
Temperature difference T_Coll_mid - T_Amb [K]
Eff
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nAir 1 bar
Air 0,01 bar
Krypton 0,01bar
Quelle: ZAE Bayern
RHC Workshop Solar Process Heat - Brussels, March 15 2003 34 Elimar Frank, SPF Research Director
Anforderungen an verschiedene Komponenten
Appropriate heat transfer fluids (sufficiently temperature-stable, anti-freeze properties, efficient thermodynamic and hydraulic performance)
Reflectors (high performance, cost effective and long service times)
Tracking systems (reliably operating for the whole service time)
Receivers (with and without selective coating, applicable in vacuum or in atmospheric conditions)
Collector loop components (appropriate and temperature-resistant pumps, piping and connection systems, heat exchangers and valves and other system components)
RHC Workshop Solar Process Heat - Brussels, March 15 2003 35 Elimar Frank, SPF Research Director
Wichtig: Messungen und Auswertungen von Kollektoren und Systemen!
Die Mehrheit der derzeit existierenden solaren Prozesswärme-anlagen werden mit Temperaturen unter 100 °C betrieben.
Integrations- und Betriebskonzepte
Um das Solarwärmepotential bis 250 °C voll auszuschöpfen, sind Analysen von Demonstrationsanlagen und verlässliche Kollektormessungen wichtig.
Charakterisierung von Kollektoren und Komponenten
Entwicklung neuer Produkte
Verständnis und Bewertung des Systemverhaltens
RHC Workshop Solar Process Heat - Brussels, March 15 2003 36 Elimar Frank, SPF Research Director
Project example: InSun - Three Solar Process Heat demonstration plants in the meat/dairy/brick industry
RHC Workshop Solar Process Heat - Brussels, March 15 2003 37 Elimar Frank, SPF Research Director
Collectors
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Collectors
www.trivellienergia.com
www.itcollect.de
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Collectors
www.nep-solar.com www.sopogy.com
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Integration on Process level
direct system: collector medium = processing medium continuous process i.e.: drying
indirect system:
discontinuous processes storage
most common system
indirect system: collector medium ≠ processing medium continuous process
heat exchanger
heat exchanger
process
process
process
heat exchanger
tank
(1) Parallel integration: Direct steam supply
(2,3) Serial integration: Preheating of make-up or boiler feed water
Integration on Supply level (steam)
RHC Workshop Solar Process Heat - Brussels, March 15 2003 41 Elimar Frank, SPF Research Director
Source: B. Schmitt, Uni Kassel