Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director...

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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

Transcript of Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director...

Page 1: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 2: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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.

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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)

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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

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Principles of system integration

RHC Workshop Solar Process Heat - Brussels, March 15 2003 5 Elimar Frank, SPF Research Director

Source: B. Schmitt, Uni Kassel

Page 6: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 7: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 8: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

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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

Page 10: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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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RHC Workshop Solar Process Heat - Brussels, March 15 2003 11 Elimar Frank, SPF Research Director

Collectors

www.schueco.com

www.solid.at

80-120 °C

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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

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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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RHC Workshop Solar Process Heat - Brussels, March 15 2003 14 Elimar Frank, SPF Research Director

Collectors

www.itcollect.de www.nep-solar.com

120-250 °C 80-120 °C

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RHC Workshop Solar Process Heat - Brussels, March 15 2003 15 Elimar Frank, SPF Research Director

Collectors

www.smirro.de www.solitem.com

120-250 °C

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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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RHC Workshop Solar Process Heat - Brussels, March 15 2003 17 Elimar Frank, SPF Research Director

Collectors

www.industrial-solar.de

www.chromasun.com

120-250 °C

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RHC Workshop Solar Process Heat - Brussels, March 15 2003 18 Elimar Frank, SPF Research Director

Collectors

www.tsc-concentra.com

120-250 °C

Page 19: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

… and new test rig specifications

Collector

testing

so far…

RHC Workshop Solar Process Heat - Brussels, March 15 2003 19 Elimar Frank, SPF Research Director

Testing and Certification

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RHC Workshop Solar Process Heat - Brussels, March 15 2003 20 Elimar Frank, SPF Research Director

Testing and Certification

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RHC Workshop Solar Process Heat - Brussels, March 15 2003 21 Elimar Frank, SPF Research Director

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

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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

Page 23: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

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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

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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 !!

Page 26: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 27: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 28: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 29: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 30: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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)

Page 31: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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»?

Page 32: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 33: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

RHC Workshop Solar Process Heat - Brussels, March 15 2003 33 Elimar Frank, SPF Research Director

Collectors

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

0 20 40 60 80 100 120 140

Temperature difference T_Coll_mid - T_Amb [K]

Eff

icie

ncy

nAir 1 bar

Air 0,01 bar

Krypton 0,01bar

Quelle: ZAE Bayern

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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)

Page 35: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 36: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

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

Page 37: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

RHC Workshop Solar Process Heat - Brussels, March 15 2003 37 Elimar Frank, SPF Research Director

Collectors

Page 38: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

RHC Workshop Solar Process Heat - Brussels, March 15 2003 38 Elimar Frank, SPF Research Director

Collectors

www.trivellienergia.com

www.itcollect.de

Page 39: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

RHC Workshop Solar Process Heat - Brussels, March 15 2003 39 Elimar Frank, SPF Research Director

Collectors

www.nep-solar.com www.sopogy.com

Page 40: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

RHC Workshop Solar Process Heat - Brussels, March 15 2003 40 Elimar Frank, SPF Research Director

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

Page 41: Process Heat Collectors and Integration Aspects of Solar ... · Elimar Frank SPF Research Director Institute for Solar Technology SPF HSR Univ. for Applied Sciences Rapperswil Process

(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