SOLAR PAYBACK - TRAIN-THE-TRAINER SOLAR HEAT FOR ... · r 23 g 156 b 125 r 242 g 148 b 0 r 31 g 130...
Transcript of SOLAR PAYBACK - TRAIN-THE-TRAINER SOLAR HEAT FOR ... · r 23 g 156 b 125 r 242 g 148 b 0 r 31 g 130...
©Fraunhofer ISE/Foto: Guido Kirsch
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Introduction
SOLAR PAYBACK - TRAIN-THE-TRAINER SOLAR HEAT FOR INDUSTRIAL PROCESSES
Dr. Wolfgang Kramer
Theda Zoschke
Fraunhofer Institute for Solar Energy Systems ISE
SPB Train-the-Trainer Workshop
Pune, Dec 3-5, 2019
www.ise.fraunhofer.de
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Solar Resource
Solar
Wind
Biomass
Geothermal
Hydro
Annual world energy demand
© Fraunhofer ISE
~1,4∙106 EJ/a
available solar energy
571 EJ/a
energy consumption
Energy Demand
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Potential of Solar Process Heat Final Energy Consumption per Sector
Total Final Energy Consumption (FEC) in industry is comparable to transport or building sectors
Process heat market is bigger than electricity market
360 EJ of FEC
[1] International Energy Agency (IEA), World Energy Statistics 2016, online tables, www.iea.org/statistics/ [2] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [1]
[1,2]
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Potential of Solar Process Heat Temperature Levels of Heat Demand
Low and medium-temperature heat demand represent 52 %
High temperature heat dominating in Energy-Intensive (EI) sectors
360 EJ of FEC
[1] International Energy Agency (IEA), World Energy Statistics 2016, online tables, www.iea.org/statistics/ [2] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [1]
[1,2]
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Potential of Solar Process Heat Temperature Levels for Industrial Processes
[1] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [2] [2] International Energy Agency (IEA), World Energy Statistics 2014, online tables
EI sectors
HT (>400°C)
42,2 EJ
MT (150°C-400°C)
18,1 EJ
LT (<150°C)
24,5 EJ
EI
Non-EI
≈ 50% : 50% [1,2]
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Potential of Solar Process Heat Installed Capacity of Solar Thermal
Estimated solar thermal capacity installed worldwide: 410 GWth (586 million m² of collector area, 1.53 EJ/year, 112.3 Mton CO2) [1]
Main application field: 85% residential sector (hot water, space heating)
[1] Weiss et al., 2019. Solar Heat Worldwide, Global Market Development and Trends in 2018, Detailed Market Figures 2017, AEE-INTEC, IEA/SHC
Share of total installed capacity in operation (glazed and unglazed water/air collectors) by economic region in 2017 [1] Total capacity of glazed FP+ET collectors by
economic region in 2017 (kWhth/1,000 inhab.) [1]
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Potential of Solar Process Heat Current Market of Solar Thermal
Installed capacity dominated by Evacuated Tube Collectors (ETC)
Recent market regression (yet expanding in Asia w/o China)
Distribution of the total installed capacity in operation by collector type in 2017 – WORLD [1]
Installed capacity worldwide (kWhth/1,000 inhab.) in 2017 [1]
[1] Weiss et al., 2019. Solar Heat Worldwide, Global Market Development and Trends in 2018, Detailed Market Figures 2017, AEE-INTEC, IEA/SHC
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Potential of Solar Process Heat Estimated Market Development of Solar Thermal
Potential of Solar Heat for Industrial Processes (SHIP) is considered significant
[1] Technology Roadmap - Solar Heating and Cooling, International Energy Agency, 2012.
Roadmap vision for Solar Heating and Cooling [1]
7.2 EJ/a
8.9 EJ/a
1.5 EJ/a
0.4 EJ/a
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Potential of Solar Process Heat Status of SHIP
Solar thermal applications in industrial sector are increasing
Installed SHIP capacity still < 1% of total installed solar thermal capacity
Distribution of total installed capacity (glazed water collectors) by application and economic region (2017) [1]
[1] Weiss et al., 2019. Solar Heat Worldwide, Global Market Development and Trends in 2018, Detailed Market Figures 2017, AEE-INTEC, IEA/SHC
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Potential of Solar Process Heat Recent Market Development
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Outlook for solar process heat The viscious circle of low deployment rates
[1]
[1] Solar Payback Brochure, https://www.solar-payback.com/wp-content/uploads/2017/07/Solar-Heat-for-Industry-Solar- Payback-April-2017.pdf (Accessed November 2019)
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Outlook for solar process heat Break the viscious circle
Step up communication efforts to raise awareness of SHIP among potential customers in industry
Support financing models to reduce risks and initial costs
Implement measures for raising energy prices (e.g. carbon tax) or stipulating a renewable quota in certain industries
[1]
[1] Solar Payback Brochure, https://www.solar-payback.com/wp-content/uploads/2017/07/Solar-Heat-for-Industry-Solar- Payback-April-2017.pdf (Accessed November 2019)
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Potential of Solar Process Heat Challenges
Competitiveness
Technology cost reductions
Optimized integration with waste heat and alternative technologies
Switch from Payback to NPV on investment appraisal
Hedging against volatile energy prices
Contracting models PPA duration, residual value
COP21 emission goals
[1] SolarPACES IEA, http://www.solarpaces.org/ [2] SHC/IEA Task 49, http://task49.iea-shc.org/ [3] INSHIP ECRIA, H2020 GA 731287, http://inship.eu/index.php
[1] [2] [3]
[4] IKI Solar Payback, BSW Solar / BMBU [5] FROnT, H2020, http://www.front-rhc.eu/ [6] SHC/IEA Task 54, http://task54.iea-shc.org/ [7] TrustEE, H2020 GA 696140, http://www.trust-ee.eu/
[5] [6] [7] [4]
Technology
Process level integrations process intensification
Supply level integration Balance of Plant
Available area building integration, compact optical designs
Hybridization combination with EE, heat pumps, biomass/biogas, power-to-heat
Durability industrial environment conditions / requirements
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Suitable Solar Thermal Technologies Available Technologies for SHIP Plants
Types of solar collectors:
Flat Plate FPC
Evacuated Tube ETC
Linear Fresnel LFC
Parabolic Trough PTC
Dish Technology
photos from https://www.solar-payback.com/gallery/gallone_en.php, Accessed October 2019
© Sunoptimo © Aschoff Solar
© Ecotherm Austria © Vicot Solar Technology © Megawatt Solutions
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Suitable Solar Thermal Technologies Collector Technology vs. Temperature Level
Suitable solar collector technologies
[1]
[1] IEA TASK 49, https://www.solar-payback.com/markets/, Accessed October 2019
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Suitable Solar Thermal Technologies Potential Supplier of SHIP Systems
International Database compiled by Solrico [1] based on three surveys 2016, 2018 and 2019
https://www.solar-payback.com/suppliers/
Turnkey suppliers that sold SHIP systems with a total of more than 10’000 m² [2]
S-O.L.I.D (Austria)
Pampa Elvira Solar (Chile)
Sunrain Group; Vicot Solar Technology; Himin Solar; Linuo Paradigma (China)
Aalborg CSP (Denmark)
Inter Solar Systems (India)
Soliterm Group (Germany)
[1] World Map Process Heat Specialists, http://www.solrico.com/fileadmin/solrico/media/doc/World_map_documents/ World_map_Process_Heat_Sepcialists_EN_2017_F.pdf [2] SOLRICO survey among SHIP specialists, carried out in October/November 2016 – 71 companies provided data and filled in a 4-page questionnaire.
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Suitable Solar Thermal Technologies Average Solar Process Heat System Costs
Wide range of installed system costs per solar field area depending on
technology
temperatures
storage size
complexity
integration point
…
[1]
[1] IEA SHC Task 49 Data base, http://ship-plants.info
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Suitable Solar Thermal Technologies Range of Solar Heat Costs
Solar heat production costs depend on
quality of solar collectors
lifetime of solar system (~20 years)
location & irradiance
general inflation
energy inflation
…
[1] G. Stryi-Hipp et al., "Strategic Research Priorities for Solar Thermal Technology," Brussels, 2012.
[1]
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Existing Projects SHIP systems in India
SHIP systems database [1]
295 projects listed worldwide
[1] World Map of Solar Thermal Plants, http://ship-plants.info/solar-thermal-plants-map, (Accessed November 2019)
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Existing Projects Examples of Stationary Technologies
[1] Arcon-Sunmark, 2015. http://arcon-sunmark.com/cases/codelco-minera-gaby-chile [2] http://ship-plants.info/solar-thermal-plants/140-jiangsu-printing-and-dyeing- china?collector_type=4&country=China
Textile Jiangsu Yitong, China
Evacuated Tube Aperture: 9,000 m² Application: process pre-heating Oper. Temp.: 50°C Commissioning : 2011
© Sunrain Co. Ltd [2]
Copper mine “Gabriela Mistral”, Chile
Flat Plate Aperture: 43,920 m² Application: Process water and electrolyte heating Oper. Temp.: 50°C Commissioning : 2015
© Arcon-Sunmark [1]
[5]
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Existing Projects Examples of Stationary Technologies
La Parrena copper mine, Mexico [1]
Flat Plate Collector Solar Field: 6270 m² Thermal Power: 4.4 MWth Solar Field covers 58% of annual heat demand
[1] http://ship-plants.info/solar-thermal-plants/155-dairy-plant-el-indio-mexico?collector_type=5 [2] http://arcon-sunmark.com
[27]
[2]
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Existing Projects Examples of Stationary Technologies
Source: AEE INTEC
Brewery Göss , Austria
Flat Plate Aperture: 1375 m² / 1064 kWth Application: Brewing Process Oper. Temp.: 50-100°C Commissioning: 2013
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Existing Projects Examples of Tracking Technologies
[1] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/ [2] http://ship-plants.info/solar-thermal-plants/155-dairy-plant-el-indio-mexico?collector_type=5
Dairy El Indio, Mexico
Parabolic Trough Aperture: 132 m² Application: Make-up water pre-heating Oper. Temp.: 95°C Commissioning: 2012
© Inventive Power S.A. de C.V. [2]
Services MTN Johannesburg, South Africa
Linear Fresnel Aperture: 396 m² Application: Air conditioning Oper. Temp.: 180°C Commissioning: 2014
© Industrial Solar [1]
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Existing Projects Examples of Tracking Technologies
FICHTNER SOLAR GmbH
El NASR Pharmaceutical Chemicals , Egypt
Parabolic Trough Aperture: 1900 m² / 1.33 MWth Application: Steam generation, 1.3 t/h Oper. Temp.: 170°C, 7.5 bar Commissioning: 2003
Tirumala Tirupati Devasthanams , India
Parabolic Dish Application: Steam cooking for 1500 people (worlds largest)
Gadhia Solar Energy Systems Pvt. Ltd.
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Existing Projects Examples for Direct Steam Generation at Supply Level
Direct Steam Generation
Steam for sterilization, drying, fermenting
Saturated Steam 160 °C
20 minutes steam storage for increased stability
Reduction of Diesel: 30.000 liter per year
https://www.youtube.com/watch?v=ibiUoACea6o
[1] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/
[1] © Industrial Solar
RAM Pharmaceuticals , Jordan
Linear Fresnel Aperture: 396 m² Application: Process Steam Operating Temp.: 160°C Commissioning : 2015
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Existing Projects Examples for Direct Steam Generation at Supply Level
Stable steam pressure under variable solar radiation conditions
[1] Berger, M. et al: First year of operational experience with a solar process steam system for a pharmaceutical company in Jordan, SHC 2015, International Conference on Solar Heating and Cooling for Buildings and Industry
So
lar
rad
iati
on
(D
NI)
[W
/m2
] Te
mp
era
ture
[°C
]
© Industrial Solar [7]
Ste
am
pre
ssu
re [
ba
r]
[1]
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Existing Projects Examples of Tracking Technologies
The largest SHIP project: 5.6 trillion BTUs, 300 kton/year CO2
[1] MIT, 2016. Technology Review, Arab Edition. http://technologyreview.me/en/energy/oman-explores-solar-powered-oil-recovery/ [2] https://www.glasspoint.com/
Miraah Solar EOR Pilot Project, Amal, Oman
Petroleum Development Oman Parabolic Trough in greenhouse
Status (autumn 2019): Delivered first steam in 2017, 4 of 36 blocks operational
Pilot: 6 ton steam / day
Full-scale: 1.0 GWth, 6,0 ktons steam/day, 3 km² (1.9 km² aperture)
[1] © Petroleum Development Oman.
[2]
[2]
© GlassPoint
© GlassPoint
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Suitable Industrial Processes Overview on Sectors and Processes
Main industrial sectors
Chemicals
Food & Beverages
Paper
Fabricated metal
Rubber & Plastic
Machinery & Equipment
Textiles
Wood
Suitable industrial processes
Preheating (input or raw material)
Pasteurization and Sterilization
Washing and cleaning
Chemical reactions
Surface treatment
Space heating
Supply of hot water or steam
Drying and dehydration (Concentration)
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Suitable Industrial Processes Temperature Levels of Sectors and Processes
[1] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012
[1]
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Suitable Industrial Processes Temperature Levels of Sectors and Processes
[1]
[1] C. Lauterbach, B.Schmitt, U.Jordan, K.Vajen; The potential of solar heat for industrial processes in Germany; Kassel University; June 2012
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Suitable Industrial Processes Main Characteristics
temperature level (feed and return)
heat demand of specific processes
load profile per day, week and year
overall energy demand of plant
heat recovery and energy efficiency potential
solar system should always be based on minimum heat demand (avoiding expensive oversizing during entire lifetime)
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Suitable Industrial Processes Best Available Techniques BAT
Industrial processes descriptions and specific BAT for several branches [1]
Ceramic Manufacturing
Ferrous Metal Processing
Food, Drink and Milk
Organic and Inorganic Chemicals
Glass
Non-ferrous Metals
Iron and Steel
Pulp, Paper and Board
Textiles
…
[1] http://eippcb.jrc.ec.europa.eu/reference/
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Suitable Industrial Processes Example of Brewing Process
The brewing process uses malted barley and/or cereals, unmalted grains and/or sugar/corn syrups (adjuncts), hops, water, and yeast to produce beer.
Brewing Handbook, Novoyzmes, 2013
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Suitable Industrial Processes Example of Brewing Process
All thermally driven processes in breweries and malting plants require heat at temperature on process level of between 35 and 105°C
Processes for wort preparation in the brew house:
Pilotanlage zur Bereitstellung solarer Prozesswärme bei der Hütt-Brauerei, Uni- Kassel, 2011
Mashing Purifying Cooking Cooling
Fermentation/Storage
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Suitable Industrial Processes Example of Brewing Process
Integration of solar thermal options in breweries:
Solar return temperature of integration
(large bar = low return temperature)
Effort to integrate the solar heat
(large bar = low effort)
Running time of the process
(large bar = frequent&long running time)
Integration thermischer Solaranlagen zur Bereitstellung von Prozesswärme in Industriebetrieben, Bastian Schmitt, 2014
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Suitable Industrial Processes Example of Brewing Process
Hot water supply integration
Tunnel pasteurisation
Integration thermischer Solaranlagen zur Bereitstellung von Prozesswärme in Industriebetrieben, Bastian Schmitt, 2014
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Outlook for Solar Process Heat SHIP Benefits and Shortcomings
Benefits
Supports companies in long-term cost stability of heat supply and contributes to competitiveness
Opens up new business fields for the renewable energy industry and promotes business development and green jobs
Contributes to climate and environmental goals of the region
Shortcomings
Lack of awareness on technologies
Upfront investment regarded on the pay back period side
Faces resistance to changes in existing heat production systems
Individual assessment of feasibility and layout of solar system
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Outlook for Solar Process Heat SHIP Brief Summary
Solar process heat has a huge potential, however this is not yet tapped
Barriers are lack of certified products, planning expertise and missing models for financing
Many advanced collectors are available for solar field optimized for certain temperature ranges
Using concentrating collectors process steam, absorption chilling, power generation and poly-generation is possible
Different plant layouts and integration schemes can be realized and optimized to loads and load profiles
Markets in many countries with high direct solar irradiation
Solar thermal process heat is a market of the future
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Outlook for Solar Process Heat SHIP Challanges and Approaches
Challenge Approach
Commercial viabilitiy without subsidies, tax credits etc.
Mass production of customized systems and components ESCO and financing models
Match of process load demands and variable solar input
Development of improved storage concepts (i.e. phase change storage systems)
Storage for periods with little irradiation Hybridisation with conventional sources / biomass
Space availability, collector orientation, building integation, shading
Customised solar engineering
System integration and efficiency optimisation
Process control mechanisms and planning tool
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Content
Potential of Solar Process Heat
Suitable Solar Thermal Technologies
Examples for Installed Plants
Suitable Industrial Processes
Outlook for Solar Process Heat
SHIP in India
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Solar potential [1]
Global horizontal irradiation for major industrial sites 1’800 – 2’200 kWh/m²
Share of Direct normal irradiation: 1’400 – 1900 kWh/m²
Potential of Solar Process Heat Solar Potential (India)
[1] 2017 The World Bank, Solar resource data: Solargis
[1]
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Potential of Solar Process Heat Forecast in Final Energy Consumption (India)
Rapid increase in almost all sectors [1]
Economic growth
Forecast final energy consumption 5 GWh in 2012 to 13-16 GWh in 2040 [1]
Primary energy comsuption > 85% coal + oil [3]
36% of coal and 85% of oil imported [3]
[1] Draft National Energy Policy, NITI Aayog, https://www.statista.com/statistics/263771/gross-domestic-product-gdp-in-india/ [2] https://www.statista.com/statistics/263771/gross-domestic-product-gdp-in-india/ [3] India’s CST Sector’vison 2022, MNRE-GEF-UNIDO
[2]
GDP India in USD
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Potential of Solar Process Heat in India Heat Demand in SHIP-relevant Industrial Sectors
India has many conventional industries that use low to medium temperatures [1]
dairy and other food and beverage industries
automotive
textile
chemicals
pharmaceutical industries.
viable option for replacing the existing fuel. [1]
[1] Solar payback: Solar Heat for Industrial Processes -Enabling SHIP in India
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Potential of Solar Process Heat in India Market Potential
Market Potential SHIP in India 13,6 GWth = 4,4 % of fuel consumption of 2013/2014 , including 6,45 GWth CST [1]
[1] India’s CST Sector’vison 2022, MNRE-GEF-UNIDO [2] STFI
0,00
0,20
0,40
0,60
0,80
1,00
1,20
1,40
1,60
Up
to 2
001
2001
-02
2002
-03
2003
-04
2004
-05
2005
-06
2006
-07
2007
-08
2008
-09
2009
-10
2010
-11
2011
-12
2012
-13
2013
-14
2014
-15
2015
-16
2016
-17
2017
-18
2018
-19
0,62
0,03 0,10 0,13
0,20
0,40 0,42 0,45 0,56
0,62
0,98 1,06
1,43
1,10 1,18
1,55
0,98
1,16 1,20
Financial Year
Solar collector installations in India in million m2
National Solar Mission
[2]
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Suitable Solar Thermal Technologies Critical Heat Costs for India
Current technology costs :
Collector cost: [1]
Non-conc: ~ 12000 INR/m²
Concentr: ~ 7000-20000 INR/m²
OPEX: 1% of CAPEX
Lifetime: 20
Macroeconomics:
Inflation: 5.2 % [1]
Energy inflation: 10.5%[1]
Equity Hurdle rate: 14.7 %[1]
[1] Solar Payback 2018, Online Calculator, https://www.solar-payback.com/calculator/ [2] 2017 The World Bank, Solar resource data: Solargis
[2]
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Suitable Solar Thermal Technologies Critical Heat Costs for India
Example Case: Washing, bleaching, re-tanning, pasteurising, and cleaning
System:
Vacuum Tube, 900 m², 12 m³
Annual solar yield: 363 MWh/year
Total Invest: ~ 8,889,125 INR
Current Diesel costs: 5,635 INR/MWh
Operation:
Nagpur
Temperature: 75°C
Daytime, 7days/week, continuous daytime
[1] Solar Payback 2018, Online Calculator, https://www.solar-payback.com/calculator/ [2] 2017 The World Bank, Solar resource data: Solargis
Solar LCOH ~ 7,044 INR/MWh [1]
vs.
Current LCOH ~ 13.412 INR/MWh [1]
[2]
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Potential of Solar Process Heat in India Heat Demand in SHIP-relevant Industrial Sectors
India has many conventional industries that use low to medium temperatures – particularly dairy and other food and beverage industries, automotive, textile, chemicals, and pharmaceutical industries. [1]
SHIP will be particularly competitive with expensive fuel sources – such as electricity and petroleum products, especially in states with high irradiation such as the north western and central states of India [1]
There are significant industry agglomerations in parts of the country with good or very good irradiation. Depending on the conventional heater’s efficiency and the cost of the conventional fuel, it can be evaluated if any of the solar thermal technologies might be an economically viable option for replacing the existing fuel. [1]
[1] Solar payback: Solar Heat for Industrial Processes -Enabling SHIP in India
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Different source of information available on Solar Payback Website [1]
Outlook for Solar Process Heat Learn more about SHIP
[1] Links and detailed information on Solar Payback, https://www.solar-payback.com/learn-more/, (Accessed November 2019)
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Thank you for your Attention!
Fraunhofer Institute for Solar Energy Systems ISE
Dr. Wolfgang Kramer
Theda Zoschke
www.ise.fraunhofer.de