Solar Thermalfor Industrial Use (S.B.K)

Solar Thermal Systems for Industrial Process Applications
10000 storage volume,m 3
Dr. Shireesh Kedare

Energy Systems Engineering, IIT-Bombay
Load temperature constraint b 1000 volume limits for given area
operating region Area limits for given volume o
100 m
Adjunct Associate Professor
10 Minimum Volume 1 50 0.1 70 90
Maximum temp.constraint (100C) 130 150 170 190 210 230
110
Minimum Area Collector area,m 2
Clique Developments Pvt. Ltd., Mumbai
Director
RENET Workshop, IIT-Bombay September 21-22, 2006
Solar Industrial Process Heat

Potential: Vast potential exists in industry for application of solar devices for process heat Technologies: A few solar devices are available for industrial applications Flat plate water heaters / air heaters Evacuated glass tube collectors Concentrating solar devices producing higher temperatures (100 to 250 C) are being available Integration: The basic technology for thermal integration is available Challenge: Specific applications of solar energy and its optimization is needed
10000 Load temperature constraint storage volume,m 3 b 1000 100 m volume limits for given area operating region Area limits for given volume o 10 Minimum Volume 1 a Maximum temp.constraint (100C) 190 210 50 70 90 110 130 150 170 230 Minimum Area 0.1 Collector area,m 2
Why Solar Industrial Process Heat ?

India uses 100 mill tons of oil annually
40% of this oil consumption is in industry 60 to 70% of industrial energy use is in thermal form 70% of industrial thermal energy use in the range below 250C
15 to 20% of total energy use, say 15 mill tons of oil is used in industry below 250C. 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 3
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 India About 5 to 6 kWh per day on horizontal surface
India has large number of decentralized, small industrial units Fuel cost is high in India Paraboloid Concentrators can be fabricated at lower costs
Challenges: Solar Industrial Process Heat

BUT
Solar Energy is dilute Solar 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 technologies Other renewable technologies Conventional fossil fuel based thermal systems ?
What will be its cost ?

Quest for
Concentrated Solar Energy

Initially, parabolic trough with line focus and heliostats were pursued for power generation. In India, Scheffler dish is available for low temperature steam generation. Solar Bowl at Auroville is also an important effort. 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 Installation and Focus Tests of ARUN160 Integration and Performance Tests of ARUN160 Solar Industrial Process Heat
6
Solar Concentrators
Comparison: In a nut-shell
PTC is costly in the present Indian scenario and has less applicability Heliostats 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 fabricate ARUN has high potential in industrial as well as power generation applications, but its comparatively involved to fabricate
ARUN Solar Concentrator for Industrial Process Heat

Industrial Process Heat at 200 to 250C can be supplied any time of the day or night Steam can be generated up to 40 kg/cm2 Thermic oils can be heated to 200 - 250C Air can be heated for drying
Possibilities of Industrial Process Heat Applications, technical Potential in India and Economics
Comparison of Solar Systems

Cost of Thermal Energy from different solar thermal units (Rs./m2) 40,000 35,000 30,000
37,600 36,000
Rs./m
25,000 20,000 15,000 10,000 5,000 0

6,000 10,000
20,000 20,000
21,429 15,625 11,000
8,000
So la ra ir he So at Ev la er rw ac ua at er te d he tu at be er W at er H ea te r Sa nd ia ,U S AN A U ,A us tra Pa l ia ra bo lic Tr ou gh So la rB ow l Sc he fl e rd is h
Ar un 16 0
10
Ar un 70

Power Cost (Capital cost / Power) (Rs./ kW th)
100000 90000 80000 70000 R k s./ W
th
89524
85714
60000 59571
61500
60000 50000 40000 30000 20000 10000 0 14760 21648 38500 34167
he at er w at er he at er S an di a, U S A A N U ,A us tr P ar al ia ab ol ic Tr ou gh S ol ar B ow S l ch ef le r di sh
S ol ar
S ol ar
ai r
A ru n1 60
11
A ru n7 0

Cost of Thermal Energy from different solar thermal units (Rs./kWhth) 6.00 5.00
4.77 3.73 4.00 3.57 2.56 2.20 1.42
Rs./ kWhth
4.00 3.00 2.00

0.92 1.35
1.00 0.00
So la ra ir he So at er la rw at er he at er Sa nd ia ,U SA A NU ,A us tra Pa lia ra bo lic Tr ou gh So la rB ow l Sc he f le rd is h A ru n1 60 A
12
ru n7 0

Power specific system cost, Rs./ kWth
120000 100000 80000 60000 40000 20000 0 0

Schefler dish
50
100
Arun70
150
Arun160
T-Ta 200
250
13

6
Comparative Life Cycle Energy cost, Rs./ kWhth
5 4 3 2 1 0 0 50
Schefler dish
T-Ta
100
150
Arun70
200
Arun160
250
14
Solar Concentrator Economic Viability

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
Existing government support : 12% subsidy available from MNES. 80% accelerated depreciation CO2 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 250C 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 technologies Other renewable technologies Conventional fossil fuel based heaters Economic today: Positive cash flow from year 1
10000 Load temperature constraint storage volume,m 3 b 1000 volume limits for given area
100 m
operating region Area limits for given volume o
10 Minimum Volume 1 50 0.1 70 90
Maximum temp.constraint (100C) 130 150 170 190 210 230
110
Minimum Area Collector area,m 2
Dr. Shireesh Kedare

sbkedare@iitb.ac.in sbkedare@gmail.com sbk@cliquetechnologies.com
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-Bombay Various optical, mechanical, electrical, electronic and thermal components were designed by Clique Developments Pvt. Ltd., vendors were developed and the components were sent to Latur The 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.
900 800 700
Temp (C)
600 500 400 300 200 100 0 -0.75 -0.25 0.25 0.75
r (m)
450 400 350
Flux (kW/m2)
300 250 200 150 100 50 0 -0.75 -0.25 0.25 0.75
r (m)
900 800 700
Temp (C)
600 500 400 300 200 100 0 -0.75 -0.25 0.25 0.75
r (m)
450 400 350
Flux (kW/m2)
300 250 200 150 100 50 0 -0.75 -0.25 0.25 0.75
r (m)
Clique Developments Pvt. Ltd. www.cliquetechnologies.com
Energy Systems Engineering Indian Institute of Technology Bombay
Integration and Performance testing of ARUN160

The thermal components were installed and insulated Instrumentation and data-logging were completed Performance data was collected System was run with water in place of milk System was run for milk pasteurization Boiler is shut-off for Sunny days
Design Space for Optimization of Integration

Storage volume,m 1000
3
Design space for 25000 LPD Milk Pasteurization
F=0.8 F=0.9 1
100
F=1 Limiting line of 200C
10
*
1
Latur Design Point 160 m2, 4.5 m3
0.1
Collector area,m
130 150 170 190 210 230 250 270 290 310 330 350
0.7 0.6 0.5 Efficiency 0.4 0.3 0.2 0.1 0 0 0.02 0.04 0.06
y = -1.3336x + 0.5964
0.08
0.1
0.12
(Tm-Tamb)/Ibn, C.m 2/W
Solar Thermal Power from Large Solar Concentrator : ARUN

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 / biogas In combined cycle plant with steam in Rankine cycle from Exhaust-Gas-Heat-RecoveryBoiler augmented by Solar units Stirling engine with gas fired back-up heating Using Suryamukhi PV on Tracker Using Concentrated PV cells
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
Steam Engine Gen /Turbn
Thermal Storage
Gas/oil Superheater
Condenser and filter
Solar Energy hybrid system with Combined Gas Cycle (CGC)
Large Solar Concentrator ARUN with 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 installations Solar farm for power generation is now feasible.
Stirling engine for 100 m2 paraboloid dish
Large Solar Concentrator ARUN with Stirling Engine

ARUN160 as well as ARUN70 may be fitted with Stirling engine
ARUN160 Ap. Area Electrical Power Operating hours 160 m2 25 kWelect ARUN70 70 m2 9.2 kWelect 20,000-25,000 Units / year
2500 (6-9 h/day;300-340 day/yr)
Annual Electricity 60,000-75,000 generated, kWh Units / year
Paraboloid Dishes with Stirling Engine at Point Focus
100 m2 Dishes with Stirling Engine by SES for 500 & 800 MW plants at Mojave Dessert, US
Suryamukhi
as PV Tracker
Suryamukhi
as PV Tracker
ARUN may be used as Suryamukhi for solar PV on Tracker

Normal PV Capacity PV Cost Cost of mounting Annual operation Cost ratio Output Energy ratio 22 kWp Rs. 300/W 2% 1500 hrs 100 % 100 % PV on Suryamukhi 22 kWp Rs. 300/W 15% 2000 hrs 113 % 125 to 130 %
Large Solar Concentrator ARUN with Concentrated PV

ARUN160 as well as ARUN70 may be fitted with Concentrated PV cells Receiver can be designed for efficient cooling Concentrated PV cells need to be imported Cost of Concentrated PV cells ?
Paraboloid Dish with Fixed Focus on ground
m2
Scheffler dish for cooking, INDIA
m2
Scheffler dish for cooking, INDIA
7 m2 Scheffler dish for cooking, Mt.Abu, India
Scheffler Paraboloid Dish with Fixed Focus on ground 7 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/(kWh /day)
4
Fixed Spheroidal Dish with Moving Focus
176 m2 Solar Bowl at CSR, Auroville, INDIA
Parabolic Trough Collectors with Line Focus
At Tehachapi, US
1
Parabolic Trough Collectors with Line Focus
At SEC of MNES, New Delhi

2
Heliostats with Receiver on Central Tower
Solar 2, US
At Sandia Lab, US At Armenia, Spain Solar 2, US

5
Heliostat by SERI
Paraboloid Dish 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 Engine at Test Field
100 m2 SAIC Dish with Stirling Engine, US
56 m2 Dish with Stirling Engine at VIT, INDIA
Paraboloid Dish Stirling Engine at Point Focus
100 m2 Dishes with Stirling Engine by SES for 500 & 800 MW plant at Mojave Dessert, US
Solar Water Heaters
Potential in India : 140 million sq. m Installed capacity : 1,500,000 sq. m Manufacturing capacity : 150,000 sq. m/year
Solar Water Heaters

Large scale operators coming in New designs coming into the market :
Selective-coated glass tube in evacuated glass tube units being imported from china New synthetic materials by Sintex, India
Other Solar Thermal Systems
Solar cookers Solar air-heaters and dryers

(Design specific to application)
Wind Energy Conversion Systems

Potential in India : 45,000 MW Installed capacity : 4,434 MW Manufacturing capacity : 1800 to 3000 MW/year
Wind Energy Conversion Systems

Multi-bladed water pumping machines In field since 1970s Initially 80% subsidy on such machines misuse Problems in matching the needs
Wind speeds are high in monsoon, but water table is also near surface Wind pumps are installed near waterwells. But wind speeds is not always high near a water-well.
Biomass Energy :
Thermo-Chemical Conversion
Traditional energy source Availability of woody biomass: 1 kg/day/person Potential for power generation:19,500 MW Installed 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
Technology development of gasifier run engine since 1980s in research institutes India is a leader in gasifier technology today Availability, collection, processing and transport of agricultural biomass is a challenging task Insistence on Energy Plantation is required Thermal process applications are also attractive
Biomass Energy :
Bio-Chemical Conversion
Bio-gas from cattle dung Waste to energy
2 to 5 cu.m plants : 75,000 per year Community plants : 3,500 per year Industrial waste processing using bio-route Urban solid waste processed to get biofertilizers 1.5 million per year in 10,000 villages Through self-employed workers and entrepreneur
Few plants of up to 200 kW capacity
Improved cook-stoves
Biomass Energy :
Bio-Chemical Conversion using starch

Starch to Natural Gas using Tri-phasic bio-conversion 24 hrs process, compact Any starch can be used !
Spent oil-cakes Waste grain Starchy bio-mass
Applications: Cooking, process heat upto 700C, stationery engines, mobile engines
Biomass Energy :
Bio-Diesel
40 to 50% of liquid fossil fuels go into transport and stationery diesel engines Bio-Diesels can be used: Any oil can be used ! Reducing the viscosity Improving the Octane number Availability of raw material Blending Life of engine
Non-edible oils Waste cooking oils
Solar Photo-voltaic System
Potential in India : 20 MWp / sq. km Installed capacity : 2.74 MWp (Grid) + 1.6 MWp Exported capacity : 40 MWp Manufacturing capacity : 60 MWp / year
Economics
Solar 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

Solar Thermalfor Industrial Use (S.B.K)

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Solar Thermal Systems for Industrial Process Applications

10000 storage volume,m 3

Dr. Shireesh Kedare

Load temperature constraint b 1000 volume limits for given area

operating region Area limits for given volume o

Adjunct Associate Professor

10 Minimum Volume 1 50 0.1 70 90

Maximum temp.constraint (100C) 130 150 170 190 210 230

Minimum Area Collector area,m 2

Clique Developments Pvt. Ltd., Mumbai

RENET Workshop, IIT-Bombay September 21-22, 2006

Solar Industrial Process Heat

Solar Industrial Process Heat

Why Solar Industrial Process Heat ?

+ Reduction in the emission of carbon dioxide as well as other pollutants

Why Solar Industrial Process Heat ?

India has abundant Solar Energy

Challenges: Solar Industrial Process Heat

What will be its cost ?

Concentrated Solar Energy

Solar Industrial Process Heat

ARUN Solar Concentrator for Industrial Process Heat

Comparison of Solar Systems

25,000 20,000 15,000 10,000 5,000 0

21,429 15,625 11,000

Solar Industrial Process Heat

Comparison of Solar Systems

Solar Industrial Process Heat

Comparison of Solar Systems

4.00 3.00 2.00

Solar Industrial Process Heat

Comparison of Solar Systems

120000 100000 80000 60000 40000 20000 0 0

Solar Industrial Process Heat

Comparison of Solar Systems

Solar Industrial Process Heat

Solar Concentrator Economic Viability

Possibilities of Electrical Power Generation

operating region Area limits for given volume o

10 Minimum Volume 1 50 0.1 70 90

Maximum temp.constraint (100C) 130 150 170 190 210 230

Minimum Area Collector area,m 2

Dr. Shireesh Kedare

ARUN 160 at Latur

Energy transfer mechanism in the cavity receiver

Experimental set-up of the open mouth cylindrical cavity receiver

Focus Test : ARUN 160 at Latur

900 800 700

450 400 350

300 250 200 150 100 50 0 -0.75 -0.25 0.25 0.75

900 800 700

450 400 350

300 250 200 150 100 50 0 -0.75 -0.25 0.25 0.75

Clique Developments Pvt. Ltd. www.cliquetechnologies.com

Energy Systems Engineering Indian Institute of Technology Bombay

Integration and Performance testing of ARUN160

Design Space for Optimization of Integration

Design space for 25000 LPD Milk Pasteurization

F=1 Limiting line of 200C

(Tm-Tamb)/Ibn, C.m 2/W

Clique Developments Pvt. Ltd. www.cliquetechnologies.com

Energy Systems Engineering Indian Institute of Technology Bombay