ST Switzerland by gstec

VIEWS: 4 PAGES: 33

									SOLAR INDUSTRIAL PROCESS HEAT




          Example of concentrated solar systems (PTC)
          in the dairy industry in Switzerland

          Stefan Minder - NEP Solar AG
          SHC Workshop on Solar Process Heat for Industry
          15th of March 2013


                                                                          2012


         Technoparkstrasse 1 | 8005 Zürich | Switzerland
         Phone +41 44 445 1695 | Fax +41 43 411 9008| www.nep-solar.com
                                NEP Solar
                                Medium Temperature Process Heat
                                Project Examples in Swiss Milk Industry
                                Lessons




SHC Workshop - March 2013   Solar Industrial Process Heat                 Page 2
                                       NEP Solar AG

 Supplier of parabolic trough collectors for process heat in the 100 - 250°C range
 Start-up with roots in Australia, a Swiss company since 2011
 Robust, modular, industrial quality troughs PolyTrough 1200 and 1800




                                                                                  © ewz
 SHC Workshop - March 2013           Solar Industrial Process Heat                    Page 3
                                         NEP Solar Experience
            9 Projects in Europe and Australia installed or in execution since 2008

                                                                                         Emmi / LESA




Prototype (2008)            Desalination R&D (2009) Solar Cooling (2010)                 Process heat (2011)


                                                                            Emmi / TdM      Cremo




Waste treatment (2011)      Tri-Generation (2011)          Process heat (2012)


                                                              2 Projects in Execution: 1x Process heat, 1x CSP

SHC Workshop - March 2013                   Solar Industrial Process Heat                                      Page 4
                                NEP Solar
                                Medium Temperature Process Heat
                                Project Examples in Swiss Milk Industry
                                Lessons




SHC Workshop - March 2013   Solar Industrial Process Heat                 Page 5
                                    Solar Thermal Applications
                     Temperature range of typical solar thermal applications




                                                                                       Power Generation

                                                Industrial Process Heat

      Thermal      1 stage                     2 stage                      3 stage
       Cooling
                  DHW

               Heating

             Pre-Heating


  40°C        70°C          100°C   130°C     170°C         200°C           230°C     260°C   290°C   320°C


SHC Workshop - March 2013                   Solar Industrial Process Heat                                 Page 6
              Solar Heat: Technology choice depends on application temperature


                                                                      300 - 500°C            Utility scale
                                                                  Large concentrating        power gen.
                                                                       collectors            (CSP)


                                                                          •   Industrial Process Heat
Temperature




                                         100 - 300°C
                                    Concentrating Medium                  •   Solar cooling
                                    Temperature Collectors                •   Seawater desalination
                                                                          •   Decentralised power Gen

                         60 - 120°C                        • DHW
                        Vacum tubes,                       • Solar cooling (single stage)
                        CPC Collectors                     • Low temperature process heat


                  40 - 80°C
                                               • DHW
                  Flat Plate                   • Space heating
                  Collectors

               <10kW     10-100kW        0.1 – 10 MW                 20 – 500 MW
SHC Workshop - March 2013                 Solar Industrial Process Heat                                 Page 7
                            Temperature Levels in Industrial Processes
 Why medium
 temperature?
 Industrial heat demand at
 100-400°C is large, but the
 demand at <100°C is also
 huge. Concentrating solar
 technology is not required for
 <100°C supply temperature.
  Why develop solar
   technology for medium
   temperature?
  Tap into lower
   temperature first with
   lower cost technology?




SHC Workshop - March 2013                Solar Industrial Process Heat   Page 8
        Advantages of medium temperature vs. low temperature solar heat

 Industrial process heat:
  Central heat generation in boiler, distribution with steam- or hot water network.
  Many systems in the 3-12 bar saturated steam range (130 to 200°C range)

 Concentrated solar thermal:
  Heat generation with the same quality as the industrial boiler (T, P)
  Solar collector field as additional, parallel (or serial) boiler, injects steam or hot water into the
   existing distribution network
  Collectors can be “Switched off” (defocused)

 Compared to low temperature solar heat:
  No disruption / influence on production processes, very simple interface
  Solar heat is delivered to several (all) processes, leading to a smoother load profile
  “Self-regulating” system between solar and conventional boiler

SHC Workshop - March 2013                 Solar Industrial Process Heat                               Page 9
                            Challenges for engineering and integration
       Solar thermal technology and industrial process heat are two different worlds




                                                 Solar
                                                Process
                                                 Heat



       Solar thermal <100°C                                                Industrial process heat
 Domestic hot water, space heating                                  Steam, thermal oil, pressurized water
 Few kW heating capacity                                            >1MW boiler capacity
 Water/Antifreeze, low pressures                                    Up to 15 bar steam/water
 Integrated solutions, Combisystems                                 Own set of norms, tools, standards
 Solar thermal specific norms, tools,                               No experience with solar thermal
  standards
SHC Workshop - March 2013                Solar Industrial Process Heat                               Page 10
                                NEP Solar
                                Medium Temperature Process Heat
                                Project Examples in Swiss Milk Industry
                                Lessons




SHC Workshop - March 2013   Solar Industrial Process Heat                 Page 11
LESA Bever, Switzerland, 115m2
Saignelégier, Switzerland
Collectors installed 22% of turn key cost
627m2 / 125°C / Water-Antifreeze / Milk processing
Ordered March 2011
Delivered Mai 2011
Installed June 2011
Commissioned Oct 2011
Handover March 2012
Inauguration April 2012




 SHC Workshop - March 2013             Solar Industrial Process Heat   Page 12
Bever, Switzerland
115m2 / 190°C / Thermal oil / Indirect Steam Generation / Milk processing




  SHC Workshop - March 2013             Solar Industrial Process Heat       © ewz
                                                                            Page 13
                               LESA Bever Project: Fact Sheet

 Milk processor LESA in Engadin                            Installed an started up in 2011,
  (CH) is end client                                         handed over in Spring 2012
 ewz, Zürich utility is NEP Solar’s                        Performance evaluation by
  client, ESCO contract with LESA                            testing institute SPF Rapperswil

                       Extreme alpine climate conditions at 1700m high site:
                                   -30°C, heavy snow, high UV




SHC Workshop - March 2013              Solar Industrial Process Heat                            Page 14
                             LESA Bever Project: Integration

     Thermal oil heated
                to 180°C
  in solar collector field




                                                                    Injection into
                                                                    existing
                                                                    client steam network




                                    Indirect steam
                                  generation, 3-6bar,
                                  tube-and-shell HEX
SHC Workshop - March 2013           Solar Industrial Process Heat                   Page 15
                        Experience and Lessons from the LESA Project

 Engineering, Installation, Commissioning
  High engineering effort for non-standard, small project with two fluids
  Extended period of commissioning and optimisation (EMC problems, steam circuit)
  High cost because of small project size. Collector cost less tan 25% of total project cost


 Operation experience, 1.5 years after start-up:
  Reliable operation, high availability, remote surveyed by ewz Staff (3h away from site). Only
   one collector technology related stop in one year.
  Snow sticks to reflector panel back and builds up. Manual snow-cleaning is required after
   heavy snowfall (average twice per winter).
  Promised steady state collector efficiency is reached.
  Heat-up “losses” are considerable. Difference of gross energy delivered by collectors and net
   energy delivered to client is significant. Very pronounced in partly cloudy days.


SHC Workshop - March 2013               Solar Industrial Process Heat                           Page 16
EMMI Saignelégier, Switzerland, 627m2
Saignelégier, Switzerland
Collectors installed 50% of turn key cost
627m2 / 125°C / Water-Antifreeze / Milk processing
Ordered Jan 2012
Delivered Jul 2012
Installed Sep 2012
Commissioning Oct 2012
Inaugurated Oct 2012
Optimization still ongoing




 SHC Workshop - March 2013             Solar Industrial Process Heat   Page 17
Saignelégier, Switzerland
Project Example Tête de Moine (Emmi) Saignelégier, Switzerland
         125°C / Water-Antifreeze / Milk processing
627m2 / New PolyTrough 1800 Collector / 125°C / Water-Antifreeze / Cheese Manufacturing




 SHC Workshop - March 2013            Solar Industrial Process Heat                       Page 18
Saignelégier in Winter (1000m Altitude)
Temperatures as low as -20°C, 0.5m snow cover




 SHC Workshop - March 2013            Solar Industrial Process Heat   Page 19
                               Saignelégier Project: Fact Sheet


 Fromagerie de Saignelégier (Emmi
  Group) is end client; Production of
  Tête de Moine Cheese AOC
 Financially supported by state and
  canton
 627m2 Collector aperture,
  360kWth, installed on new building
 Water/Glycol, 110-130°C Supply T.
 HEX brings heat into existing 15m3
  hot water storage.
 In Series/Parallel with 2x 1MW oil
  fired boilers
 Started up in 2012, Optimization
  still ongoing


 SHC Workshop - March 2013              Solar Industrial Process Heat   Page 20
                              Saignelégier Project: Integration
 Scondary circuit with
  Heat Exchanger
 “Solar only” when
  solar production is
  sufficient
 In series with boilers
  (preheating) when
  solar output too low.




  SHC Workshop - March 2013           Solar Industrial Process Heat   Page 21
CREMO Fribourg, Switzerland
Saignelégier, Switzerland
587m2 / 165°C Water / Waste heat for freeze protection / Milk processing
627m2 / 125°C / Water-Antifreeze / Milk processing
Ordered Feb 2012
Delivered Sep 2012
Installation ongoing
Planned Startup April 13




 SHC Workshop - March 2013             Solar Industrial Process Heat       Page 22
                                                                                CREMO Fribourg, 587m2
Saignelégier, Switzerland
627m2 / 125°C / Water-Antifreeze / Milk processing                                Collector Axis E-W aligned
                                                                       Collectors on inclined steel structure
                                                                             Extremely compact installation
                                                                              Extended collector (36m long)




 SHC Workshop - March 2013             Solar Industrial Process Heat                               Page 23
                                NEP Solar
                                Medium Temperature Process Heat
                                Project Examples in Swiss Milk Industry
                                Lessons




SHC Workshop - March 2013   Solar Industrial Process Heat                 Page 24
                            Experiences with Project execution
                                           Cost

 Often underestimated cost factors:
  Cost for roof substructure: Engineering,                           Early assessment,
   foundations, reinforcements, fixation points                        standardized systems
  Cost for preassembly / installation                                Smart design and PM
  Cost for conceptual engineering                                    Turn key responsible
  Cost for optimisation, integration logic, overall                  Turn key responsible,
   control system                                                      modular system with
                                                                       simple interfaces, simple
                                                                       integration concepts


 Generally: Target projects >1M total investment to reduce specific cost



SHC Workshop - March 2013            Solar Industrial Process Heat                                 Page 25
                 Total specific investment cost is strongly size dependent

Engineering, installation, integration and commissioning are comparably complex and blow up
                                    cost for small Installations.


  Example for 6 bar process
       steam generation in
                Switzerland

(pre-studies by independant
     engineering consultant)




SHC Workshop - March 2013            Solar Industrial Process Heat                   Page 26
                            Experiences with Project execution
                                        Schedule



 Typical milestone schedule for 500-1000m2 plant:
  Long sales / project development cycles
  3-4 Months from order to delivery (to site)
  1-2 Months installation                                            8 – 12 Months from order
                                                                       to final hand-over
  1 Month basic commissioning
  3-6 Months optimisation until final hand-over




SHC Workshop - March 2013            Solar Industrial Process Heat                           Page 27
                            Experiences with Project execution
                                        Schedule

 Causes for delays in recent projects; Customer responsibility:
  Delivery time of steam generator
  Issues with steam injection and condensate return, instrumentation
  Delay in construction of roof-mounting substructure

 Causes for delays in recent projects; NEP Solar responsibility:
  Material supplier quality issues / reworks / delivery times
  Electromagnetic interferences in collector tracking control
  Control system bugs and communication errors


                                                                     … and the weather!


SHC Workshop - March 2013            Solar Industrial Process Heat                    Page 28
Concentrating collector installations have excellent communication potential for
                                    customer.

 Web picture search for
  “LESA Bever”




SHC Workshop - March 2013       Solar Industrial Process Heat              Page 29
                  High visibility – Excellent potential for communication


 Web picture search for “ewz prozesswärme”




SHC Workshop - March 2013            Solar Industrial Process Heat          Page 30
                  High visibility – Excellent potential for communication


 Web picture search for
  “Emmi Saignelégier”




SHC Workshop - March 2013            Solar Industrial Process Heat          Page 31
                            Lessons from our Experience in a Nutshell


          Target large projects >500m2, >300kW

          Target simple, low cost integration

          Design hydraulics for low thermal inertia of system

          Proper integration and control are key – work with first class system
            integrators

          Deliver industrial quality durable, simple collector systems

          System must operate with low maintenance and high availability

          Cost of heat must be further reduced to access broad market



SHC Workshop - March 2013               Solar Industrial Process Heat              Page 32
NEP Solar AG
www.nep-solar.com




 SHC Workshop - March 2013   Solar Industrial Process Heat     © ewz
                                                             Page 33

								
To top