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Final report - PRoof 1.1 Projectdetails

Projecttitle PRoof

Projectidentification(programabbrev.

andfile)

64015-0099

Nameoftheprogrammewhichhasfund-

edtheproject

EUDP

Projectmanagingcompany/institution

(nameandaddress)

InnogieApS

Thrigesvej23

7430Ikast

Projectpartners

Cenergia

Brdr.Paulsen

CVR(centralbusinessregister) 33148879

Dateforsubmission

1.2 Shortdescriptionofprojectobjectiveandresults1.2.1 DanskversionPRoofhavdetilformålatudvikleetæstetiskflottagløsningderkandækkedetårligeforbrugafelektricitetogvarme.Projektetharialtsinenkelthedbeståetiatudvikleensolcelle(PV)tag-løsningtilatproducereelektricitetogindarbejdeentermiskabsorber(T)tilopvarmning.SelvePV-delenafprojektetharværetutroligtsuccesfuldtoghariprojektperiodenvundetflerepri-ser,DanishDesignawards2016ogiFAwards2017.Dentermiskedelharvedfuldtestinstalla-tioneniprojektetikkebeståetdestandarderforstresstestsomønskes,hvorfordennedelkræveryderligereforskningogudviklingforatkunnekommetilkommercialiseringsstadie.1.2.2 EnglishversionTheaimofPRoofistodevelopanaestheticpleasingroofingsolutionwhichcoverstheannualneedofheatandelectricityforahousehold.Theprojectsincludesdevelopmentofphotovolta-ic(PV)toproduceselectricityandthermalabsorbers(T)productionofheat.ThePVpartoftheprojecthasbeenverysuccessfulbywinningawardsundertheproject,DanishDesignAwards2016andiFAwards2017.Thethermalparthasnotpassedthestandardsundertestonfullinstallation.Thethermalpartneedsfurtherresearchanddevelopmenttoreachcommerciali-sationstage.1.3 ExecutivesummaryThePRoofprojectonthePVparthasbeenverysuccessfulwithtwoprestigiousdesignawards,DanishDesignAwards2016andiFDesignAwards2017.Themanagementtookthisgoldenop-portunitytothethePVRoofingSystemintothecommercialisationstageandmarketlaunchtheproductinnovember2016atBuildingGreenFairinForum,Copenhagen.ThePVRoofing

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SystemhasbeenpatentedtosecuretheIPRandanewbusinessplanhasbeenmade.Incasesofrenovatingtheroofofa70shouseitwillsecurethehouseownerapprox.70%oftheyearlyconsumptionofelectricityandheatgiventhatthehouseiselectricallyheated.TheambitionistoreachfullcoveroftheheatandelectricityconsumptionandtheThermalabsorbersisavitalpartofthatambition.Therewereseveraltheoreticaltestsand3Dsimulationstodeterminethecorrectmaterialforthethermalabsorbers.Inparticularcertainmaterialsperformedverypromisingatthe3Dsim-ulation,buteventuallydidnotpassthestresstestatreallifetest.Theinitialresultsduringthewintertimeshowgreatoutputofheat.Thecalculationsaremadeon10meters,whichresultin202𝑊,becausethetemperatureinsidethetubeisincreasingthrougheverymeteroftheconcept.Whenthereare23rowsofsolarpanels,thenthereare22channelsbetween,whichgiveatotalenergyoutcomeon202∗ 22=4450𝑊.1.4 ProjectobjectivesTheaimoftheprojectistodevelopanaestheticpleasingroofingsolutionwhichcoverstheannualneedofheatandelectricityforahouseholdorapartmentcomplex.Themilestonesintheprojecthavebeendefinedas:

• M1Systemspecification• M2PVTIntegrationinroof• M3Installationfullscale

• CM1UpdatedBusinessplan

M1Systemspecificationwasdeliveredasexpectedwithavisionofaphotovoltaic(PV)roofingsolution as the core product where the customers can add-on thermal (T) absorbers, heatpumporbattery.TheprojectwouldonlyfocusonPVTandstandardheatpumpsandbatterywillbeusedforthefinalsolution.M2PVTIntegrationinroofwasseparatedintwosteps:thePVpartwhichshouldbethecoreproductandTpart that shouldbeanadd-on function.Thedevelopmentof thePVwasverysuccessfuland Innogiewaswinning theDanishDesignAwards2016.Themanagementof In-nogiedecidedthePVRoofingsolutioncouldbecommercialisedwithouttheTpartinthefirstplace.ThatdecisiondelayedthedevelopmentoftheTpartoftheprojectandallresourceswasusedtopreparethePVroofingsolutionformarket launch.AtBuildingGreen2016inForum,CopenhagenthePVRoofingsolutionwasmarketlaunchedandfocustofinishtheTpartoftheprojectcouldstart.ThemilestoneM3Installationfullscalehasareallybadstart,astheoriginaltesthouseownerdecidedtopullouttheagreement,becausethePVTinstallationwouldmeananewroofcon-struction.Thetestcustomerwasnotpreparedtomakethosechangesforhisownexpenses.Theprojectwasdelayedtofindanewtesthouse,whichwasalittlebitbiggerthantheorigi-nal.ThecompletiononthefullscaleconstructionofthePVTwentfine,butthefollowingtest

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resultsontheTpartdidnotturnoutasexpected.TherefortheTpartisnotreadyforcommer-cialisationandfurtherresearchanddevelopmentisneeded.1.5 Projectresultsanddisseminationofresults1.5.1 PVRoofingsolutionThePVroofingsolutionwastransformedfromtheexistingproject,Solarowithsolartubesun-der“Fornyelsesfonden”intoafullfunctionalPVRoofingsystem.

TheresultswereverypromisingandintheearlystagethePVRoofingsolutionawardedbyDanishDesigninApril2016.ThatwasagoldenopportunitythatthemanagementofInnogiecouldnotpass.ThePVsolutionhasappliedforpatentforthedesignsolution,tosecuretheIPR.AlresourceswereusedtoputPVRoofingSolutiononmarket,whentheawardwasstillcounting.Inthebeginningof2017thePVroofingsolutionalsowontheprestigiousiFDesignAwards.

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CASE: PV Roofing solution at Heimdalsvej, Haderslev (not incl. in this project)

Renovationofa1970sroofon145m2buildingcovers70%ofallpowerconsumption.Thead-ditionalcostforPVpartcomparedtotraditionalroofingsurfacehasanexpectedpaybacktimeon10years.Withthefullroofcostapaybacktimeon20yearsisexpected.

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1.5.2 ThermalAbsorberThedevelopmentoftheTpartwasmadewithseveraldesignsand3Dsimulations.Requirements1.Minimizematerialusage

2.Maximizeenergyoutcome(thermalconductivity)3.Makeroomforcuttingtool4.Mustbemountedfromabove5.MustbeUVresistant6.Avoidicingonthebackoftheroof7.Makeroomforthescrews8.Makethesolutionaffordable(thinkabouttheusageofmaterials)SpecificationsTemperaturearea −25℃−+75℃Lifetime 20yearsormoreGeometry Within95mm*40mmPrice Within5%ofnearestcompetitor

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Figure1-smalltestwith3Dprint

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Thechosenconceptisfurtherstudiedtofinddifferentwaystooptimizetheenergyoutcome,whichledtothefollowingmodel.

Simulationsshowthatthefinalconcepthasanenergyoutcomeat27,7𝑊foronemeter.Thereisalsomadeanexamplewherethesizeofatesthouseisused,whichhave23rowsofsolarpanels,wherethereare9solarpanelsineveryrow.Everysolarpanelis1,2meterandtherefore1,2∗ 9=10,8𝑚intotal,andtogivetheproductsomeroomforthematerialtoexpandcalculationsaremadeon10meters.Thisresultin202𝑊,foreveryrow,becausethetemperatureinsidethetubeisincreasingthrougheverymeteroftheconcept.Whenthereare23rowsofsolarpanels,thenthereare22channelsbetween,whichgiveatotalenergyoutcomeon202∗ 22=4450𝑊.ThesecalculationsarebasedonanormalwinterdayinDenmark,andextremesarenottakenintoconsiderations.Theaverageenergyoutcomepr.meteronthishouseisthen20210=20𝑊/𝑚,whichiscompa-rablewiththegeneralgroundheatingsolutionwheretheenergyoutcomeisabout11,5𝑊/𝑚–23,3𝑊/𝑚.Thegeneralgroundheatingsolutioniswherethetubesarespreadoutonalargeareainthedepthofoneortwometersundertheground.Anotheropportunityisthegroundheatingsolutionwherethetubesaredrilled23𝑚–91𝑚intotheground,whichgivealargerenergyoutputon19,2𝑊−55,5𝑊.ThisinitialworkhasbeenthefirststepinaplanthatInnogiehasmadetodevelopthethermalabsorbers.

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1.5.3 InstallationfullsizeThenewtestsitewasfoundatNorgesvej,Haderslev.TheinstallationforPVRoofingSystemwasperfectlymatchingthecriteriaoftheproject.Severaltestsandstresstestswiththether-malabsorberdidnotpasstherequirements.Thereforethethermalabsorberneedstobeeval-uatedbeforefurtherresearchanddevelopmentcantakethetechnologyintocommercialisa-tionstage.Whenpressurewasaddedtothesystem,thematerialbecameunstableandeventuallypunc-tured.Thereforefurthertestonthematerialandclosecooperationwiththeexistingsuppliercouldsolvetheproblems.Othersupplierscouldbetestedaswell,beforenewresearchanddevelopmentofthethermalabsorbersshouldbegin.Thesupplieriscurrentlydoinginternaltestingofthematerialtypes.

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1.5.4 DisseminationTheprojecthasbeenwellexposedat:

• “temadageforSolarCity”inSønderborgandCopenhagen• ErhvervsakadamietLillebæltinOdense• BuildingGreenExhibitioninCopenhagen

WinningawardsatDanishDesignAwardsandiFDesignAwardshavegiventheprojectalotofpublicity.1.5.5 Turnover,exportsandemploymentTheresultsoftheprojectatcurrentstageandexpectedresultsin3years 2017 2018-2019 2020-2022Employment 2 10 25Turnover <1milDKK 15milDKK 55milDKKExport 0 5milDKK 35milDKK1.6 UtilizationofprojectresultsTheresultsoftheprojecthavealreadybeentakenintocommercialisationstageatthePVpartoftheproject.InnogiehasmadepatentonthePVRoofingSystem.BothInnogieandTømrerfirmaetPaulsenisapartofthecommercialisationstagewhileInnogieissellingPVRoofingSystemsandTømrerfirmaetPaulsenisinstalling.ThenewbusinessplanforthePVpart

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hasbeenupdatedandtriedexecuteddoing2017whilefinishingthethermalabsorberatthePRoofproject.ThemarketforBuildingIntegratedPhotovoltaic(BIPV)productsisinterestingespeciallyinEUwherethenewrulesofNearlyZero-energyBuildingsapplyfromtheendof2018.AccordingtoTransparencyMarketResearch,2015theglobalannualinstallationofBIPVsystemsgoesfrom343.1MWpin2012to1,152.3MWpin2019withaCAGRof18.7%.NanoMarkets,2015pre-dicttheBIPVmarketwillgrowfrom€2.6billionin2015to7.9billionin2019.Completionoftheproject,meanthePVRoofingSystemwillreachthepricelevelofconven-tionalroofingmaterials.Theglobalroofingmarketwasvaluedat€56.58Billionin2013andisanticipatedtoreach€85.62billionin2020,expandingataCAGRof6.3%between2014and2020.Intermsofvolume,themarketstoodat10,600millionsquaremetersin2013approxi-mately70millionroofsof150m2.ThemarketishighvolumeandveryattractiveforPVRoof-ingSystem.MakingPVRoofingSystemcompetitivetoconventionalroofingmaterialswillraisethemarketvolumewith8-10timescomparedtotheBIPVmarket.Thethermalabsorberstillneedsfurtherresearchanddevelopment,whichmeanitisnotinthecommercialisationstage.Thereforthebusinessplanhasnotbeenupdatedforthatarea,butthestrategystillincludesthatpart,duethepositiveresultsofthesimulation.Newmaterialorsuppliercouldsolvetheproblematthestresstestofthethermalabsorbers.Innogiewillcon-tinuetodevelopthethermalabsorbertofulfilthestrategyofofferingadd-onsforthePVRoof-ingSystem.FromthegoodexperienceofgoingintothecommercialisationstagewiththePVpart,Innogieiseagertodothesamewiththethermalabsorberswhentheyareready.1.7 ProjectconclusionandperspectiveTheconclusionontheprojectisthePVparthasbeenverysuccessfulwithtwoprestigiousde-signawardswhichgavethegoldenopportunitytoreachtothecommercialisationstageandmarketlaunchedtheproduct.ThePVRoofingSystemhasbeenpatentedtosecuretheIPRandanewbusinessplanhasmade.Whenpressurewasaddedtothesystem,thematerialbecameunstableandeventuallypunc-tured.Thereforefurthertestonthematerialandclosecooperationwiththeexistingsuppliercouldsolvetheproblems.Othersupplierscouldbetestedaswell,beforenewresearchanddevelopmentofthethermalabsorbersshouldbegin.Thesupplieriscurrentlydoinginternaltestingofthematerialtypes.