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1 Final report - PRoof 1.1 Project details Project title PRoof Project identification (program abbrev. and file) 64015-0099 Name of the programme which has fund- ed the project EUDP Project managing company/institution (name and address) Innogie ApS Thrigesvej 23 7430 Ikast Project partners Cenergia Brdr. Paulsen CVR (central business register) 3314 8879 Date for submission 1.2 Short description of project objective and results 1.2.1 Dansk version PRoof havde til formål at udvikle et æstetisk flot tagløsning der kan dække det årlige forbrug af elektricitet og varme. Projektet har i alt sin enkelthed bestået i at udvikle en solcelle (PV) tag- løsning til at producere elektricitet og indarbejde en termisk absorber (T) til opvarmning. Selve PV-delen af projektet har været utroligt succesfuldt og har i projektperioden vundet flere pri- ser, Danish Design awards 2016 og iF Awards 2017. Den termiske del har ved fuld testinstalla- tionen i projektet ikke bestået de standarder for stresstest som ønskes, hvorfor denne del kræver yderligere forskning og udvikling for at kunne komme til kommercialiseringsstadie. 1.2.2 English version The aim of PRoof is to develop an aesthetic pleasing roofing solution which covers the annual need of heat and electricity for a household. The projects includes development of photovolta- ic (PV) to produces electricity and thermal absorbers (T) production of heat. The PV part of the project has been very successful by winning awards under the project, Danish Design Awards 2016 and iF Awards 2017. The thermal part has not passed the standards under test on full installation. The thermal part needs further research and development to reach commerciali- sation stage. 1.3 Executive summary The PRoof project on the PV part has been very successful with two prestigious design awards, Danish Design Awards 2016 and iF Design Awards 2017. The management took this golden op- portunity to the the PV Roofing System into the commercialisation stage and market launch the product in november 2016 at Building Green Fair in Forum, Copenhagen. The PV Roofing

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Page 1: Final report - PRoof...NanoMarkets, 2015 pre-dict the BIPV market will grow from € 2.6 billion in 2015 to 7.9 billion in 2019. Completion of the project, mean the PV Roofing System

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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.