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Technologies and Applications of
Solar Process Heat Potential in Mexico
Theda Zoschke
14.11.2017
CDMX,
Mexico
Motivation
14.11.2017 | Seite 2
• Thermally driven processes present largest share of final energy use
• Worldwide, 45% of heat is used in industry [1]
[1] Energy Technology Perspectives 2012 - Pathways to a Clean Energy System, Int. Energy Agency (2012)
Technologies and Applications of Solar Process Heat
14.11.2017 | Seite 3
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
Technologies and Applications of Solar Process Heat
14.11.2017 | Seite 4
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
Solar Thermal TechnologiesStationary Collectors: Flat-plate
• Lower O&M and system costs
• Limited to low temperature applications (T < 150 °C) (range: 30 °C – 100 °C)
• Usual heat transfer fluid: Water/Glycol
• Little maintenance
[2] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region
[3] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
[2]
GAMESA-QUAKER PEPSICO MEXICO
Mexico
© Modulo Solar
[3]
14.11.2017 | Seite 5
Solar Thermal TechnologiesStationary Collectors: Evacuated Tube
• Lower O&M and system costs
• Limited to low temperature applications (T < 150 °C) (range: 50 °C – 130 °C)
• Usual heat transfer fluid: Water/Glycol
• Vacuum to reduce convection losses
[4] gef, UNEP, ome; Technical Study report on SHIP, State of the art in the Mediterranean region
[5] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
[4]
Harita Seatings Systems Limited
India
© @aspirationenergy
[5]
14.11.2017 | Seite 6
Solar Thermal TechnologiesTracking Collectors: Parabolic Trough
• Suitable for medium temperature applications (T < 400 °C) (range 150 °C –
400 °C)
• More demanding in terms of O&M and costs
• Line-focusing / One axis tracking
• Usual heat transfer fluid: Water/Steam or thermal oil
v
Lesa Dairy
Switzerland
© ezw
[7]
[6]
[6] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information
[7] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
14.11.2017 | Seite 7
Solar Thermal TechnologiesTracking Collectors: Linear Fresnel
• Suitable for medium temperature applications (T < 400 °C) (range 150 °C –
400 °C)
• More demanding in terms of O&M and costs
• Line-focusing / One axis tracking
• Usual heat transfer fluid: Water/Steam or thermal oil
• Approx. parabolic trough by segmented
mirrors: Principle of Fresnel
[8] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information
RAM Pharmaceuticals
Jordan
© Industrial Solar
[8]
14.11.2017 | Seite 8
Solar Thermal TechnologiesTracking Collectors: Parabolic Dish
• Suitable for medium temperature applications (T < 400 °C) (range 250 °C –
400 °C)
• More demanding in terms of O&M and costs
• Point-focusing system / 2-axis tracking
• Moving (modular) receiver
[9] Adapted from SolarPaces.org, 2016), http://www.solarpaces.org/csp-technology/csp-technology-general-information
[9]
Tirumala Tirupati Devasthanams
India
© Gadhia Solar Energy Systems
14.11.2017 | Seite 9
Solar Thermal TechnologiesEfficiency and Temperature
• Efficiency depends on:
• Optical losses depending on incidence angle
• Thermal losses depending on operating temperature
h
T
Low temperature / Stationary collectors:• Higher optical efficiency• Higher thermal losses
Medium temperature / Tracking collectors:• Lower optical efficiency• Lower thermal losses
14.11.2017 | Seite 10
Technologies and Applications of Solar Process Heat
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
14.11.2017 | Seite 11
Solar ResourcePotential for Stationary Technologies in Mexico
• Very favourable solar resource conditions, depending on location
• Stationary technologies (T < 100 °C)
➢ Global Horizontal Irradiation (GHI)
• 1800 – 2300 kWh/m2
[10] solargis. http://solargis.com/
[10]
14.11.2017 | Seite 12
Solar ResourcePotential for Tracking Technologies in Mexico
• Favourable solar resource conditions, especially in North-West
• Tracking technologies (100 °C < T < 250 °C)
➢ Direct Normal Irradiation (DNI)
• 1500 – 3000 kWh/m2
[10]
[10] solargis. http://solargis.com/
14.11.2017 | Seite 13
Technologies and Applications of Solar Process Heat
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
14.11.2017 | Seite 14
Heat for Industrial ProcessesSectors and Temperature Levels
• Temperature levels in different sectors [12]: ~ 50% HT; ~ 50% MT + LT
[12] International Renewable Energy Agency (IRENA), calculations by Deger Saygin based on IEA source [2] (2014)
EI sectorsHT (>400°C)
42,5 EJ
MT (150°c-400°C)
18,1 EJ
LT (<150°C)
24,5 EJ
EI
Non-EI
14.11.2017 | Seite 15
Heat for Industrial Processes
Suitable Processes
• Suitable industrial processes
• Drying and dehydration
• Preheating (input or raw material)
• Pasteurization and Sterilization
• Washing and cleaning
• Chemical reactions
• Surface treatment
• Space heating
• Supply of hot water or steam
• Main industrial sectors
• Chemicals
• Textiles
• Food & Beverages
• Paper
• Fabricated metal
• Rubber & Plastic
• Machinery & Equipment
• Wood
14.11.2017 | Seite 16
Heat for Industrial ProcessesEnergy consumption in Mexico
• Energy consumption in Mexico [13]:
• Industrial sector: 1601 PJ
• Solar thermal technologies:
• Share: < 1 %
• Flat plate collectors dominating technology
• Mostly residential / commerical sector
• Fuels used in the Mexican industrial sector [1]:
[13] SENER, CONUEE, GIZ “Energía solar térmica para procesos industriales en México - Estudio base de mercado”, not yet published
14.11.2017 | Seite 18
Heat for Industrial ProcessesSuitable processes in Mexico
• Energy consumption in Mexican industry [13]:
• 14 % Iron and Steel industry
• 11 % Cement indusrty
• 6 % Chemical industry
• 6 % Petrochemical industry
• 6 % Mining industry
• 47 % Others…
➢ Textile, food and chemical industry (low temperature)
➢ Manufacuring of chemical processes (medium temperature)
[13] SENER, CONUEE, GIZ “Energía solar térmica para procesos industriales en México - Estudio base de mercado”, not yet published
High temperature thermal power
→ not very suitable for solar thermal
technologies
14.11.2017 | Seite 19
Technologies and Applications of Solar Process Heat
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
14.11.2017 | Seite 20
Design Procedures
14.11.2017 | Seite 21
Solar Thermal
System
storage
Solar
Buffer
Storage
Tank
Process Hot Water
Network
Hot Water
Boiler
Process
Water 160 °C
Return flow 100 °C
Integration
point
Process return 110 °C
Exhaust
160 °C - 200 °C
Conden-
sate
Solar thermal
System
Steam
Boiler
Feed Water
Feed Water
Tank 103°C
Make-up-
Water 30°C
Condensate
TankConcentrating-Collector
Circulation Pump
Process Steam 250 °C 36 barProcess Steam
Network
Integration
point
Evaporator
Water
preheating
Steam
generation
Design ProceduresSolar Integration of Stationary Technologies
• Dilemma: Less resistance to integration at supply level vs. lower
temperatures in integration at process level
80°C-120°C
15°C-30°C
P1
160°C
P2
80°C
P3
50°C
50°C-90°C
160°C-180°C
11
0°
C-1
30°
C
14.11.2017 | Seite 22
Design ProceduresSolar Integration of Tracking Technologies
• Dilemma: Less resistance to integration at supply level vs. lower
temperatures in integration at process level
80°C-120°C
15°C-30°C
P1
160°C
P2
80°C
P3
50°C
50°C-90°C
160°C-180°C
11
0°
C-1
30°
C
14.11.2017 | Seite 23
Design ProceduresPotential to Increase Energy Efficiency in Industry
• Energy efficiency significantly reduces energy intensity:
• Implementing best practice technologies (BPT) could reduce total final industrial energy demand by more than 25% [14]
• Pinch analysis [15]
• Cross-process heat exchange possibilities
• Optimizing heat recovery and effective heating and cooling processes
[14] Saygin, D., Patel, M.K. and Gielen, D.J. (2010). Global Industrial Energy Efficiency Benchmarking: An Energy Policy Tool, Working
Paper, November 2010. United Nations Industrial Development Organization (UNIDO), Vienna.
[15] Muster, Bettina et al., 2015. Guideline for solar planners, energy consultants and process engineers giving a general procedure to
integrate solar heat into industrial processes by identifying and ranking suitable integration points and solar thermal system concepts.
IEA/SHC Task 49/IV, Subtask B, Deliverable B2
14.11.2017 | Seite 24
Design ProceduresPre- and feasibility studies
• Pre-analysis: Boundary conditions
• Basic technical plant description
• Motivation
• Analysis of process characteristics
• Site visit to get information on:
• Temperature levels, heat network, operation details, energy costs
• Process optimization and energy efficiency
measures [17]
• Heat exchanger optimization (pinch analysis)
• Processes state-of-the-art?
• Future plans?
[16]
[16] www.solar-process-heat.eu/checklist
[17] C. Brunner et al. 2010: IEE-Project Einstein: www.iee-einstein.org
14.11.2017 | Seite 25
Technologies and Applications of Solar Process Heat
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
14.11.2017 | Seite 26
Technologies and Applications of Solar Process Heat
14.11.2017 | Seite 27
• Annuity factor with interest rate 𝑖 and lifetime T:
ANF =1 + 𝑖 𝑇 ⋅ 𝑖
1 + 𝑖 𝑇 − 1−
• Levelized Cost of Heat (LCoH) with :
LCoH =𝐶capex ⋅ ANF + 𝐶opex
𝐴𝑛𝑛𝑢𝑎𝑙 𝑌𝑖𝑒𝑙𝑑• Investment costs: 𝐶capex €
• Operation and maintenance costs:
𝐶opex €/𝑎
• Annual yield: AY [𝑀𝑊ℎ/𝑎]
Technology vs. Energy CostsPotential for Mexico
• Current technology costs:
• 220 – 620 €/m2
• For average system cost
450 €/m2 (10.000 MXN/m²)
• Critical LCOH (Levelized Cost of Heat) → 0,03 €/kWh (0,67 MXN/kWh)
[18]
[18] adapted from Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).[19] Muster, Bettina et al., 2015. Guideline for solar planners, energy consultants and process engineers giving a general procedure to integrate solar heat into industrial processes by identifying and ranking suitable integration points and solar thermal system concepts. IEA/SHC Task 49/IV, Subtask B, Deliverable B2
[19]
h = 50%
GHI, DNI = 2000 kWh/m2
14.11.2017 | Seite 28
Technologies and Applications of Solar Process Heat
• Solar Thermal Technologies
• Solar Resource
• Heat for Industrial Processes
• Design Procedures
• Profitability
• Existing Projects
14.11.2017 | Seite 29
Existing Projects Market Penetration
• SHIP systems database [20]:
• 213 projects listed
• 129 MWth installed capacity (0.18 million m2)
• Recent survey points out [21]:
• > 500 SHIP systems with
• > 280 MWth total installed capacity (0.4 million m²)
[20] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
Accessed February 2017
[21] SOLRICO, Bärbel Epp, 2017. Solar Process Heat: Surprisingly popular. Sun&Wind Energy. http://www.sunwindenergy.com/topic-of-the-
month/solar-process-heat-surprisingly-popular (online 14.02.2017)
[20]
14.11.2017 | Seite 30
Existing Projects Mexico
• SHIP systems database [20]:
• 59 projects listed
• Most solar fields 50 to 300 m²
[20] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016).
Accessed November 2017
[20]
[20]
14.11.2017 | Seite 31
Existing Projects Common Technologies
• Mostly small/medium size systems (<500 m2)
• Largest capacity in large systems (>1000 m2)
• Stationary technologies are dominating technology
[20] AEE-INTEC, 2013. Database for applications of solar heat integration in industrial processes. http://ship-plants.info/ (2013-2016). Accessed February 2017
[20]
14.11.2017 | Seite 32
Existing Projects Examples of Stationary Technologies
[22] Arcon-Sunmark, 2015. http://arcon-sunmark.com/cases/codelco-minera-gaby-chile
[23] http://ship-plants.info/solar-thermal-plants/140-jiangsu-printing-and-dyeing-china?collector_type=4&country=China
Textile Jiangsu Yitong, ChinaEvacuated TubeAperture: 9,000 m2
Application: process pre-heatingOper. Temp.: 50 °CCommissioning : 2011
© Sunrain Co. Ltd [23]
Copper mine “Gabriela Mistral”, ChileFlat PlateAperture: 43,920 m2
Application/End Use: Process water and electrolyte heatingOper. Temp.: 50 °CCommissioning: 2015
© Arcon-Sunmark [22]
[5]
Currently largest plant in the world
14.11.2017 | Seite 33
Existing Projects Examples of Tracking Technologies
[24] http://www.industrial-solar.de/content/en/referenzen/fresnel-kollektor/
[25] http://ship-plants.info/solar-thermal-plants/155-dairy-plant-el-indio-mexico?collector_type=5
Dairy El Indio, MexicoParabolic TroughAperture: 132 m2
Application: Make-up water pre-heatingOper. Temp.: 95 °CCommissioning : 2012
© Inventive Power S.A. de C.V. [25]
Services MTN Johannesburg, South AfricaLinear FresnelAperture: 396 m2
Application/End Use: Air conditioningOper. Temp.: 180 °CCommissioning : 2014
© Industrial Solar [24]
14.11.2017 | Seite 34
Existing Projects
La Parrena copper mine, Mexico [25]Flat Plate CollectorSolar Field: 6270 m²Thermal Power: 4.4 MWthSolar Field covers 58% of annual heat demand
[25] http://ship-plants.info/solar-thermal-plants/155-dairy-plant-el-indio-mexico?collector_type=5
[26] http://arcon-sunmark.com
[27]
[26]
14.11.2017 | Seite 35
Upcoming Projects Examples
Amal Solar EOR Pilot Project, OmanParabolic Trough in greenhouseThermal Power: 1 GWthProduction (pilot): 6 ton steam / day
[26] MIT, 2016. Technology Review, Arab Edition. http://technologyreview.me/en/energy/oman-explores-solar-powered-oil-recovery/
© Petroleum Development Oman. [26]
14.11.2017 | Seite 36
Technologies and Applications of Solar Process HeatSummary
• Available technologies
• Stationary technologies (T<100°C), Global Horizontal Irradiation (GHI)
• Tracking technologies (100°C<T<400°C), Direct Normal Irradiation (DNI)
• Suitable sectors
• Food and beverage, textile and chemical industry… etc.
• Potential for Mexico
• Very favourable solar resource of GHI 1800 – 2300 and DNI 1500– 3000 kWh/m2
• Great potential for industry sectors that require heat at low and medium temperature level
• LCOH of < 0,03 €/kWh (0,67 MXN/kWh) can be reached
14.11.2017 | Seite 37
Thank you for your attention!
Theda Zoschke
Dr. Pedro Horta
Annie Zirkel-Hofer
Fraunhofer ISE