Solar thermal energy technologies

for industrial applications - Indias

experience
Shirish Garud
Fellow,
TERI

Presented at
Global Renewable Energy Forum,
Brazil
1 18 to 21 May 2008
 Outline

z Introduction
z Indian industry overview
z Potential application areas
z Solar energy potential in India
z Solar thermal technological options
z Case studies
z Policy and regulatory support
z Barriers
z Way forward

2 Global Renewable Energy Forum, Brazil

 Introduction to TERI

z Vision We will work towards global sustainable

development, creating innovative solutions for a
better tomorrow
z Independent, not-for-profit energy research institute
z 700 employee (450 research professionals)
z Higher education initiative:TERI University
z ISO 9001
z Headed by Dr R K Pachauri, Director General, TERI
and Chairperson, Intergovernmental Panel on
Climate Change (IPCC), Nobel Peace Prize Winner
3 2007 Global Renewable Energy Forum, Brazil
 Presence of TERI

z Head office at New Delhi, India

z Regional centers in India: Bangalore, Mumbai, Goa,
Guwahati and Mukteshwar
z Affiliate institutes: Washington and London
z Presence in Tokyo, Kualalampur, and Dubai
4 z Africa centre in Adisababa, Ethiopia Global Renewable Energy Forum, Brazil
 Indian industry overview

z Composition and
z Energy requirements

5 Global Renewable Energy Forum, Brazil

 Industrial applications

z TERI is working on UNIDO funded project on

RETs for Industrial Sector in Developing
Countries.

6 Global Renewable Energy Forum, Brazil

 Potential industries selected

1. Pulp & Paper

2. Textile
Silk, wool & cotton yarn
3. Food Processing
Diary
Bakery
Cardamom
Meat processing
Marine foods
Tea
4. Plaster of Paris
5. Rubber
6. Steel re-rolling
7. Tobacco
7 8. Ceramic tile & pottery Global Renewable Energy Forum, Brazil
 MSMEs in India

No. of SSI Units (registered &

unregistered) Functioning
Selected Industries (as on 31/3/06)
Manufacture of Wearing Apparel, Dressing & Dyeing of Fur 2145505
Manufacture of Food Products 1786890
Manufacture of Fabricated Metal Products 637740
Manufacture of Wood and Wood Products 606761
Manufacture of Textiles 451304
Manufacture of Other Non-Metallic Product 331415
Manufacture of Tobacco Products 190510
Manufacture of Rubber and Plastic Products 135638
Manufacture of Basic Metals 102279
Manufacture of Paper & Paper Products 31648
Total Number of Industries in India 12,341,665

8 Global Renewable Energy Forum, Brazil

 Details of selected industries

Tobacco Rubber & plastic

Textiles
5% 2%
9%
Fabricated Metal Basic metals
11% 2%

Pulp & paper

1%

Food Products
32%

Wearing apparel,
dress material,
17%

Percentage of industries under selected categories = 45%

9 Global Renewable Energy Forum, Brazil

 Industrial processes &
thermal energy requirements
z Pulp & paper industry
Pulping: 130-80oC
paper drying: 90-100oC
pulp bleaching: 70-90oC
z Textile industry
Silk
Reeling: 50-90oC
Dyeing: 90-110oC
Cotton dyeing: 90-110oC

10 Wool dyeing: 90-110oC Global Renewable Energy Forum, Brazil

 Industrial processes & thermal
energy requirements - contd

z Cardamom curing: 70-90oC

z Bread/biscuit baking: 90-110oC
z Dairy
Liquid milk-pasteurization: 80-90oC
Butter making-drying/evaporation: 70-110oC
Milk Powder- drying/evaporation: 130-150oC
z Tea leaf-drying: 50-80 oC
z Meat processing-drying/sterilization: 100-120oC
z Sea food-drying/sterilization: 100-120oC
11 Global Renewable Energy Forum, Brazil
 Industrial processes & thermal
energy requirements - contd

z Steel re rolling-billet reheating: 850-950oC

z Gypsum-Calcination (Plaster of Paris making):
1000-1200oC
z Tile-drying/evaporation: 500-600oC
z Pottery products-drying/evaporation: 500-600oC
z Rubber drying: 100-300oC
z Tobacco drying: 50-80oC

12 Global Renewable Energy Forum, Brazil

 Thermal energy requirements

1200

Steel-
rerolling
Maximum process heat

requirements (celcius)

1000
temperature

800 Ceramic
& Tile

600

400

200

Pulp & Plaster of Food

Paper Textile Paris Proce-
ssing Rubber
0

13 Global Renewable Energy Forum, Brazil

 Solar energy applications

14 Global Renewable Energy Forum, Brazil

 Solar radiation levels over Asia

15 http://swera.unep.net/ Global Renewable Energy Forum, Brazil

 Solar radiation map of India

If one percent of the land is used to harness solar energy for

electricity generation at an overall efficiency of 10%; 492 x 106
16 MU/year electricity can be generated Global Renewable Energy Forum, Brazil
 Some applications vs technology

z Heating/drying (low-med temperature)

Solar thermal
Biomass/biogas combustion
z Drying, melting, calcination (high temperature)
Biomass/biogas combustion
Geothermal
z Direct shaft-power
Small wind turbines
Small-micro/pico hydro turbines
17 Global Renewable Energy Forum, Brazil
 Annual fuel replacement possible

z Pulp & paper industry

Pulping: 100%
paper drying: 100%
pulp bleaching: 100%
z Textile industry
Silk
z Reeling: 50%
z Dyeing: 100%
Cotton dyeing: 100%

18 Wool dyeing: 100% Global Renewable Energy Forum, Brazil

 Annual fuel replacement possible
contd

z Cardamom curing: 70%

z Bread/biscuit baking: 100%
z Dairy
Liquid milk-pasteurization: 70%
Butter making-drying/evaporation: 70%
Milk Powder-drying/evaporation: 70%
z Tea leaf-drying: 100%
z Meat processing-drying/sterilization: 50%
z Sea food-drying/sterilization: 50%
19 Global Renewable Energy Forum, Brazil
 Annual fuel replacement possible
contd

z Steel re rolling-billet reheating: 80%

z Gypsum-Calcination (Plaster of Paris making): 50%
z Tile-drying/evaporation: 50%
z Pottery products: drying/evaporation- 100%
z Rubber drying: 100%
z Tobacco drying: 100%

20 Global Renewable Energy Forum, Brazil

 Annual CO2 savings (million tonnes)

100
Annual CO2 savings (million tonnes)

90

80

70
91
60

50

40

30

20

16
10
0.02 1 1.22 2
1.3 6
0

Plaster of Paris Pulp & Paper Rubber

Ceramic tile & pottery Tobacco Steel-rerolling
Textile Food Processing
21 Global Renewable Energy Forum, Brazil
 Solar energy 4060oC

UNGLAZED

collectors COLLECTORS

6090oC

SOLAR POND

6080oC
NON-FOCUSSING
FLAT PLATE
(FPC) 100150oC
COMPOUND
For low temperature 50200oC
PARABOLIC
applications
EVACUATED CONCENTRATOR
(ETC) 100250oC
SOLAR
COLLECTORS 100500oC LINEAR
FRESNEL TYPE
For high and medium SINGLE AXIS
TRACKING 100500oC
temperature applications
PARABOLOIC
FOCUSSING TROUGH
(CONCENTRATING) 3001000oC

3002000oC PARABOLIC
DISH REFLECTOR
TWO-AXIS
TRACKING 5002000oC
HELIOSTAT FIELD
COLLECTOR

22 Global Renewable Energy Forum, Brazil

 Non tracking collectors
thermal performance

23 Global Renewable Energy Forum, Brazil

 Industrial hot water systems

Working since: 1997.

GHG emissions saved:
700 t CO2 per annum
Energy savings 22GJ
per day
Payback period:5 years
One of the Worlds largest industrial solar
water heating system

Capacity: 1,20,000 lit /day

Application: Boiler feed water pre-heating
Installed at: M/s GFCL ltd, Kakinada
24 Area: 60m 80m (1309 collectors) Global Renewable Energy Forum, Brazil
 Solar water heating for
hotel industry

Hotel Fishermans cove, (Taj Group), Chennai

Capacity: 20000 lit /day

25 Global Renewable Energy Forum, Brazil
 Solar pond

6000m2 Solar pond at Bhuj dairy,

Bhuj, Gujarat
Designed and installed by TERI

26 Source: www.teriin.org Global Renewable Energy Forum, Brazil

 Solar steam systems

Solar steam cooking system in Leh

A view of solar steam cooking system installed at

Tirupathi, Andhra Pradesh
The system has been designed to generate over 4000 kg.
of steam/day at 180 0C and 10 kg/cm2 which is sufficient
to cook two meals for around 15,000 persons.

27 Source: www.gadhia-solar.com/ Global Renewable Energy Forum, Brazil

 India
Innovates

ARUN160: Fresnel
Paraboloid concentrator with
cavity receiver with 2-axes
tracking having
160 m2 aperture area
installed under IIT-Bombay -
Clique R & D Project
sponsored by MNRE for milk
pasteurization at Mahanand
Dairy, Latur, Maharashtra,
INDIA

ARUN160: Solar dish

Source: M/s Clique Technologies, Mumbai
28 Global Renewable Energy Forum, Brazil
 Solar drying applications

z Men-Tsee-Khang, (A
pharmaceutical company)
based in Dharamsala
z Application - Drying of herbs
- 100Kg/day
z Moisture need to be reduced
to 4%
z Operation hours
1000 to 1530 hrs during
winter
0930 to 1600 hrs during
29 summer Global Renewable Energy Forum, Brazil
 Solar drier for fish processing

z Processing of fish experiences a large

wastages solar dehydration leads to low
cost and longer shelf life for fish
z The system consists of 23m2 solar air
heating sections V-Corrugated aluminum
absorber air flow below the absorber, 4mm
tempered glass and rock wool insulation and
180 W blower.

Source: Planters Energy Network, Coimbatore

30 Global Renewable Energy Forum, Brazil
 Solar drier for fish processing
contd

31 Source: Planters Energy Network, Coimbatore

Global Renewable Energy Forum, Brazil
 Solar pre-heating for tea leaf
processing

z A 212 m2 solar air heating system consists of 4

numbers of 53m2 sections with air overflow system.
Glazing by 4mm tempered glass, 20 degree tilt angle,
black paint metals absorber is used. The hot air is
pumped to the coal operated hot air generator at the
inlet point using 5.7 kW blower.
z Typically the system operates for 1545 hours per
annum, saving 71 tones of lignite coal leading to
annual CO2 reduction of 121 tones. An average 25%
fuel savings is achieved.

32 Global Renewable Energy Forum, Brazil

 Solar pre-heating for tea leaf
processing contd

33 Source: Planters Energy Network, Coimbatore

Global Renewable Energy Forum, Brazil
 RE Institutional Development

z 1981- Commission for Additional Sources of

Energy
z 1982- Department for Non-conventional Energy
Sources (DNES)
z 1987- IREDA Established
z 1992- DNES upgraded to Ministry of Non-
Conventional Energy Sources (MNES)
z 2006- MNES renamed as Ministry of New and
Renewable Energy (MNRE)

34 Global Renewable Energy Forum, Brazil

 Institutional structure -Renewable
energy
Financial
MNRE R&D

support Implemen
tation
State Government of A) Research
Multilateral IREDA, Banks Agencies schemes
institutes managed
agencies and non-banking by MNES
a
1. SEC ,
b
2. C-WET
Schemes and policy 3. AHEC
Implementing agencies
such as SNAs, NGOs B) Other laboratories
and Akshay Urja (AU) and private sector R & D

Manufacturers

End user or customers like

a) Individuals b) Corporate and Government Departments c)
Communities

35 Global Renewable Energy Forum, Brazil

 Policy and regulatory support

z Policy support since 1982

z Concessional import duty for critical components till
indigenous development takes place
Support to R & D
z Variety of fiscal and financial benefits
Capital subsidy
Low interest loans
Reduction/Removal of taxes and duties
Tax benefits
z 80% depreciation in the first year

36 Global Renewable Energy Forum, Brazil

 Barriers

z Site constraints
Shadow free area for installation
Factory layout
System integration with existing system
z Awareness and willingness to invest
z System designers and manufacturers
Limited technical capacity
Lack of instrumentation and controls

37 Global Renewable Energy Forum, Brazil

 Way forward- south-south
cooperation

z India can offer simple affordable

technologies
z Its important for us to share the
experience
z Capacity building of manufacturers and
system designers
z Need to develop technical solutions and
demonstration projects for industrial
applications
38 Global Renewable Energy Forum, Brazil
 Thank you for your attention!

Contact
shirishg@teri.res.in

www.teriin.org

39 Global Renewable Energy Forum, Brazil