Professional Documents
Culture Documents
Stefan Hess
www.ise.fraunhofer.de
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Agenda
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Agenda
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Industrial process heat accounts for more than 20 % of the final energy
demand (in Germany, similar for EU 25)
A significant share of 33 % is needed at temperatures below 150 °C
Huge potential:
über 250°C
Germany: ca. 16 TWh 62%
(3,1 % of industrial heat
demand) = 36 Mio. m2 (450 unter 100°C
23%
kWh / (m2*a)) [1]
100°C..150°C
EU 25: ca. 70 TWh 10%
= 155 Mio. m2 [1]
(overall installed collector 150°C..250°C
area in EU 27, 2009: 5%
ca. 46 Mio. m2 [2]) Demand per temperature range (Germany) [1]
[1] C. Lauterbach et al. 2010: Potential of Solar Process Heat in Germany. Uni Kassel
[2] W. Weiß et al., 2011: Solar Heat Worldwide Report 2009. AEE INTEC 4
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Reality and obstacles
[3] W. Weiß, 2010: Speech at Intersolar Conference Solar Process Heat. IEA Task 33/IV
and research of AEE INTEC 5
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Agenda
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SO-PRO Design Guide [4]
© Fraunhofer ISE
Heat demand:
Thermal load: demand per day or year
Load profile:
daily, weekly and annual variation of the
heat demand
Available temperature level: temperature
level at the heat integration point
(low temperatures are often favorable) Source: Fraunhofer ISE
Support of open or closed processes:
A process is open, if the medium to be heated is not circulated.
Directly or indirectly heated processes:
Heat supply to the process via heat exchanger is indirect.
The supply is direct, when the heat carrier is consumed by the process.
Integration on process- or supply level:
On the process level the solar heat is supporting a process, on the supply level
the ST-system is supporting a hot water or steam network.
8
© Fraunhofer ISE
Holistic planning approach – consecutive steps
Pre-analysis: building and boundary conditions
Checklists, phone calls (www.solar-process-heat.eu/checklist)
What is / could be the motivation of the company ?
Analysis of process characteristics and heat distribution network
Site visit with technician, sketch of the building
Temperature levels, condition of heat distribution network
Open / closed processes, direct / indirect heat integration, heat integration
at process level or supply level (heat distribution network)
Process-schemes, load profiles, installation of measuring equipment
Process optimization and energy efficiency measures [5]
Processes state-of-the-art? Future plans?
Heat exchanger optimization (pinch analysis)
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Agenda
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a) Heating of water for washing or cleaning
backup
heating
tank boiler
solar
buffer
storage
tank
© Fraunhofer ISE
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 0 1 2 3 4 5 6 7 0 5 10 15 20 25 30 35 40 45 50
time of day day of week week of year
Example for the discontinuous load profile of the hot water demand for cleaning of
production equipment in a medium-sized company.
© Fraunhofer ISE
Example: thermal load and annual heat demand
For a measured demand of 10 m3 hot water per working day the heat demand
Qworking day can be calculated (simplified):
kJ kJ
QWorking day mWorking day c p T (10,000 kg 4.18 45 K ) / 3600 522.5 kWh
kg K kWh
The load profile shows, that between 05:30 and 20:00 the hot water demand is
about 408 l / h. Within the last two hours it is 2040 l / h.
Weekends and company holidays (235 working days out ot 365) lead to a
mean daily demand of 6,44 m3 per day and an annual energy demand of this
process of 122,8 MWhth / year.
© Fraunhofer ISE
kWh kWh
AAp (QYear 0.4) / 500 2
(122 .8 MWh 0.4) / 500 2 100 m Ap
2
m Ap m Ap
l l
VSto AAp 50 100 m Ap
2
50 2 5 m 3
m2 m Ap
14
© Fraunhofer ISE
Simulated nomograms for system design
80 800
Würzburg:
Total horizontal radiation = 1090 kWh / (year* m²)
70 700
50 500
40 400
30 36 300
solar fraction
solar gains
20 200
10 liter storage vol. / m²Ap
30 liter storage vol. / m²Ap
10 100
50 liter storage vol. / m²Ap Discont. load profile slide 13, 15 °C to 60 °C,
70 liter storage vol. / m²Ap flat-plate stratified storage, collector slope 35 °
0 0
0 25 50 75 100 125 150 175 200
2
utilisation ratio [liter cleaning water / (day * m Ap)]
15
© Fraunhofer ISE
Calculation of the resulting collector aperture area by using the utilization ratio
of 75 l hot water per day and m2Ap:
l WW l WW
AAp ( 6,440 ) / (75 2
) 86 m Ap
2
day day * m Ap
The resulting solar system gains are valid for a storage volume of:
l
V Sto 50 2
2
* 86 m Ap 4,300 l
m Ap
kWh MWh
specific system gains: E year 515 2
2
* 86 m Ap 44 .3
year * m Ap year
MWh MWh
solar fraction: E year 122 .8 * 36 % 44 .2
year year
16
© Fraunhofer ISE
Variation: A “smaller” system?
Example: demand = 6,440 l / day
80 800
Würzburg:
Total horizontal radiation = 1090 kWh / (year* m²)
70 700
50 500
515
40 400
30 36 300
solar fraction
27 solar gains
20 200
10 liter storage vol. / m²Ap
30 liter storage vol. / m²Ap
10 100
50 liter storage vol. / m²Ap Discont. load profile slide 13, 15 °C to 60 °C,
70 liter storage vol. / m²Ap flat-plate stratified storage, collector slope 35 °
0 0
0 25 50 75 100 125 150 175 200
2
utilisation ratio [liter cleaning water / (day * m Ap)]
17
86 m2 64 m2
© Fraunhofer ISE
Location Madrid
Example: demand = 6,440 l / day
100 1200
Madrid:
90 Total horizontal radiation = 1615 kWh / (year* m²)
solar system gains [kWh / (year* m2Ap)]
80 1000
1015
70
solar fraction [% ]
solar fraction
60 solar gains 800
50
53
40 600
30
20 400
© Fraunhofer ISE
Exemplary system concept for pre-heating the make-up water of a steam process
© Fraunhofer ISE
Thermal load profile
heat demand [ % ]
heat demand [ % ]
heat demand [ % ]
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 0 1 2 3 4 5 6 7 0 5 10 15 20 25 30 35 40 45 50
time of day day of week week of year
Example for the make-up water consumption profile of a partly open steam network in a
small laundry.
© Fraunhofer ISE
solar
buffer
storage
storage inlet 90 °C
tank
heater
65 °C
outlet 70 °C
Exemplary system concept for the solar heating of an industrial bath. Direct heating of the
bath possible by bypassing the storage. The electrical heater is used for temperature
control.
© Fraunhofer ISE
Thermal load profile
heat demand [ % ]
heat demand [ % ]
heat demand [ % ]
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 0 1 2 3 4 5 6 7 0 5 10 15 20 25 30 35 40 45 50
time of day day of week week of year
Example for the continuous heat demand of an galvanic bath in a smaller company
© Fraunhofer ISE
ambient air
No storage necessary
Continuous heat demand favorable
Efficiency of air collectors decreases with decreasing mass flow
24
© Fraunhofer ISE
Agenda
© Fraunhofer ISE
26
© Fraunhofer ISE
Design case 1: Solar heating of a galvanic bath
solar
buffer
storage
storage inlet 70 °C
tank
heater
45 °C
outlet 50 °C
© Fraunhofer ISE
kWh
QYear 250 365 d 91, 250 kWh
d
m Ap a a m Ap
l l
VSto AAp 50 2
73 m Ap
2
50 2 3.65 m 3
m m Ap
28
© Fraunhofer ISE
Design case 1: Solar heating of a galvanic bath
2) Do a more accurate dimensioning of aperture area and storage
volume based on the simulation results in the following nomogram.
Apply vacuum tube collectors and 50 l / m2 storage. Which solar
fraction should be selected?
100 500 f sol 40 %
Würzburg:
90 Total horizontal radiation = 1090 kWh / (year* m²)
2
70
AAp d
solar fraction [% ]
60 300 kWh
2 .5
50 d m2
solar fraction
100 m 2
40 solar gains 200
30
50 liter storage vol. / m²Ap, flat-plate
20 100 l
70 liter storage vol. / m²Ap, flat-plate
VSto 100 m 2 50
10 50 liter storage vol. / m²Ap, evacuated-tube
70 liter storage vol. / m²Ap, evacuated-tube Bath temp.: 45 °C
m2
5 m3
0 0
0 1 2 3 4 5
specific thermal energy demand of bath [kWh / (day * m2Ap)]
29
© Fraunhofer ISE
80 400
70 liter storage vol. / m²Ap
250
70
AAp d
solar fraction [% ]
60
solar fraction
300 kWh
solar gains 2 .5
50 d m2
40 200
100 m 2
30
20 100 l
VSto 100 m 2 50
10
Bath temp.: 65 °C, evacuated tubes
m2
0
0 1 2 3 4 5
0
5 m3
2
specific thermal energy demand of bath [kWh / (day * m Ap)]
30
© Fraunhofer ISE
Design case 1: Solar heating of a galvanic bath
4) Suppose the company would be located in Madrid.
How would you design the system for 45 °C there?
Selected collector type: flat-plate
100
Madrid:
800 f sol 56 %
Total horizontal radiation = 1615 kWh / (year* m²)
90 700
70 500
kWh
3
d m2
solar fraction
60 400
solar gains
50 300 83 m 2
40 50 liter storage vol. / m²Ap, flat-plate 200
l
VSto 83 m 2 70
70 liter storage vol. / m²Ap, flat-plate
30 50 liter storage vol. / m²Ap, evacuated-tube 100
70 liter storage vol. / m²Ap, evacuated-tube Bath temp.: 45 °C
m2
5 .8 m 3
20 0
0 1 2 3 4 5
specific thermal energy demand of bath [kWh / (day * m2Ap)]
31
© Fraunhofer ISE
© Fraunhofer ISE
Design case 2: Solar heating of make-up water
50 500
AAp d
l
40 400 75
d m2
30 300
solar fraction
20
solar gains
200
200 m 2
30 liter storage vol. / m²Ap
l
VSto 200 m 2 50
10 50 liter storage vol. / m²Ap 100
70 liter storage vol. / m²Ap
flat plate collectors m2
0 0
0 25 50 75 100 125 150
2
utilisation ratio [liter make-up water / (day * m Ap)]
175 200
10 m 3
33
© Fraunhofer ISE
2) What is the difference in the recommended solar fraction and the solar
system gains between make-up water (slide 33, load profile slide 21) and
cleaning water (slide 15, load profile slide 12)?
a) Recommended solar fraction:
25 % for make-up water and 36 % for cleaning water
b) Solar system gains:
570 kWh / m2 for make-up water and 515 kWh / m2 for cleaning water
4) Which are the two main reasons for the different solar system gains?
a) The load profile for cleaning shows company holidays.
b) Solar gains above 60 °C can not be used for the cleaning water. 34
© Fraunhofer ISE
Results for case 1: Solar heating of a galvanic bath
solar
buffer
storage
storage inlet 70 °C
tank
heater
45 °C
outlet 50 °C
© Fraunhofer ISE
kWh
QYear 250 365 d 91, 250 kWh
d
m Ap a a m Ap
l l
VSto AAp 50 2
73 m Ap
2
50 2 3.65 m 3
m m Ap
36
© Fraunhofer ISE
Results for case 1: Solar heating of a galvanic bath
2) Do a more accurate dimensioning of aperture area and storage
volume based on the simulation results in the following nomogram.
Apply vacuum tube collectors and 50 l / m2 storage. Which solar
fraction should be selected?
100 500 f sol 40 %
Würzburg:
90 Total horizontal radiation = 1090 kWh / (year* m²)
2
70
AAp d
solar fraction [% ]
60 300 kWh
2 .5
50 d m2
solar fraction
100 m 2
40 solar gains 200
30
50 liter storage vol. / m²Ap, flat-plate
20 100 l
70 liter storage vol. / m²Ap, flat-plate
VSto 100 m 2 50
10 50 liter storage vol. / m²Ap, evacuated-tube
70 liter storage vol. / m²Ap, evacuated-tube Bath temp.: 45 °C
m2
5 m3
0 0
0 1 2 3 4 5
specific thermal energy demand of bath [kWh / (day * m2Ap)]
37
© Fraunhofer ISE
80 400
70 liter storage vol. / m²Ap
250
70
AAp d
solar fraction [% ]
60
solar fraction
300 kWh
solar gains 2 .5
50 d m2
40 200
100 m 2
30
20 100 l
VSto 100 m 2 50
10
Bath temp.: 65 °C, evacuated tubes
m2
0
0 1 2 3 4 5
0
5 m3
2
specific thermal energy demand of bath [kWh / (day * m Ap)]
38
© Fraunhofer ISE
Results for case 1: Solar heating of a galvanic bath
4) Suppose the company would be located in Madrid.
How would you design the system for 45 °C there?
Selected collector type: flat-plate
100
Madrid:
800 f sol 56 %
Total horizontal radiation = 1615 kWh / (year* m²)
90 700
70 500
kWh
3
d m2
solar fraction
60 400
solar gains
50 300 83 m 2
40 50 liter storage vol. / m²Ap, flat-plate 200
l
VSto 83 m 2 70
70 liter storage vol. / m²Ap, flat-plate
30 50 liter storage vol. / m²Ap, evacuated-tube 100
70 liter storage vol. / m²Ap, evacuated-tube Bath temp.: 45 °C
m2
5 .8 m 3
20 0
0 1 2 3 4 5
specific thermal energy demand of bath [kWh / (day * m2Ap)]
39
© Fraunhofer ISE
© Fraunhofer ISE
Results for case 2: Solar heating of make-up water
50 500
AAp d
l
40 400 75
d m2
30 300
solar fraction
20
solar gains
200
200 m 2
30 liter storage vol. / m²Ap
l
VSto 200 m 2 50
10 50 liter storage vol. / m²Ap 100
70 liter storage vol. / m²Ap
flat plate collectors m2
0 0
0 25 50 75 100 125 150
2
utilisation ratio [liter make-up water / (day * m Ap)]
175 200
10 m 3
41
© Fraunhofer ISE
2) What is the difference in the recommended solar fraction and the solar
system gains between make-up water (slide 33, load profile slide 21) and
cleaning water (slide 15, load profile slide 12)?
a) Recommended solar fraction:
25 % for make-up water and 36 % for cleaning water
b) Solar system gains:
570 kWh / m2 for make-up water and 515 kWh / m2 for cleaning water
4) Which are the two main reasons for the different solar system gains?
a) The load profile for cleaning shows company holidays.
b) Solar gains above 60 °C can not be used for the cleaning water. 42
© Fraunhofer ISE