SOLAR INDUSTRIAL

PROCESS HEAT
Dr. B.F. TCHANCHE
Agricultural University of Athens, Greece
tfb@aua.gr OR tfb_tchanchef@yahoo.fr
Overview
 Introduction

 System components

 Solar thermal collectors

 Market potential

 System design

 Examples

 System cost

 Barriers

 African context

 Conclusion

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Introduction
Annual solar radiation -
© Meteotest, Berne, Switzerland

PV panels

Batteries, inverter,
Electricity
cables, etc

Solar thermal
collector Heat exchangers,
storage tank, Heat Electricity
controllers, etc

PV-T
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System Components

Water Auxiliary
Vapor heater/
Pressurized boiler
water Space heating
Solar radiation
PCM
etc Domestic hot
water

Industrial
Storage
Solar End-uses processes
tank
collector (cooling,
heating, etc)
Flat plates
Power
Evacuated tubes
generation
Parabolic trough
etc
Control system

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Solar thermal collectors

Global Irradiance
Reflection
Ig 100%
8%

radiation
Glass cover
Forced
convection

Absorption 2%

Free
convection

Usable heat
insulation Heat conduction
(<60%)

Collector operating principle – flat plate

(photo-thermal conversion)

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Solar thermal collectors

Unglazed flat plate Double glazed flat plate Evacuated tube

Hot Air solar collector single glazed flat plate Parabolic trough

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Solar thermal collectors

Maximum reflector collector Combined heat and power

CPC collector solar collector (CHAPS)
(mareco)

heliostat Compact linear fresnel reflector Paraboloidal dish reflector

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 Solar thermal collectors
Type T [C] Concentra Tracking
tion ratio
Air collector 0-50 1 -
Pool collector 0-50 1 -
Reflector collector 50-90 - -
Solar pond 70 – 90 1 -
Solar chimney 20 – 80 1 -
Flat plate collector 30 – 100 1 -
Advanced Flat Plate 80-150 1 -
collector
Combined heat and 80-150 8-80 One-axis
power solar
collector (CHAPS)
Evacuated tube 90 – 200 1 -
Efficiency vs temperature ranges (1kW/m2)
collector
Compound 70-240 1-5 - Temperature and Applications
Parabolic CPC
Fresnel reflector 100 – 400 8 – 80 One-axis Low temperature solar collectors (T<80 ºC)
technology  Heating (swimming pool, hot water, space)
Parabolic trough 70 – 400 8 – 80 One-axis
Heliostat field + 500 – 800 600 – Two-axis Medium Temperature collectors (80<T<400 ºC)
Central receiver 1000  Process industrial heat!!
Dish concentrators 500 - 1200 800 - Two-axis
8000 High Temperature collectors (T>400 ºC)
Typical operating temperature and concentration ratio  Power generation
for different solar collectors

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Market potential

Final Energy Use of the EU-Industry Industrial sectors

 Paper
 Food & beverage industries
 Textile industry
 Metal & plastic
 Chemical industry
Electricity
33%
Processes
Heat  Drying
67%  Washing
 Cleaning
 Frying/cooking
 Liquid/solid heating/cooling
 Space heating/Cooling
 Sterilization
ESTIF – European Solar Thermal  Distillation
Industry Federation (www.estif.org)  etc

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Market potential
Industry Process Temperature (°C)
Food industry Sterilization 60-120
Pasteurization 60-80
Cooking 90-100
Bleaching 60-90
Washing 60-90
Chemical Soaps 200-260
Synthetic rubber 150-200
Processing heat 120-180
Pre-heating water 60-90
Plastics Preparation 120-140
Distillation 140-150
Separation 200-220
Extension 140-160
Textile Bleaching, dyeing 60-90
Drying, degreasing 100-130
Fixing 160-180
Pressing 80-100
Processes and temperature ranges
(kalogirou, 2003)

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System design example

Solar collector Boiler

Buffer solar
storage tank

90 ºC

Heater

70 ºC
Heat
exchanger Bath

Industrial bath
Ref. SOPRO

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System design example

Gas/liquid heat
Air solar collector exchanger Hot air for
Fan Fan the process

Ambient air

Air pre-heating for an open drying process

Ref. SOPRO Boiler

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Examples
Metal processing company Steinbach & Vollman,
Germany (2008)

Solar coll: vacuum tube, 400 m2, 280 kW

Storage: 9 m3
Design: bath heating, heating, domestic hot water
Temperature: 60 - 80 ºC
Energy savings: 30-35% (gas reduction)
Capital cost: 240,000 € (50% subsidies)
Payback period: 7 years (Subs. Incl.)

Brewery, Neumarkteur Lammsbrau Gebr.

Ehrensperger e.K., Germany (2000)

Solar coll.: single glazed flat plate, 72 m2, 50 kW

Design: air preheating (drying process)
Storage: no
Temperature: up to 60 ºC

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System Cost

In Europe
Investment Cost
 Capital cost: 180-500 €/m2
Distribution
Collector field  Heat: 2-8 c€/kWh
6%
3% Capital cost
Piping
11%
 location (solar resource, local
Planning
wages)
53%
Storage & Heat  Application (temperature, load
exchangers profile)
14% Control system
 System concept
14%
Others  Size of the system

 System components

Ref: SOPRO project

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Barriers/Obstacles
Identified obstacles
 Awareness (not known by public, decision makers)

 Resistance (new tech & “business as usual attitude” of managers)

 High investment cost (as most renewable energy technologies)

 Lack of standard technology (designs, materials)

 Lack of suitable planning guidelines & tools

 Lack of training & education

How to overcome the barriers

 Information campaign

 More demo projects (references)

 Subsidies

 Training (workshops, seminars,…)

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African context
Industries
- agro-food & beverage
- textile
- chemical

Conservation of
agricultural products
- drying
- refrigeration

Buildings
- Air conditioning (60% of
energy consumption)

The solar resource

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African context
Major obstacles
- lack of technology
- high upfront cost
- lack of subsidies
- lack of appropriate energy policy
- lack of skilled workers
- lack of research facilities

Benefits for countries

- landlocked countries/oil imports (energy security)
- development of remote areas (PV + solar thermal)
- more jobs
- less CO2 emissions

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More …

Potential of Solar Heat in Industrial Processes. – POSHIP - 2001

SO-PRO Project (http://www.solar-process-heat.eu/)- 2009/28

months

IEA –SHC (solar cooling & heating): Tasks 33, 38 and Task 49 “Solar
Process Heat for Production and Advanced Applications” – begin
January 2012. (http://www.iea-shc.org/)

MEDISCO project – (Morocco, Tunisia, Egypt) http://www.medisco.org

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Conclusion

Low temperature solar heating (swimming pools, space heating,

domestic hot water) well known and mature!

High temperature thermal applications are under development

for electricity generation since the 1980s(CSP)!

Medium temperature solar applications are at the infancy stage

(start 2000) despite the huge potential that exist in industries and
buildings.
Major technology in the coming decades provided the barriers are
overcome:
 More research
 Financial support
 Increase awareness (managers, policy makers)

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