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Joint Saudi-German CSP Workshop
Integration of Solar Process Heat Systems
19th - 20th November 2013
§ systems are smaller compared to utility scale CSP collectors e.g. Eurotrough
§ Modular collectors, scalable layout § construction of plants without on-site
preassembly, turn-key § ground – or roof installation possible § typical temperature range from 70°C to
320°C up to today § proven systems to deliver hot water,
steam or saturated steam § capable to be integrated into existing
conventional boiler systems § integration of thermal storages allow
24/7 operation
2 Integration of Solar Process Heat Systems Martin Scheuerer 20.11.2013
Solar process heat collectors
Characteristics of concentrating solar process heat systems:
3 Integration of Solar Process Heat Systems Martin Scheuerer 20.11.2013
Solar process heat collectors
Examples of parabolic trough and fresnel collectors for process heat
PT-1: 6m x 2.3m
LF-11: 7.5m x 4m
PTC1800: 5m x 1.8m
Solar PolyTrough1200 CF100: 12m x 3m
EST 6000: 8.3m x 6m
4 Integration of Solar Process Heat Systems Martin Scheuerer 20.11.2013
Industrial applications for process heat
Food and beverage industry Drying, cleaning, cooking, baking, pasteurization
Wineries and distilleries Steam juicing, sterilization of wine making + bottling
Textile and leather industry Dying, shaping, ironing, tanning
Hotel and tourism Laundry, heating, cooling
Paper industry Bleaching, thermo mechanical pulping, drying
Pharmaceutical + chemical industry Process specific applications, distillation
Mining and oil industry Undeveloped oil recovery, cleaning, oil distillation
Plastics and rubber industry Heating, cooling, vulcanization
Water treatment Desalination and water purification projects
Slaughter houses Cooling and refrigeration of meat and meat products
Industry Applications and processes
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Realized solar process heat projects
Solar process heat for water desalination
I. Port Augusta, Australia
§ Parabolic trough § Heat storage tank § MED (Multi Effect Desalination) 10m3/day
§ ORC Turbine
II. Um Saied (Qafco), Qatar
§ Parabolic trough § Heat storage tank § MED (Multi Effect Desalination) 10m3/day § Greenhouse heating
Integration of Solar Process Heat Systems
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Realized process heat projects
Solar process heat for cooling applications
§ Solar cooling project at a holiday resort in Turkey
§ Cooling provided with double effect absorption chiller
Integration of Solar Process Heat Systems
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Realized process heat projects
Solar process heat plant with thermo oil
Frito Lay (PepsiCo) California, USA § Heating of oil used for
cooking corn and potatoe chips
§ 5.068 m² § 250°C, 41bar § Indirect steam
generation § Back-up by natural gas
fired steam generators
Integration of Solar Process Heat Systems
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Realized process heat projects
Solar process heat plant with direct steam
§ Direct steam generation plant at aluminium anodising factory § Saturated steam delivered by solar plant at 143°C and 4 bar
Integration of Solar Process Heat Systems
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Realized process heat projects
Solar process heat plant with indirect steam generation
Switzerland, milk processing plant § Indirect supply of heat to
4-6 bar steam network § Thermal oil circuit,
180-200°C § 116m² collector surface § Indirect steam
generation in tube-and-shell steam generator
Integration of Solar Process Heat Systems
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Solar Process Heat
Project Study I: Integration of CSP power plant for Desalination, Greenhouse, Sludge drying and Biomass
Fresh water
Waste water
Electricity
Heating
Cooling
Housing estate Greenhouse Chicken farm
Waste water treatment plant Sludge drying
CSP Biomass Solid Fuel Desalination Power plant
Solid fuel
Nutrients Fertilizer
Food
Local industry - Oil/Steal - Medical - Food
Sea water
Integration of Solar Process Heat Systems
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Solar Process Heat
CSP Greenhouse project § A typical decentralised
greenhouse needs fresh ground water, fossil fuels, nutrients and sunlight
§ In a CSP driven greenhouse system external fresh water is not longer required. The system requires only sea or salty ground water.
Integration of Solar Process Heat Systems
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Benefits of CSP driven greenhouses
§ Land use close to the coast and regions (arid zones) which you never can use for traditional greenhouse concepts
§ Highest food production, e.g. 60 [kg]/[sqm][year] § Decentralized, high quality food production and reduction of transportation
and CO2 reduction § Food production independent from seasons (365 days) § Implemented MED desalination system can handle high salinity sea/
groundwater in comparison to Reverse Osmosis (RO) § Own electricity production, absorption chiller cooled warehouse § Independence from price trends and availability of water, fuel, and
electricity § Local green jobs in every region
Integration of Solar Process Heat Systems
Solar Process Heat
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Engineering for a 200.000m2 greenhouse project / serial connection of components in a chain / 60.000m2 solar field CSP
Steam turbine
Desalination
Absoption chiller
Greenhouse heating
Heat storage
Electricity
Water
Cooling heating
Note: Erfis/Sunlis complex basic engineering (CSP, steam, Multi Effect Desalination, fresh water, cooling)
Integration of Solar Process Heat Systems
Solar Process Heat
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Solar Process Heat
Project Study II: Solar sludge drying concept study (decentral)
§ Volume reduction up to 40% § Humidity reduction up to
90% § Solid fuel production for
cement industry or coal power plants
§ Disinfection of sludge § Nutrients production for
agriculture industry § Significant fuel savings § Neutralization of smell
Note: Sheme from Buss-SMS-Canzler
Integration of Solar Process Heat Systems
15 Präsentationstitel Referent Datum
Solar Process Heat
Project Study III: CSP for Enhanced Oil Recovery (EOR) EOR Process Characteristics § High steam consumption
– injection into wells § Low electricity § High reliability of operations (24/7) § Operational flexibility of plant
Typical plant § Fossil fired boilers and gen-sets § Desalination (MED) to generate feed-water
Economics § Low Investment (CAPEX) § High Fuel consumption (OPEX)
Boiler 1
Boiler 2 MED
Tank
Deaerator
steam supply oil wells for EOR
brackish water (from well) (feed)
brine (to disposal well)
diesel fuel
diesel fuel G
G
electricity to oil field
Engine
Engine
other
power plant own consumption
16 Präsentationstitel Referent Datum
Solar Process Heat
CSP can contribute 40%-80% solar steam to EOR at competitive rates § Solar share can reach 40-50% (up to
80% with thermal storage)
§ On 25 year project life time, solar steam is at half of cost of diesel steam, still below LSFO steam
§ Payback period can be as low as 8 years
§ Solar steam also is competitive against LSFO, but with reduced advantage
§ Fuel price increase lifts benefit
⇒ CSP can provide a very attractive commercial option for EOR
Note: * Source: Suntrace internal study
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Solar Process Heat
Project Study IV: Oil Industry 10 MW Solar Crude Oil Pre-Heater
§ In an oil exploration camp in Yemen, 400 oil quells are powered with diesel generators with a total capacity of 250 MW!
§ The diesel is produced in an on-site distillation facility.
§ The required heat energy to process the crude oil into diesel, is powered with diesel
Integration of Solar Process Heat Systems
§ By installing a solar crude oil pre-heater the current diesel consumption in the topping plant will be reduced by 34%
§ Leading to a reduction in fuel consumption of 3.2 Million litre per year § Return on investment 3-4 years [based on a diesel price of 1$/litre]
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Solar Process Heat
Integration of Solar Process Heat Systems
Project Study V: Process Steam Supply of a Bakery in Jeddah § 2.5 MW solar boiler to supply process
steam directly in the production process of the bakery
§ The producing requires 4 tones of steam per hour that is currently produced by 3 oil boilers
§ Installing a solar steam boiler will reduce the fuel consumption of light fuel oil (LFO) of 630.000 litre p.a.
§ Return on investment 3 years based on a diesel price of 1 $/litre
§ Current fuel price: 0,07 $/litre
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Challenges in system integration
The solar process heat technology is developed and proven, what are the hurdles to integrate the systems in Saudi Arabia?
System Integration
Project preparation: Project Execution:
Successful system integration by joining competences of Saudi and German partners
- Knowledge of the local conditions?
- Solar resources? - Investment incentives? - Permissioning? - Available land?
CSP- Technology
- Engineering? - Application? - Manufacturing? - Operation? - PPA? - Feed-In tariff?
Integration of Solar Process Heat Systems
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Solar Process Heat
Why is this topic important for Saudi-Arabia?
§ Preserving oil resources: “sell it, don’t burn it” § Local content
§ Creation of job § Local production of components § Operation & maintenance § Capacity building
§ Decentralization § Off-grid solutions (IPP- Independent Power Production) § Hybrid project design creates flexibility (heating/cooling/electricity)
§ Energy strategy § Contributing to KSA’s energy targets installing 24GW of CSP till 2032 § Establishing a Saudi Solar industry by initiating commercial project
Integration of Solar Process Heat Systems
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Solar Process Heat
§ What are the specific topics to be addressed?
§ Localisation of potential applications § Industrial matrix § Process temperatures § Project development
§ Pre-feasibility studies § Evaluation of requirements § New system or re-fit § Application – or branch specific system
§ Re-cooling temperatures for solar cooling § District cooling (system design) § Acknowledge generation by pilot plants § Utilisation of local resources (construction, engineering and production) § Creation of incentive mechanism for the industry
Integration of Solar Process Heat Systems
Summary and key take-aways
Key Statements § CSP = proven technology for process heat § Solar process heat for local industry (decentralization) § Substitution of oil is more economical – industrial leadership
Our Proposal § Project studies for certain applications § Pilot projects with full system integration § Technology transfer/capacity building
Opportunities and Benefits for Saudi partners § Local content § Developing a Solar Process Heat Industry § Preserving oil resources for export
Why choosing German Partners § Global leadership in Concentrated Solar Power (CSP) § Engineering “Made in Germany” § Long term commitment in KSA
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