sun focus jan mar 2014

8/12/2019 Sun Focus Jan Mar 2014

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INDIAS QUESTFOR SOLAR STEAM

AND PROCESS HEAT

CSTs for IndustrialApplication

SPECIAL ISSUE

a quarterly magazine on concentrated solar heat

Issue 3 | JanuaryMarch 2014

UNDP-GEF Project on CSHMinistry of New and Renewable EnergyGovernment of IndiaMNRE


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National Workshopon Solar Thermal

SystemsA National Workshop on Solar Thermal Systems cum AwardDistribution Function wasorganized by the Ministry of Newand Renewable Energy (MNRE)

under the aegis of the UNDP-GEF project on Concentrated Solar Heat on 17 December2013 at Hotel Ashok, New Delhi. Around 250 stakeholders from various parts of the countryparticipated in the Workshop, which included of cials from State and Central governmentdepartments, State Nodal Agencies, manufacturers and bene ciaries, technical experts,and consulting organizations. The workshop included a technical session conducted underthe chairmanship of the Secretary, MNRE, along with an award distribution function. Theawards for the year 2012 13 were presented to various stakeholders working in the elds ofsolar water heating and concentrated solar thermal systems by Dr Farooq Abdullah, HonbleMinister for New and Renewable Energy. A total of 28 awards were presented, which includedawards to State Nodal Agencies, bene ciaries, and Channel Partners of the Ministry.

A few knowledge documents developed under the project were also released by theHonble Minister on this occasion, including success stories and video lms on installations, iers on concentrating solar technologies (CSTs), and a compendium of such existingtechnologies. Besides this, a video lm on the use of CSTs in industries for process heat andcooling applications was also played during the workshop, which was appreciated by allthe participants.

I am in receipt of the inaugural issue of SUN FOCUS and congratulate you. Iappreciate the contents therein and would motivate the industries to consider use of

concentrated solar systems in a positive manner.Jaideep N Malaviya, Editor

www.insolthermtimes.in

The entire issue content giving the focus on Schef er dish is very useful and hasgiven the insight into the technology. Thanks for the awareness and way of sharing.Wish the SUN FOCUS long knowledge sharing and spread into people.

G Balaji, CSP Initiatives SolarWater & Renewable Energy IC, Larsen & Toubro Limited

Readers Responses


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F rom the editors desk...

Dear Readers,

Let me begin by wishing you all a very happy and prosperous new year! In this new year, I am happyto share the third issue of SUN FOCUS with you all. The rst two issues of SUN FOCUS have been much appreciated and I thank you all for your letters ofencouragement and support. They help reassure us that we are heading in the right direction.

In this issue, we have focused on industrial applications of CSTs, one of the key focus areas of the UNDP-GEF Project on Concentrated Solar Heat. This issue brings you articles to guide you on how to optimizeCST choice for maximizing fossil fuel displacement in industrial process heating, global technological

advancements that have taken place in this arena, as well as the status of international policies andprogrammes supporting CST for industrial heating applications. Our endeavour is to make readers awareof the enormous opportunities provided by CSTs and to bring in an understanding of the internationalpolicies and regulatory initiatives in the area.

We also present to you success stories of CST application in the Indian dairy industry, with case studies ofthe Mahanand and Chitale dairies in Maharashtra that are reaping the bene ts of early CST installation.

I hope this issue throws light on this aspect of CST application and that you nd it as useful as the previousissues. As always, we await your comments and suggestions to help us improve the quality of the magazinefurther, and hope that you contribute to future issues with enthusiasm. Once again, I wish you a bright and

sunny year ahead!

Sd/-Tarun Kapoor

Joint Secretary, Ministry of New and Renewable Energy


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SUN FOCUS | JanuaryMarch 2014 | 5

Policy

Programmes/Policies/OtherInitiatives

Year Countries Implementingorganization

Description**

IEA Solar Heating andCooling Programme

2008 Australia, I taly,Germany, Austria,

Spain, Mexico,Portugal

International Energy Agency(IEA)

$ Collaborative projects of SHC programme,IEA and SolarPACES

$ Aim was development of STP for industrialprocess heat

Solar Heat for IndustrialProcesses

N/A Morocco, Tunisia,Egypt, Jordan, Turkey

The Observatoire M diterran ende lEnergie (OME), supported byUNDP and UNEP

$ To provide overview of Solar Heat forIndustrial Processes (SHIP) application inthe Mediterranean

$ To learn from best practices

Renewable Energy Law 2012 China Government of the PeoplesRepublic of China

$ Intensi ed efforts towards medium andhigh temperature industrial applications ofsolar energy along with other solar thermaltechnologies

Jawaharlal NehruNational Solar Mission

2009 India Government of India $ To achieve 15 million sq. m solar thermalcollector area by 2017 and 20 million sq. mby 2022

High Temperature Solar Thermal Technology Roadmap

2008 Australia New South Wales and VictorianGovernment

$ To aid development of suitablepolicy regime for deployment of hightemperature solar thermal technologyin Australia for domestic, residential, andindustrial purposes

Market Developmentand Promotion ofSolar ConcentratorBased Process HeatApplications in India(2012 2017)

2011 India Ministry of New and RenewableEnergy, Government of India andUNDP

$ Study was conducted to developunderstanding of installed systems andtheir functionality for up-scaling

Solar Heating andCooling for a

Sustainable EnergyFuture in Europe

N/A Europe ESTTP Secretariat jointly run byEuropean Solar Thermal Industry

Federation (ESTIF), EuropeanRenewable Energy CentresAgency (EUREC Agency) and PSE

$ Vision document for 2030 to assist inde ning strategic research agenda

for heating and cooling in Europe andworldwide

**The descriptions are part of larger multi-year projects, of which concentrating solar thermal power in industrial process heating is a par t.

non-imaging solar collectors forlow temperature processes. REN21 also reports that automation ofmanufacturing processes increased in2012, with innovation spanning fromadhesives to materials and beyond. The major drawback that thisindustry suffers is because of lack ofawareness as well as the persistinghigh cost of the system. Further, the nointerest no know-how no marketproblem means there is a great lackof information across the value chain. These problems need to be addressedquickly to increase the share of CSTs forproducing industrial process heat.

Table 2: Some programmes/policies on CST for industrial process heat

NEP Solar Collector Field on Sun in Newcastle, Australia


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6 | SUN FOCUS | JanuaryMarch 2014

Features

GLOBAL TECHNOLOGICAL ADVANCEMECST FOR INDUSTRIAL PROCESS HEATChinmay Kinjavdekar

There is a pressing need toaccelerate the developmentand deployment of advancedclean energy technologies in orderto address the global challengesof energy security, climate change,and sustainable development.Concentrating solar thermal (CST)systems for industrial process heat(IPH) can have an important role toplay in realizing targets in energysecurity and economic developmentand in mitigating climate change. Today, concentrating solar heatingtechnology development is mainlyfocusing research and development

(R&D) resources on goals relatedto power production, for example,realizing higher temperatures. Butthe thermal energy produced byconcentrating solar technology canalso be used for heat applications, suchas for low, medium, or high temperatureindustrial processes in areas with goodlevels of direct normal irradiance (DNI).

Although this application has till nowreceived far less attention, it has hugepotential in both developed anddeveloping countries.

As per the Technology Roadmap:Solar Heating and Cooling reportpublished by the InternationalEnergy Agency, solar heat has avery signi cant role in industrialapplications. The report estimates thatby 2050, the potential of solar heat inindustrial applications will be around3,200 GWth for only low temperatureapplications (up to 120 C). The Scenarioalso estimates more than 1,000 GWthcapacity for solar cooling systems

by 2050.CST systems for IPH have speci c

bene ts. They are compatible withnearly all sources of back-up heatand almost universally applicable dueto their ability to deliver heat in theform of low or high pressure steam,pressurized hot water, and thermicoil heating.

Research, Development, andDemonstrationCST systems for IPH are still at an earlystage of development. At present, only

around 200 operating solar thermalsystems for process heat are estimatedworldwide, with a total capacity ofabout 42 MWth (60,000 sq. m), oronly 0.03% of the total solar thermalcapacity installed. Most of thesesystems are of small scale experimentalor demonstrational nature. Despite the limited penetration ofsolar technologies in the industrialsector, its potential is quite large.Indeed, in 2007 the industrial sectorrepresented 28 per cent of the nalenergy consumption in the EU 27,with a large part of the heat requiredbeing below 250 C. Tapping into thispotential would provide a signi cantsolar contribution to industrial energysystems. Many reputed organizationssuch as Fraunhofer, DLR (Germany),

The author is Research Associate, Renewable Energy Technology Applications,TERI. Email: [email protected]

SMirros solar steam for textile industry at Germany, 2010


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Features

NREL (USA), etc., are active in R&D inthis eld. Their efforts can be mainlyclassi ed as:$ Solar Collector Development: The

current solar collector technologies,such as parabolic trough collectors,parabolic dishes, and linearconcentrating Fresnel collectors,can be adapted to serve mediumand high temperature processheat applications. So the focus ison development of modular andlow cost design and ef ciencyimprovements in order to caterto high temperature applications.Extensive work is also being doneon stationary concentrators, suchas CPC or evacuated tube collectors,

having high ef ciency in the lowtemperature region (up to 120 C). These types of concentrators costcomparatively less and are exiblein installation. Additionally, theirability to supply heat in the form oflow pressure steam and pressurizedwater increase their potentialapplications tremendously.

$ Integration Systems: A lot of workis going into optimization and

cost reduction of the integrationsystems, such as direct steamgeneration in collectors whicheliminates the requirement of aheat exchanger and enables an easycontrol strategy. Work is also beingdone on the possible use of newthermal storage technologies whichwill enable CST systems to deliverheat as per the requirement of theload pro les.

$ New Applications: There is alot of work going on to identifynew applications in the mediumand high temperature rangesthat will be suitable for CSTsystems. Applications such as highpressure direct steam generation,desalination, co-generation, tri-generation, and high temperaturethermo-chemical processes are being

studied extensively. FraunhoferISE has worked thoroughly onthe combined generation of heat,electricity, and cooling in theMedifers project, and has concludedthat decentralized combinedheat, cooling, and power can bean interesting future option, butfurther demonstration projects arerequired. Work is also being carriedout for hybrid applications such assolar heating systems with biomassboilers, PV-T systems, and solarassisted heat pumps.

Some examples of recently installedCST systems are:

Brick Drying at Laterizzi

Gambettola, ItalyA solar eld of total 2,640 sq. m ofLFR technology has been installed bySoltigua. 1,584 sq. m re ector area isused for direct steam generation, andthe rest of the re ector area is used forindirect steam generation via thermicoil heating. The total peak thermalcapacity of the solar eld is about 1.2MWth. The solar eld generates steamat 12 bar, 180 C which is used in thesteam red radiant heat exchangers(brick dryers). The steam is also usedfor air pre-heating. The system wascommissioned in 2012.

Solar Based Thermic Oil Heatingfor Milk Powder Productionat Lcteas Cobreros (LACO)Castrogonzalo-Zamora, SpainParabolic trough collectors of 2,040 sq.maperture area have been installed bySMirro. The solar eld is used for thermicoil heating at 200 C. Steam is generatedusing a heat exchanger at ~ 185 C. Thecapacity of the solar eld is 1 MWth. Thesystem was commissioned in 2012.

Solar Process Steam Plant atBEVER, Engadin, SwitzerlandNEP Solar has installed 116 sq. m ofparabolic trough collectors for thermicoil heating at 200 C. The saturatedsteam is generated at 4 6 bar usingshell and tube heat exchanger. Thenominal capacity of the plant is 70kWth. The system was commissionedin November 2011, and has been fullyoperational since then.

Solar Process Steam for TextileIndustry at Germany SMirro Gmbh has installed parabolictrough collectors with nominalcapacity of 50 kWth at textileindustry Carl Meiser Gmbh. The plantgenerates pressurized steam at 4 bar,140 C which is fed directly to the mainboiler header. The installation wascommissioned in 2012.

Solar process steam for brick drying at Italy installed by Soltigua, 2012


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Solar Steam Generation Plant atSaignelgier, SwitzerlandNEP Solar has installed 627 sq. m ofparabolic trough collectors at T te deMoines Cheese Factory for pressurizedhot water generation at 130 C. Thenominal capacity of the plant is 400kWth. The system was commissioned inNovember 2011, And it has been fullyoperational since then.

Solar Based Thermic Oil HeatingSystem, California, USAAbengoa has installed 5,068 sq. m ofparabolic trough collectors for thermicoil heating at ~ 300 C for indirectsteam generation at 41 bar, 250 C forFrito Lay. The oil is used for cookingcorn and potato chips. The solar systemhas a back-up of natural gas red steamgenerators. The system is operationalsince 2008.

International CollaborationInternational collaboration willensure that important issues areaddressed by making full use of areasof national expertise and takingadvantage of existing R&D activitiesand infrastructure. One example ofcollaboration in the eld of solar heatingand cooling is the IEA Solar Heatingand Cooling Implementing Agreementwhich includes technology experts from

20 countries and the European Union.

Other examples of collaboration arethe International Solar Energy Society(ISES), the International Associationof Plumbing and Mechanical Of cials(IAPMO), ISO TC 180, the European Solar Thermal Industry Federation (ESTIF),and the European Technology Platformon Renewable Heating and Cooling. The IEA Solar Heating and Coolingprogramme has launched a four yearresearch project (IEA SHC Task 49/IV: Solar process heat for productionand advanced applications) aimedat growing market for solar heat inindustrial processes. Researchers at IEASHC (DLR, Fraunhofer, SPF, AEE INTEC,etc.) and SolarPACES will work togetherfor this project.

Addressing the BarriersDeployment of concentrating solartechnology in industry needs adaptedindustrial system designs andoptimization of industrial processesto increase the potential integrationof CST systems. Integration systemstandardization and solar collectorperformance characterization is neededto encourage use of CST systems. Fromthe perspective of the demand side,barriers hindering the uptake of CSTfor IPH systems include a general lackof information about the technology

NEP Solar system for milk powder production LACO, Spain, 2012

NEP Solar steam installationfor dairy processes at Bever,

Switzerland, 2011

Features

and its potential. Some countrieshave chosen to carry out awarenessraising campaigns, thus building upunderstanding and con dence in thetechnology. Important stakeholderscan also be addressed with speci cactions, such as tackling the highpriority given to low capital costenergy systems in various industries.Increasing transparency on energycosts including external factorsthat are not included in the marketprice for energy such as the costs ofnatural resource depletion, healthimpacts from pollution, and climatechange should also help. It should beemphasized that overall the bene ts ofCST systems for IPH are substantial andsound, from both the nancial and thesustainability points of view.


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PARABOLOID DISH TECHNOLOGY FORINDUSTRIALPROCESS HEATSiddharth Malik

The author is the Managing Director and CEO of Megawatt Solutions Pvt. Ltd. Email: [email protected]

Indian manufacturing industriesare today facing a dire situationwith their cost of production risingdisproportionately over the last fewyears due to rise in raw materialsand energy costs. While demandis in uenced by macro-economicfactors, Indian industries, especially theenergy-intensive ones which utilizediesel, furnace oil, electricity, coal, etc.,need to look towards addressing thiscritical input energy, and its costs.

Indian industries consumed about138 MTOE of energy in 2011 12,including about 28.80 MTOE ofpetroleum products and 87.43 MTOEof coal and lignite, which are mostlyused for process heating applications.Concentrated Solar Thermal (CST)power is a solution which can meetthe quality of energy demand requiredin industries and emerge as a viable

long-term alternative. There is atremendous potential for retro tting,augmenting, or replacing fossil fuel-based heating systems in industriesusing CST systems which operate onthe simple principle of shifting themajority of industrial heat loads ontoCST technology during sunshine hours.Like most other renewable energysystems, CST systems are a one-timecapital investment with a 20 30-yearequipment lifetime. It then becomescritical to ensure maximum energyyield throughout the lifetime of theCST system to make it a commerciallyviable option.

This article summarizes the keycriteria for selecting a CST system sincethe commercial viability of a CST systemhinges on the ability to maximize solar

energy contribution and fossil fuelsavings. One particular CST technology the dual axis tracking paraboloiddish CST technology meets theabove requirements.

How it WorksAlmost all CST systems utilize there ection or refraction principle toconcentrate incoming solar radiationto achieve high ef ciencies and deliverenergy to the subsequent working uid.Utilizing a basic set of fundamentalphysical principles, various technologycon gurations have emerged. UnlikePV, since the concentration necessarilyrequires direct normal irradiance(DNI), it necessitates the tracking ofthe concentrator to follow the sun. The solar energy thus captured andconverted into thermal energy of theworking uid is then routed to the end

application using instrumentation andpiping networks. Based on combinations of theabove elements, various technologycon gurations are largely classi edeither as line concentrators or point

SNo. Element Alternatives

1. Re ectors Glass based, Metal based, Curved, Flat, etc.

2. Tracking Single axis, Dual axis, Ez/AL, Polar/Declination, etc.

3. Thermal receiver Cavity receiver, Evacuated tube, Selective coatedmaterials, etc.

4. Heat transfer uid Water, Steam, Organic uids, Air, etc.

5. Thermal piping Suitable to heat transfer uid temperature,pressure, and mass ow rate

6. Structure andfoundation

Central, Nodal, Truss, Torque tube, etc.

Table 1: Common elements of all CST technologies

Dual Axis Tracking Paraboloid Dishconcentrators. Both these are wellknown and understood in the globalindustry. One particular CST optionis the Dual Axis Tracking ParaboloidDish which has the highest thermalef ciency, and therefore high operatingtemperatures. While applying CSTsystems to industrial process heat (IPH)applications, operational and practicalconstraints become critical for theeconomic viability of the application.

Key Questions when Choosinga CST System for IPH Typically, certain key metrics may beutilized to evaluate overall feasibility of

Features


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adopting a particular CST technology(see Table 2).

Fuel from the Sky: DirectNormal Irradiance (DNI) The nature, quality, and availability

of input DNI to a CST plant differssigni cantly from those of conventionalheating plants. A clear understandingof the impacts of DNI on CST plants isrequired to understand how varioustechnology con gurations respondto a wide range of incoming DNI. Theusable instantaneous value of thisparameter ranges anywhere from 100W/m 2 to 1,000 W/m 2. When integrated

over an entire day, it is expressedin kWh/m 2 /day. While a long-termdata set is required to accuratelypredict the performance of a givenCST system, there are certain largertrends on treatment of DNI by eachCST technology-type which is a strongindication of how well the particularCST technology is suited for anindustrial application.

A striking feature of CST systemsis that for a given technology, theannual energy yield for two differentlocations on earth for the same valueof cumulative annual DNI is drasticallydifferent, i.e., a DNI of 2,000 kWh/m 2 /year at two different locations will

Criteria Requirement for IPH Advantage of Paraboloid Dish

Modularity System needs tobe designed andengineered suitableto industrial scaleapplications

Being a modular technology, itcan be deployed at all scales. Therefore, optimal system designis possible for all applications andscales.

Installationspace

Smaller installationfootprint is desirable

The dish is mounted on a singlecolumn so installation footprintarea is very small.

Dependence onelectricity grid

Needs to be low so thatstand-alone operationis possible

Very low auxiliary powerconsumption makes thetechnology suitable for stand-alone operation.

Optics andconcentrationratio (CR)

Perfect optical pro leand high concentrationratio is desirable forhigher energy outputper unit area andhigher operating

temperatures

The concentrator is a perfectparaboloid and has highconcentration ratio which ensureshigh thermal performance andhigh temperatures.

Availability:System andcomponent

Indigenouslydeveloped technologydesirable toensure technologysupport

The dish is indigenouslydeveloped and designed, and amajority of the components areavailable off-the-shelf.

Annual energyyield

Highest energyyield per unit cost isdesirable

The dish has high thermalperformance which ensures highenergy per unit cost.

Table 2: Key metrics for choosing an optimum CST system

result in drastically different outputsfor a given amount of area. This is dueto two factors:$ Histogram distribution of a given

cumulative value of DNI: A functionof frequency distribution of DNIvalues

$ Non-linear response of CSTtechnology to DNI value: A functionof geometrical con guration andthermal response

Figure 1 shows the frequencydistribution of DNI at two locations:in India and in Spain. It can be seenthat while the cumulative value forboth locations might be similar, theirdistribution of high and low DNI valuesis different. Hence, it is evident that a CSTtechnology in India which has goodresponse across the entire wide DNIrange, including lower DNI values, willoutperform an alternate CST systemthat is designed and engineered toharness high instantaneous DNI valuesfor a location such as Spain. Among allCST con gurations, only ParaboloidDishes have high concentration ratio(CR) to provide maximum energy

response even at small values of DNIsince their loss characteristics arealmost at compared to Parabolic Troughs, as is shown in Figure 2. To summarize, paraboloid dishesensure maximum fuel savings andemerge as the ideal choice for heatingin industrial applications.

Paraboloid Dish TechnologyDeveloped by Megawatt

SolutionsMegawatt Solutions has developed aparaboloid dish which has a completelyparaboloid optical pro le. The dish hasa highly ef cient cavity receiver whichis suitable for both thermic oil heatingand direct steam generation. The dishalso has a completely automated two-axis tracking system with very highaccuracy (~ 0.1). It is mounted on a

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SUN FOCUS| JanuaryMarch 2014 | 11

single column which requires verylittle installation area. The technologyhas been developed with the supportof the Ministry of New and Renewable

Energy, Government of India. Thethermal performance of the dish hasbeen extensively tested in the eld. Thedish has high thermal ef ciency (peakef ciency = 70% at 300 C) due to highconcentration ratio (more than 700) anddual axis tracking. The dish is currentlyavailable in two sizes: 90 m and 55 m. The performance details of these twomodels are mentioned in Table 3.

S o

l a r

R a

d i a t i o n

[ H r s

/ Y e a r ]

Figure 1: Frequency distribution of DNI in India and in SpainImage courtesy: Suntrace

Figure 2: Comparison of Parabolic Dish and Parabolic Trough performanceImage courtesy: William B. Stines Power from the Sun

ModelName

Aper-tureArea(m)

ThermalOutputat DNI =750 kW/m

TotalWeight(Tonnes)

M90 90 40,000kcal/hr

4

M55 55 20,000kcal/hr

1.5

Table 3: Performance details of paraboloid dishes developed byMegawatt Solutions

Table 4: Thermic uid based systems of MWS under

execution/ in pipeline

SummaryAmongst all the available CSTtechnology options, the paraboloiddishes developed by MegawattSolutions have the followingadvantages:$

Manufactured with commercial off-the-shelf components

$ State-of-the-art technology:automated dual axis tracking,highly ef cient receiver, and highconcentration ratio

$ Requires minimal land forinstallation

The paraboloid dish technologydeveloped by Megawatt Solutions(M90 and M55 dishes) is thus offeringa commercially viable alternative todiesel and furnace oil-based heatingsystems. Its highly ef cient state-of-the-art indigenously developed technologyand high performance per cost ratiohave put the technology on the cusp ofsuccessful commercialization, makingit the most well-suited for industrialapplications.

Features

ProjectSize

Application Location

1440 m 2 Industrialprocess heat

Gujarat

275 m 2 -do- Haryana

90 m 2 -do- Haryana

2250 m 2 -do- AndhraPradesh

450 m2

-do- AndhraPradesh

55 m 2 Cooking Nepal

55 m 2 Cooking AndhraPradesh

55 m 2 Cooking Gujarat

540m2 Thermic OilHeating

AndhraPradesh


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Case Study

ARUN dish installed at Chitale Dairy

ARUN DISHES INSTALLED AT MAHANAN AND CHITADAIRIES FOR MILK PASTEURIZATIONAbhishek Bhatewara

The author is Director, Clique Solar. Email: [email protected]; website: www.cliquesolar.com; YouTube: www.youtube.com/cliquesolarTV

India is the largest milk producingcountry in the world, with thepresent level of annual milkproduction estimated at 100million tonnes. The dairy industryutilizes a large amount of energyfor milk processing, pasteurization,sterilization, cleaning-in-place (CIP),etc., which is in the form of mediumtemperature thermal energy, and canbe provided through the use of solarconcentrators. The automatic dualaxis tracking ARUN solar concentratorsystem has been successfullydeployed for over 7 years at MahanandDairy and for 4 years at Chitale Dairy. This article covers details of thesetwo installations.

ARUN Dish Installation atMahanand DairyMahanand Dairy, although acomparatively small dairy

ARUN dish installed atMahanand Dairy

pasteurizing around 30,000 litresper day, has been a pioneer in theadoption of new technologies. Whenthe then Chairman of Mahanand Dairychanced upon the pilot 10 sq. m ARUNinstallation in Pune way back in 2004,use of solar concentrators to deliverthermal energy at high temperaturesfor process heat applications hadnever even been attempted. With his

vision, nancial support from MNRE,and the technical capabilities of CliqueSolar, Indias rst solar concentratorfor commercial use in industry wasinstalled in 2006 at Mahanand Dairy inLatur, Maharashtra. It has been runningsuccessfully ever since. At MahanandDairy, milk pasteurization takes placeover just 3 4 hours. Since solar energyis available for over 8 hours in Latur,a thermal storage system had to bedesigned so that no energy is wasted.A brief explanation of the operationswith the integration schematic isexplained as follows:

$ In the morning, the circulatingpump extracts water from thestorage tank and circulates itthrough the receiver coil.

$ The water is then heated and sentback to the storage tank. The wateris stored at 18 bar, 180 C.

$ The hot water then ows throughthe heat exchanger to transfer theheat to milk for pasteurization.

This system continues to saveabout 100 to 115 litres of furnaceoil on a clear sunny day. On thesedays, 100% of the thermal energyrequirement is met by the ARUNdish installation.

ARUN Solar Boiler atChitale DairyChitale Dairy is one of the mostrespected and largest private dairies

in Maharashtra. It is well known forits state-of-the-art process plant andattractive pricing due to its superbcost control.


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Case Study

The dairys visionary leadershipidenti ed very early that furnace oilcost would increase sharply with time. They began their search for a back-up in 2007 08. Initially, they exploredthe use of biomass. However, due toissues with future availability, quality,transportation, and storage, ChitaleDairy decided to explore the solaroptions. After evaluating various

technologies, Chitale Dairy optedfor the ARUN technology due to thefollowing factors:$ It could deliver 5 6 bar steam:

the pressure rating of theexisting system

$ The robustness of the technology: ithas to last for 25 years

$ The footprint area required was verysmall: less than 10 sq. m per dish

$ Clique Solars experience withintegrating ARUN with the

dairy processOperation Philosophy The operation philosophy of thisscheme is explained here. The basicaim of the control system in thisscheme is to deliver steam to theexisting boiler header.

The ARUN dish automaticallytracks the sun from morning toevening. The solar radiation falling

on the reflecting collector surfaceis concentrated at a single point atwhich the receiver is placed. Thereceiver coil at the focus of the dishtransfers the heat of the sun to theheat transfer medium (water). Thesteam generation system consists ofthe ARUN 160 dish system, pumps,valves, etc. Once the system startsgenerating steam, the pressure in

the line starts increasing. Once thispressure matches the pressure in theexisting boiler header, a valve will

Figure 1: Schematic of ARUN solar concentrator integration with pasteurization unit at Mahanand Dairy

Figure 2: Schematic of ARUN solar concentrator integration withoperations at Chitale Dairy

open and steam will be deliveredto the common header. This processwill continue whenever sunlightis available. When sunlight is notavailable, the conventional heatingsystem will turn on. This switchoverbetween the solar and existingconventional system is automatic.

EconomicsA typical financial feasibility modelfor a single ARUN160 solar boilerinstallation is presented above.


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Item Cost (in lakhs) Comments

ARUN160 Dish Supply 33.80 Selling Price for ARUN160

Dish Erection and Commissioning 2.00

ARUN160 Price 35.80

Add: Balance of Plant 4.00 Includes piping, control panel, etc.

Add: Civil Foundation 3.50 For mounting of dish

Add: Transport 2.00 From workshop to site

Total Project Cost 45.30

Less: Subsidy* -10.14 Fixed MNRE subsidy on ARUN160

Less: Tax Bene t due to AD** -9.56

Net Project Cost to User 25.60 [A]

Annual Savings Comments

Furnace Oil (in litres) 17,000 Using 1 ARUN160

Rate per Litre of FO (in Rs/litre) 48

Total Fuel Savings (in Rs) 816,000 [B]

Simple Payback Period = [A]/[B] 3.14 years

* MNRE provides a capital subsidy of Rs 6,000 per sq. m of aperture area for dual axis automatically tracked system (ARUN160 has an aperturearea of 169 sq. m).

**According to Income Tax rules, any investment in solar equipment will be eligible to avail 80% accelerated depreciation (AD) on theinvestment, i.e., 80% of the capital value of the equipment can be expensed in the rst year itself. This helps in reducing the taxable income,thus reducing the tax payment.

Table 1: Typical nancial feasibility model for single ARUN160 solar boiler installation

Case Study

(The simple payback periodcalculation does not include anyescalation in fuel prices or theeconomic benefit after the paybackperiod up to the 25 years+ life ofthe product. It also does not include

any maintenance expenses incurredduring the life of the system.)

Concluding Remarks The Mahanand and Chitale Dair ieshave set an example by pioneeringthe successful use of solar technologyfor satisfying their thermal energyneeds for various applications such

as pasteurization, can washing, cratewashing, and CIP. Not only have the

systems been operating successfully,but the economics of the investmentalso makes a strong case for allindustries in general, and dairiesin particular, to install such CSTsystems.


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SOLAR CONCENTRATOR PROJECTSIN UNDP-GEF PORTFButchaiah Gadde, Chitra Narayanswamy, and S N Srinivas

Butchaiah Gadde is Regional Technical Specialist, UNDP-GEF, Bangkok. Email: [email protected]

Chitra Narayanswamy is Programme Associate (Energy and Environment Unit), UNDP, India. E-mail: [email protected]

S N Srinivas is Programme Ofcer (Energy for Development), UNDP, India. E-mail: [email protected]

Two concentrated solar projects

are being implemented in theUNDP-GEF portfolio, one in

Namibia and the other in India. Bothcountries have a high potential forcapturing solar energy. Both countrieshave around 3,000 sunshine hoursper year with 6 kWh per sq. m per dayinsolation. Annual solar insolation isabout 2,200 kWh per sq. m.

The concentrated solar power (CSP)project in Namibia is a technologytransfer project that appliesconcentrated solar technologies forpower applications. The electricitygenerated from the pilot projects willbe supplied to the national electricitygrid. As part of technology transfer,

it aims to establish partnership

agreements between concentratedsolar power technology suppliers fromabroad and Namibian stakeholdersin the private sector, government,and academia. It also aims to developa market policy framework for CSPtechnology development and toincrease CSP investments in thecountry. The rst pilot project of a 50MW CSP plant is supported with loansfrom local banks for its construction. Thus, project interventions areexpected to overcome the barriersrelated to technology, policy, and nance. In contrast, the concentratedsolar technology (CST) for processheat applications project in India

builds on the experiences of solar

water heater development in thecountry and contributes to the targetof the Jawaharlal Nehru National SolarMission (JNNSM). While concentratedsolar heat (CSH) application hasbeen successfully demonstrated forinstitutional cooking in the past, thisCSH project is aiming to expand itsscope to other applications such asdairy and food processing, metaltreatment, and space cooling. System integration of CSP for processheat applications is complex due tothe intermittent nature of solar energyas process heat demands constantthermal energy. Therefore, solutionsneed to be tailored in combination

Average values for solar radiation in Namibia Average solar radiation in kWh/m 2 in India

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with the existing or backup heatingsystems. The UNDP-GEF CSH projectaims to simplify this throughestablishing standard technologyapplication packages, and is currentlyassessing the performance of existingCSH systems in the country. There are14 existing CSH technology suppliersin India and the project is tryingto add 12 more suppliers to meetthe increasing demand for CSP forprocess heat applications. The CSHproject targets a cumulative installedCST area of 60,000 sq. m by the end ofthe project in July 2016.

The worldwide experience to datein actual working CSH applicationsis rather limited. A survey conductedunder the IEA Task 33 Solar Heat

for Industrial Processes in 2007showed that there were then about10 CSH installations worldwide(the survey excluded India). Asper the information available inDecember 2010, there are around70 CSH installations in India (this hasincreased to more than 140 in 2013)and it is estimated that there arearound 100 working CSH installationsworldwide. This places India as one ofthe leading countries in the practicalCSH market deployment domain. The current experience in CSHapplications is summarized sector-wise in Table 1. The knowledge generated underboth the projects will provideuseful inputs to the global effort

by networking with institutionssuch as the International EnergyAgency (IEA). The IEA established the SolarHeating and Cooling Programme(SHC) in 1977 to enhance the use ofsolar thermal energy and promote itstechnologies for varied applicationsin industry and commercial sectors. The multidimensional approachthrough its 51 projects/tasks (as ofdate) helps to educate potential usersand decision makers, expand andstrengthen the solar thermal energymarket, and facilitate research andtesting of the hardware components. Two specific tasks Task 33 SolarHeat for Industrial Processes (SHIP),and Task 49 Solar Heat Integration in

End Use Sector Location

Cooling Hospital Ipswich, Australia; Thane, Maharashtra; Harnosand,Sweden; Morocco

Industry Gurgaon, India; Chennai, India; Bergamo, Italy; Long Island,USA; Germany

Stadium Doha, Qatar

Hotel Dalaman, Turkey; Jordan

Shopping mall Newcastle, Australia

Supermarket Antalya, Turkey

Of ce building Abu Dhabi (Masdar), UAE; Abu Dhabi, UAE; Rosenfeld,Germany

University/Technology institute Seville, Spain; Newcastle, Australia; Gebze, Turkey

Food production Winery Grombalia, Tunisia

Steam cooking Institutions: hostels, religiousinstitutions, hotels, etc. More than 50 installations in India

Baking of bread Bakery India; Burkina Faso; Argentinian Altiplano, Argentina

Hot water/steamgeneration

Dairy (pasteurization) Latur and Sangli, India; Marrakech, Morocco

Auto industry (7-tank process) Chakan, India

Ball bearing factory Ankara, Turkey

Metal factory Germany

Piano factory Long Island, USA

Beverage factory Fritolay, Turkey

Laundry India; Dalaman, Turkey

Evaporation Nuclear facility Kota, India

Table 1: International experience base of CSH applications

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sun focus jan mar 2014

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