Solar
Bettina Muster-SlawitschAEE – Institut für Nachhaltige Technologien (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA
Integration of Solar Heat in Industry – method to select the best integration
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CONTENTS
We know how to integrate a solar process heat plant – but where is it placed best?
Complex industrial environment
Tools and methodologies for systematic analysis
Criteria for selecting integration points
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Integration Guideline
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Basic selection criteria
Energy storage
Boiling
Brew waterTank Wort preheating
Mashing
Wort separation
malt
Spent grain
Vapours
Whirlpool
Wort cooler
Hot wort
Cold wort to cellar
Fresh water
fermentation maturation
Filtration
pasteurization
Bottle/KEG washer
filling
pasteurizationfilling
Packaging of Returnable bottels/KEGs
Packaging of Non-Returnable bottels/cans
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Complex industrial environment
Several processes
Various products
Different operating schedules
Inter-dependencies between processes, waste heat and heat recovery
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Complex industrial environment
Various technologies
E.g. Simple brewhouse process
Many technology options
Many heat recovery options
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Technologies influence heat demand
Product formulation influence energy flows, energy supply and make-up water heating demand
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Technologies influence heat demand
Product formulation influence energy flows, energy supply and make-up water heating demand
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Technologies influence heat demand
Influence on net heat demand and requirements on different temperature levels
Influence on variability of heat demand
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Systematic analysis is required
Overview of heat sinks and sources
Evaluation of heat recovery and thermal energy management Existing heat exchangers New heat recovery options
Identify where solar process heat can contribute best (to a hybrid energy supply system)
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Solutions
Pinch analysis as systematic approach
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Solutions Simulation of energy
flows of a thermal energy system
• Variable process demand profiles as base date (from measurements; time steps user-defined)
• Display of HX performance, storage stratification, remaining energy over time
• Variation of design parameters for optimized performance
• For complex projects
• In conjunction with energy supply - solar heat
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Solutions
Criteria for the selection of integration points based on solar process heat concepts
Process continuityLoad balancingControl HardwareControl SoftwareFouling risk HX sizingStorage sizingDistance to solarAuxiliary energyEstimated solar yield Multi-supplyModulation Dependency on radiation
Replacement of CHPReplacement of WH/HR
post
-inte
grati
on
Reliability
Benefit
Efficiency
Cost
P(M)
PROCESS
Qconv.
PL_3
P(M)
Qsol
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Criteria for identification of best integration point
Theoretically very little make-up water demand (boiler)
KEG/bottle washing
connected to local heating network / large distance to solar
Pasteurization: flash pasteurization with high demand peaks at 70-75°C
Low estimated solar yield / Difficult regulation, large HX
Hot water demand only over weekends
Energy storage
Boiling
Brew waterTank Wort preheating
Mashing
Wort separation
malt
Spent grain
Vapours
Whirlpool
Wort cooler
Hot wort
Cold wort to cellar
Fresh water
fermentation maturation
Filtration
pasteurization
Bottle/KEG washer
filling
pasteurizationfilling
Packaging of Returnable bottels/KEGs
Packaging of Non-Returnable bottels/cans
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PROJECT CONSORTIUM
- AEE INTEC (coordinator)
- HEINEKEN Supply Chain B.V.
- GEA Brewery Systems GmbH
- process engineering
- Sunmark A/S
- solar engineering
Introduction to SolarBrew
Solar Brew: Solar Brewing the Future
EU FP7 (2012 – 2015)Projekt Nr. 295660
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State of the project
BREWERY GOESS- Solar assisted mashing process
- 1.500m² ground mounted flat plate collector field
- 200m³ pressurized hot water energy storage tank
- Commissioned: June 2013
4.6 million pints of beer per year brewed with the power from the sun*
* assuming 60 MJ thermal energy consumption per hl of beer in the brewery Goess
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BREWERY GOESS- Schematic diagram of the solar primary and secondary loop
State of the project
GEA brewery systems
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State of the project
BREWERY GOESS- Construction of the 200m³ solar energy storage
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State of the project
BREWERY GOESS- Construction of the 1,500m² solar thermal collector field
5 workers
1 crane
foundation: 4 days
collectors: 5 days
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State of the project
BREWERY GOESS- Construction of the 1,500m² solar thermal collector field
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BREWERY GOESS- Solar heat integration to mash tuns
- Retrofit of two existing mash tuns with heat exchanger templates
State of the project
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BREWERY GOESS- Construction of the heat exchanger templates
State of the project
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Change in product formulation can have tremendous effects on integration effort
Future research
Brunner et al., 2013
GEA Brewery Systems
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Future research
Industry is changing
Emerging technologies
Biobased industry developments
Trends for more electrity use
Which new technologies can stimulate the use of renewable (solar) heat?
Which technologies must be developed for reacting best on the hybrid energy supply in future?
Close cooperation between process engineers and energy experts is necessary
Future goal: to develop solar process technologies and turn-key solutions
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