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