Solar assisted industrial steam networks: two cases from the building & meat industry Dipl.-Ing. Ilyes Ben Hassine SHIP event, Montpellier 2015
Content The InSun project Case 1: brick drying Case 2: meat processing The pre-heater The booster Lessons learned 2
research zafh.net, Germany coordinator + research EURAC, Italy research manufacturer SOLTIGUA, Italy system supplier Demo Partner Laterizi Gambettola SRL, Italy 2 640 m² linear Fresnel collectors steam generation brick drying S.O.L.I.D, Austria system supplier SOLERA, Germany system supplier BERGER, Austria 1 067 +123 m² flat plate & parabolic trough collectors make up water preheating Service water meat industry 3
Case 1: the demo partner Laterizi Gambettola SRL (I) Italian SME Manufacturer of hollow bricks Production capacity (2011) 1000 t/a Cooking and drying processes Existing direct gas fired air heaters New: steam-to-air heat exchanger 4
Case 1: the process Part A Fan 1 Water Steam 2 HX Ambient air 4 3 Air from oven Air from top of the hall Heat demand Dryer: 13 GWh/a Dryer air at 200-260 C 5
Case 1: the solar system Planned and installed by Soltigua (I) Field 1- HTF with thermal oil 1072 m² 600 kg/hr steam production 230 C in Field Field 2- DSG 1608 m² 900 kg/hr steam production 180 C Installed within 2012-2014 6
Case 1: the solar system 7
Case 1: the system integration Field 2: DSG Steam-to-air HEX Steam boiler BU boiler Field 1: HTF Thermal oil 8
Case1 : the system integration Steam pipeline steam-to-air HEX main condensate tank 9
Case 2: the demo partner chiller level 3, 7% Fleichwaren Berger (A) Austrian producer of hams, Sausages... 80-90 tons produced per day Heat demand : 10 GWh/a chiller level 2, 20% chiller level 1, 7% HD Boiler, 27% ND boiler, 39% Extended 2-level steam network Pressure 1,3 and 9 bar Several units with direct steam injection Water tanks with external HEX Advanced heat recovery measures 11
Case 2: the solar system Planned and installed by S.O.L.I.D. (A) 1067 m² flat plate collectors South oriented, 40 tilted 60m³ water storage tank Commissioned in April 2013 Monitored since July 2013 12
Case 2: the solar system
Case 2: the system integration 14
Case 2b: the booster system Parabolic trough collectors Originally designed to feed solar heat to a cheese plant Later added to the FP installation 122m² Aperture E/W orientation (5) 20m² water tank Installed by SOLERA (D) Extremely tight time schedule (still under construction!!)
Case 2b: the solar system 17
Case 2b: the system integration 18
Case 2b: the system integration 19
Case 2b: the system integration 20
Lessons learned Authorization process is very time consuming (+3 authorities) Containerized BOP advantageous DSG is challenging from an - approval - control point of a view Roof-top installation to be cleared up in time (350 instead of 470 /m²) large field = large storage: suitable place? Extended heat supply system: local insiders are key personalities Monitoring: trade-off between sensor costs and grade of analysis detail Long-term Monitoring and fault detection to demonstrate the reliability and quality of large scale solar thermal systems increase market confidence 21
Common workshop with Sardegna Ricerche 22
Thank you! ilyes.benhassine@hft-stuttgart.de 23