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Werner Weiss, Klaus Hennecke, (C. Richter)
Task IV ended in 2007, but final reports and deliverables were published in 2008. This overview of accomplishments and deliverables is therefore included in the 2008 report.
Solar Heat for Industrial Applications was a collaborative project of the IEA’s Solar Heating and Cooling and SolarPACES Programs in which 16 institutes and 11 companies in 8 countries participated. The purpose of the project was to provide the knowledge and technology necessary to foster installation of solar thermal plants for industrial process heat.
To do this, studies on the technology’s potential were conducted in the participating countries, mediumtemperature collectors were developed for the production of process heat up to temperature levels of 250°C, and solutions to the problems involved in integrating solar heat into industrial processes were sought. In addition, demonstration projects were carried out in cooperation with the solar industry.
Participants carried out research and development in the framework of the following four Subtasks:
Subtask A: Solar Process Heat Survey and Dissemination of Task Results
Subtask Leader: Riccardo Battisti (I)
Subtask B: Investigation of Industrial Processes
Subtask Leader: Hans Schnitzer (A)
Subtask C: Collectors and Components
Subtask Leader: Matthias Rommel
Subtask D: System Integration and Demonstration
Subtask Leader: Klaus Hennecke (D)
The project definition phase was organized by Werner Weiss (AEE INTEC), who also served as the Task Operating Agent. Task 33 was a four-year project that ended in October 2007. Commencement date: November 1, 2003 Completion date: October 31, 2007
The main Task findings are published in four booklets, summarized briefly below:
Potential for Solar Heat in Industrial Processes:
The purpose of this report, developed in the framework of IEA Solar Heating and Cooling Program Task33 and IEA SolarPACES Program Task IV, Solar Heat for Industrial Processes (SHIP), is to show the potential of solar thermal (ST) plants for industrial heat applications. To do this, several local potential studies in different countries were surveyed and compared with a focus on the key results and the methodologies applied. The primary targets of this report are the solar industry and policymakers, who can learn about the relevant and so far unexploited market sector in industrial applications. Moreover, policymakers will realize that solar thermal energy should not only be promoted for the more “traditional” residential applications, but also for such innovative applications as solar process heat. This report is designed as a reference for developing national and local campaigns and policies on solar thermal energy for industrial use. It reports on the main out-comes of the potential studies performed in different countries all over the world and extrapolates these results to a figure indicative of the European potential. The country studies carried out in Austria, the Iberian Peninsula (Spain and Portugal), Italy and the Netherlands are included in this report as well as two regional studies (Wallonia for Belgium and Victoria for Australia) and two specific industrial sectors studies from Greece and Germany.
Industrial Process Indicators and Heat Integration in Industry
This report, developed in the framework of International Energy Agency Task 33/IV Solar Heat for Industrial Processes (SHIP), provides an overview of the tools developed under IEA Task 33/IV. The first tool is the “Matrix of Industrial process indicators – MATRIX”, which is a comprehensive database developed in Subtask B as a decision support tool for solar experts. MATRIX facilitates work with industry and identification of suitable solar applications. The solar process heat production installation can be studied and calculated without detailed knowledge of the relevant unit operation and production processes. Some industries such as food, chemistry, plastics, textile and surface treatment have been identified as very promising sectors for solar thermal applications. For these industries, detailed information like general benchmark data, process temperatures, production line flow sheets and generic hydraulic schemes for solar integration can be found in the specific Sub-MATRICES. Economic feasibility studies of these industries must focus on an integrated analysis of cooling and heating demands which takes into account competitive solar thermal energy technologies. Among the competing technologies are heat integration, cogeneration and heat pumps, which are also described in MATRIX in the relevant parts. In addition to technology optimization, energy consumption also has to be reduced by system optimization. Most industries have a production heat demand and at the same time a lot of waste heat which can be used, with the advantage of being simultaneous with the heat demand of other processes. Waste heat has to be reused at the highest possible temperature. The most promising methodology for identifying the maximum heat recovery in a predefined system (industrial process) is to design a heat exchanger network using Pinch Analysis, which can indicate how to optimize the system and minimize external heating and cooling demand. The Pinch Energy Efficiency (PE²) computer program, which calculates the heat recovery potential and designs a technically and economically feasible heat exchanger network for a given process, was developed under IEA Task 33/IV. PE² meets the requirements of heat integration calculation in suitable industries. One of the main advantages of the program is automatic calculation of an ideal heat exchanger network (based on mathematical criteria and aiming at maximum energy savings in kWh per year). Furthermore, heat exchanger surfaces can be calculated and a dynamic cost function gives the payback period for a given heat exchanger network based on user defined economic data, as well as the visualization of energy savings with a Sankey Editor, provide fast energy optimization and documentation of the entire process. PE² analysis shows the energy demand remaining at the corresponding temperature after the process has been optimized by heat recovery, and gives the temperature at which external heat/cold is necessary, which is important to know for implementing solar energy for heating.
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