Periodic Reporting for period 2 - ASTEP (Application of Solar Thermal Energy to Processes)
Okres sprawozdawczy: 2021-11-01 do 2023-04-30
Solar Heat for Industrial Processes (SHIP) is becoming increasingly relevant as one of the ways to meet the high thermal energy demand required for industry. This involves a double benefit: firstly, by using a renewable energy source, fossil fuel consumption is reduced and therefore the emission of pollution and greenhouse gases into the atmosphere; secondly, heat for industrial processes becomes a different market niche for solar technology, which can lead to a decrease in the cost of solar collectors through economies of scale in manufacturing and learning-curve advances in deployment.
ASTEP project creates a new innovative SHIP concept overcoming the sume current limitations of these systems. This solution is based on modular and flexible integration of two innovative designs: (i) for the solar collector (SunDial), and (ii) for the Thermal Energy Storage, based on Phase Change Materials. These technologies are integrated via a control system which allows flexible operation to maintain continuous service. ASTEP will demonstrate its capability to cover part of the heat demand of the process industry at temperatures above 150 ºC, even for latitudes where current designs are not able to supply it. Its modularity and compactness also enables easy installation and repair with reduced space requirements. The ASTEP`s process integration will allow full compatibility with the existing systems of potential end-users of SHIP. These aspects should provide a very competitive solution to substitute fossil fuel consumption.
The developed solar concept is going to be tested at two industrial sites. The first Industrial Site of the proposal belongs to ArcelorMittal, with a heating demand above 220 ºC for a factory located at a latitude of 47.1 N (Iasi, Romania). The second site is the dairy company MANDREKAS, located at a latitude of 37.9 N (Corinth, Greece) with a heating demand for steam at 175 ºC and a cooling demand at 5 ºC. These test locations will validate the ASTEP solution for a substantial part of the potential requirements of industrial heating and cooling demand of the European Union.
ASTEP project creates a new innovative SHIP concept overcoming the sume current limitations of these systems. This solution is based on modular and flexible integration of two innovative designs: (i) for the solar collector (SunDial), and (ii) for the Thermal Energy Storage, based on Phase Change Materials. These technologies are integrated via a control system which allows flexible operation to maintain continuous service. ASTEP will demonstrate its capability to cover part of the heat demand of the process industry at temperatures above 150 ºC, even for latitudes where current designs are not able to supply it. Its modularity and compactness also enables easy installation and repair with reduced space requirements. The ASTEP`s process integration will allow full compatibility with the existing systems of potential end-users of SHIP. These aspects should provide a very competitive solution to substitute fossil fuel consumption.
The developed solar concept is going to be tested at two industrial sites. The first Industrial Site of the proposal belongs to ArcelorMittal, with a heating demand above 220 ºC for a factory located at a latitude of 47.1 N (Iasi, Romania). The second site is the dairy company MANDREKAS, located at a latitude of 37.9 N (Corinth, Greece) with a heating demand for steam at 175 ºC and a cooling demand at 5 ºC. These test locations will validate the ASTEP solution for a substantial part of the potential requirements of industrial heating and cooling demand of the European Union.
The first reporting period covered activities in tasks related to design of the ASTEP concept.
To design the SunDial (solar collector), some simulation models were developed and different choices were analysed (type of receivers and the solar fields). A set of calculations completed the analysis of the SunDial's performance at daily and yearly basis. Some activities on the thermal-hydraulic and thermo mechanical assessment have been also carried out (heat losses in the receiver, and mirrors deflection after the bending moment actuation).
For the design of the TES, a number of methodologies were developed. The PCM material was selected, the inserts and the manufacturing method were defined, and the design of the accumulator was accomplished. Application of anticorrosive coating of inserts was considered.
Regarding the design of the ASTEP concept, series and parallel layouts were analysed. Steady and dynamic simulation models were developed to define the solution for the two case-studies, Mandrekas (MAN) in Greece and ArcelorMittal (AMTP) in Romania. Finally, the control strategy was analysed and optimised, checking the suitability to manage the transients as well as the energy supply to the different demands (boiler and chiller in MAN and two heat exchangers in AMTP).
These design activities finished at the begining of the second reporting period. After that, the work focused on three spects: the construction of the demo pilots, the preparation of the end-user sites, and the LCA, LCC and Social LCA analyses.
All the equipment has been already bought and the demo is being built in Madrid (SunDials) and Cartagena (TES). Some components of the SunDial have been re-designed to improve the design/construcion. Similarly, the design of the TES system and the accumulators has evolved. Finally, due to the small power rate of the demo plant, it was not possible the purchase of a suitable absorption chiller. Instead, the system will demonstrate that is able to reach the operating conditions required by commercial ones.
Some travels to the end user sites were done to analyse the industries and select the best placement for the system. After the visits, the plans for integration also evolved although maintaining the objective of testing on-site at real operational conditions. In AMTP, the SunDial will be housed outside at ground level close to the main production building, and the TES in-house. The demo plant for preheating the tubes will be constructed adjacent to the location of the SunDial. It will use tubes typical of those produced in the plant. In MAN, the SunDial will be placed at roof height, on a platform. Due to the small contribution of the demo plant and the lack of an absorption chiller, the objetive will be to demonstrate the pilot-scale ASTEP system without steam generation.
Finally, the LCA, LCC, Social LCA and exergy analysis is ongoing. The two first stages of the LCA have been completed. The first one includes a literature review, while the second focuses on the assessment of the environmental impacts. Similarly, the first phase of the LCC has been completed, including a literature review on the economic impact of solar thermal plants; and the second one, on the Capital and Operational Expenditures, has started. Within the Social LCA analyses, the two first phases have been completed. The first one focuses on defining the goal and scope of the analysis, and the second on the social impact assessment of the ASTEP system throughout its life cycle.
To design the SunDial (solar collector), some simulation models were developed and different choices were analysed (type of receivers and the solar fields). A set of calculations completed the analysis of the SunDial's performance at daily and yearly basis. Some activities on the thermal-hydraulic and thermo mechanical assessment have been also carried out (heat losses in the receiver, and mirrors deflection after the bending moment actuation).
For the design of the TES, a number of methodologies were developed. The PCM material was selected, the inserts and the manufacturing method were defined, and the design of the accumulator was accomplished. Application of anticorrosive coating of inserts was considered.
Regarding the design of the ASTEP concept, series and parallel layouts were analysed. Steady and dynamic simulation models were developed to define the solution for the two case-studies, Mandrekas (MAN) in Greece and ArcelorMittal (AMTP) in Romania. Finally, the control strategy was analysed and optimised, checking the suitability to manage the transients as well as the energy supply to the different demands (boiler and chiller in MAN and two heat exchangers in AMTP).
These design activities finished at the begining of the second reporting period. After that, the work focused on three spects: the construction of the demo pilots, the preparation of the end-user sites, and the LCA, LCC and Social LCA analyses.
All the equipment has been already bought and the demo is being built in Madrid (SunDials) and Cartagena (TES). Some components of the SunDial have been re-designed to improve the design/construcion. Similarly, the design of the TES system and the accumulators has evolved. Finally, due to the small power rate of the demo plant, it was not possible the purchase of a suitable absorption chiller. Instead, the system will demonstrate that is able to reach the operating conditions required by commercial ones.
Some travels to the end user sites were done to analyse the industries and select the best placement for the system. After the visits, the plans for integration also evolved although maintaining the objective of testing on-site at real operational conditions. In AMTP, the SunDial will be housed outside at ground level close to the main production building, and the TES in-house. The demo plant for preheating the tubes will be constructed adjacent to the location of the SunDial. It will use tubes typical of those produced in the plant. In MAN, the SunDial will be placed at roof height, on a platform. Due to the small contribution of the demo plant and the lack of an absorption chiller, the objetive will be to demonstrate the pilot-scale ASTEP system without steam generation.
Finally, the LCA, LCC, Social LCA and exergy analysis is ongoing. The two first stages of the LCA have been completed. The first one includes a literature review, while the second focuses on the assessment of the environmental impacts. Similarly, the first phase of the LCC has been completed, including a literature review on the economic impact of solar thermal plants; and the second one, on the Capital and Operational Expenditures, has started. Within the Social LCA analyses, the two first phases have been completed. The first one focuses on defining the goal and scope of the analysis, and the second on the social impact assessment of the ASTEP system throughout its life cycle.
The main innovation related to the solar collector is the design itself of a rotary Fresnel collector for industrial processes at 150 ºC - 400 ºC with two possible arrangements: longitudinal for saving costs, with fixed mirrors; and transversal, for enhanced performance even at high latitude, with a 2 axes solar-tracking system. In both cases the methodology for blending the reflecting mirrors is also innovative and provides good performance at low cost.
Innovations in the TES involves the new geometric design and the manufacturing method for macro encapsulation of PCM, providing custom made, flexible and optimised design for each application, short manufacturing time, high heat capacity and good charge/discharge characteristics. Innovation also involves the design of accumulator and the methodology for assembly the system. A patent on these aspects has been applied for.
The major contributions of the integrated system, beyond the compactness and ease installation, are the concept design with the TES connected in series to the Sundial, that leads to a robust and simple control strategy; and also the strategy for operating and dispatching the stored energy, involving two thermal loads that allows the maximization of solar energy supply to the industry. Thanks to these two features, a simplified integration and self-controlled operation is attained with lower requirements for the control system.
Fianlly, regarding the integration of the ASTEP system within the industrial processes, an oven for solar heat integration is being developed and analysed. The objective is to partially replace the current induction heater, providing the same temperature to the steel tubes in the coating process and avoiding changes in the production line of the factory.
Innovations in the TES involves the new geometric design and the manufacturing method for macro encapsulation of PCM, providing custom made, flexible and optimised design for each application, short manufacturing time, high heat capacity and good charge/discharge characteristics. Innovation also involves the design of accumulator and the methodology for assembly the system. A patent on these aspects has been applied for.
The major contributions of the integrated system, beyond the compactness and ease installation, are the concept design with the TES connected in series to the Sundial, that leads to a robust and simple control strategy; and also the strategy for operating and dispatching the stored energy, involving two thermal loads that allows the maximization of solar energy supply to the industry. Thanks to these two features, a simplified integration and self-controlled operation is attained with lower requirements for the control system.
Fianlly, regarding the integration of the ASTEP system within the industrial processes, an oven for solar heat integration is being developed and analysed. The objective is to partially replace the current induction heater, providing the same temperature to the steel tubes in the coating process and avoiding changes in the production line of the factory.