Solar Process Heat in Oil and other Industries
Dr. Joachim Krüger
CSP Workshop @ ETD 2017, 22nd March 2017
COMPANY
SOLARLITE CSP TECHNOLOGY GMBH
•
Competence: Development and Construction of decentralized solar
thermal Parabolic Trough Power Plants (CSP) for Electricity
Production and Process Heat
•
Plant Sizes: 2 to 50 MWe or 2 to 200 MWth
•
Innovations: Direct Steam Generation (DSG), Parabolic Troughs made
of Composite Material, Leight Weight Design, Solar Co-Gen
•
Product: SL 4600+ – a precisely formed Parabolic Collector for
operations up to 500 °C, suitable for Mass Production.
•
Advantages: CO²-free Energy Production, lower LCOTs (levelized cost
of thermal energy), Increase of technical efficiency, modular Design,
easy Maintenance and Repair
•
Research Partners: Deutsches Zentrum für Luft- und Raumfahrt –
German Aerospace Agency (DLR), School of Renewable Energy
Technology, Naresuan University Phitsanulok, Thailand (SERT),
University of Rostock, Technical University of Berlin, RWTH Aachen,
Science Center Jülich, CIEMAT Spain, PSA – Plataforma Solar Almeria
www.solarlite.de
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FIRST USE SOLAR POWER! IT IS COST-EFFICIENT AND
ENVIRONMENTAL-FRIENDLY AT THE SAME TIME.
ECOLOGICAL ADVANTAGES
ECONOMIC ADVANTAGES
 Significant CO2 savings
 Most sustainable energy recovery in terms
of environment, resources and availability.
 Easy adaptive reuse for power generation
or desalination
 Recycling of solar field components
 Improvement of sustainability balance and
image with consumers
 Significant reduction of operation
expenditures by saving fuel
 Energy savings up to 50 % with guaranteed
constant and stable production
 Design lifetime of 30 years and a much
longer operating time
 Increase of energy production
 Lowest LCOT against any technology
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THREE IMPORTANT INNOVATIONS OF THE SOLARLITE TROUGH
DIRECT STEAM GENERATION
Steam
production in
Absorber pipe
Parabolic trough
Compared to traditional parabolic trough
collectors that use thermal oil and additional
heat exchanger, the direct steam generation
implemented by Solarlite® is more efficient
and less expensive.
LIGHTWEIGHT MATERIALS
The modular collector design is
based on the combination of robust
and lightweight composite panel
materials with a efficient reflecting
material. Hereby costs for transport,
mounting, maintenance and steel
structure can be saved.
The steel construction needed for the
stability of the supporting structure
can be minimized.
Different installation sizes are
possible, at the moment modules of
2.3 m and 4.6 m are being used.
www.solarlite.de
SPS CONTROLLED AND SELFPROTECTING DRIVE
Tracking system
SPS controlled algorithms of the Solarlite®
parabolic troughs facilitate optimal adjustment
and tracking of the mirrors. A self-protecting
drive allows safe operation of the collectors in
case of black-outs.
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SOLARLITE HAS THE MOST PROVEN DSG TECHNOLOGY
SL 4600 TROUGH DETAILS
DUKE/Spain
www.solarlite.de
DUKE/Spain
SL4600+/Spain
SL4600/Thailand
- CONFIDENTIAL -
TSE1/Thailand
Segment Length
12 m
Aperture Width
4.6 m
Gross Aperture Area
of 1 segment
55.2 m2
Collector Length
up to 120 m
No. of segments
up to 10
Focal Length
1.2 m
Rim Angle
87.6°
Concentration factor
66
Deviation from ideal
parabola - RMS
< 1.2 mrad
Maximum operating
windspeed
72 km/h
Maximum survival
windspeed
126 km/h
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TECHNOLOGY ADVANTAGES
• Custom DSG receiver
• Electro-hydraulic drive
• Thin mirror = higher
reflectivity and efficiency
• Selective coating = greater
spectral absorption,
efficiency
• Greater accuracy
• Composite material = lower
overall cost
• Lower thermal losses =
cheaper steam
• Lightweight, rigid trough =
excellent wind performance
www.solarlite.de
• Fail-safe independent
power
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PROJECT “TSE 1”
WORLD´S FIRST SOLAR DIRECT STEAM POWER PLANT
KANCHANABURI - THAILAND
www.solarlite.de
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DIRECT STEAM GENERATION – Saturated or superheated steam
water tube boiler
1
forced circulation boiler
(Solarlite)
7
4
2
5
3
6
1.
2.
3.
4.
5.
6.
7.
feed water pump
pre-heater
evaporator
downcomer
steam drum
superheater
to turbine
www.solarlite.de
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WIDE RANGE OF APPLICATIONS FO INDUSTRIES
WITH HIGH ENERGY DEMAND
POWER
 Solar thermal power
plants from 500 kW
up to 100 MWel
 Solar field design
 Hybrid solutions
 Storage systems
www.solarlite.de
PROCESS HEAT
Heat and steam up to
400 °C for processes in
industries with high
energy demand e.g.:
 Breweries, Beverage
 Dairies, Food
 Chemical
DESALINATION
 Solarlite technology
can be used for
desalination
 Desalination can be
made also with
residual heat from a
power plant.
COOLING
 District cooling
 Cooling can be
made also with
residual heat from
a power plant
 Cooling systems
for high demand
EOR
 Environmentally
solution for EOR
 savings of fossil
fuels
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SOLAR HEAT PRODUCTION COST
Sources: Worldbank, IEA, EIA, Eurostat, country statistics, boiler efficiency, including waste heat
www.solarlite.de
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SOLAR INTEGRATION FOR PROCESS HEAT PURPOSES:
MULTIPLE APPLICATIONS ARE POSSIBLE
Solar cooling / District
climatisation
Industrial steam
Desalination
Domestic hot water
Simple integration principal without interfering in existing production processes.
Solar field is directly connected to interface at the steam cycle.
www.solarlite.de
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SOLAR EOR
Solar thermal energy for Enhanced Oil Recovery
CSP Technology
offers a simple, proven
technical solution
“Made in Germany “.
-

up to 50 % reduction of
operation expenditures
over 25 years lifetime

modular and scalable
installation system without
limitations

Solarlite CSP has high
competence in Solar EOR
 Engineering study for
Solar EOR
 Feasibility study in
cooperation with the
German Aerospace
Center
www.solarlite.de
Parabolic Trough
Collector
high efficient, proven,
robust product
Easy integration
without any impact on
production and with high
flexibility
Direct Steam
Generation – unique
commercial technology
concept
- CONFIDENTIAL -
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Where can the technology be used?
Estimated heavy-oil deposites by region
How the region will benefit?
Russia
182
North
America
75
Middle
East
651
971
South
America
83
52
168
 Higher export revenues
East
Asia
18
68
 High local content of up to 30%
Sotheast
Asia
1,127
Source: U.S. Geological Survey, Billions of Barrells

Onshore oil fields, most of the on-shore operations happen in
sunny regions

Regions with high solar radiation

Upstream oil & gas industry and mid and downstream where
heat is needed
www.solarlite.de
 High social impact
 Substantial reduction of CO2
emissions
 1-2 permanent job per MW during
25 year plant life
 20 – 30 temporary jobs per MW
during two year construction
 For every MW installed CSP
capacity, 1 to 3 million € revenue
for the region
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CSP Technology and its unique technical concept
THE
PROCESS
DIRECT STEAM
GENERATION
(DSG)
 Heat transfer medium is water
 Single-circuit and elimination of
mechanical components
 No environmental and fire hazard
 Higher operation temperatures
FITS PERFECTLY
WITH
WELCOME
THE WORLD
IN QATAR
www.solarlite.de
THERMAL
ENHANCED OIL
RECOVERY
 Boiler feed water, no oil
 Water quality suitable for existing Once
Through Steam Generation (OTSG)
 Existing steam generation equipment
(steam separator/drum can be used
 Steam fraction similar to OTSG boilers
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A step ahead in terms
of efficiency, environment and technology
TECHNICAL ADVANTAGES
 Significant reduction of
operation expenditures
 Simple and easy to
integrate
 Modular and scalable
installation without
limitations
 Without any disruption
of your production
www.solarlite.de
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Case study on economics – boundary conditions
 The thermal energy is provided by steam
boilers with a total capacity of 216 t / h.
 The once-through-boilers supply
saturated steam at 545 °F ( 1,000 psig).
 With 7,884 yearly operating hours, gas
consumption amounts to 67.2 million
USD costs for gas requirement.
 The objective is to achieve a solar share
of up to 25 %.
 The solar share should amount of up to
75 % of the boiler capacity.
288 CSP collectors will be used to provide the
solar steam output of around 162.5 t / h.
The solar facility requires 106 acres of space.
www.solarlite.de
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Case study on economics presents:
Economic key parameters
250
OPEX
For oil importing countries
Gas import price
Gas & O&M Savings over 25 years
For oil exporting countries
Gas export price
Revenue over 25 years
CAPEX
200
150
100
12.6
50
193.8
94.0
Solar field lifetime expenses
(25 years)
Gas & O&M Savings over 25
years
It makes good economic sense and
improves the sustainability balance
and your image with consumers.
www.solarlite.de
193.8 Million USD
10 $ MMBTU
242.3 Million USD
Annual inflation on gas price
3%
Other O&M savings for client
10 %
Solar field Capex
12.3
0
8 $ MMBTU
Solar field O&M for 25 years
Solar field lifetime expenses (25 years)
94 Million USD
12.6 Million USD
106.6 Million USD
Ecological parameters
CO2 saving per year
CO2 saving after 25 years operation
34,629 t
865,725 t
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PROJECT „DUKE“
PLATAFORMA SOLAR
ALMERIA, SPAIN
The DUKE project leads to the next level of cost saving direct steam generation. Solarlite, CIEMAT and DLR
have developed new processes and hardware, which allows to generate direct steam out of the sun at less
cost.
www.solarlite.de
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DENIM INDUSTRY EXAMPLE
TURKEY PROJECT DETAILS
PROJECT
OBJECTIVE
• Construct a parabolic trough CST plant to generate and
supply steam for the denim factory
• Solar steam utilized to reduce conventional fuel and thereby
enabling chances to cut O&M costs
• 5 MWth of thermal energy to be produced
ENERGY
DEMAND
• To produce 7.7 t/h of saturated steam at 150 °C and 5 bar
• Feed water is assumed to be 80 °C
• Kayseri, Turkey (38.73 °N, 35.48 °E)
PROJECT
LOCATION
www.solarlite.de
• DNI resource varying from 1800 to 2000 kWh/m²/a;
• Solarlite assumed DNI of 1,857 kWh/m²/a (obtained from
SoDa GIS) is used for the analysis here
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SOLAR FIELD CONFIGURATION
18 SL4600 collectors with 9,936 m²
aperture area oriented in North-South
direction;
75% peak optical efficiency, 70%
collector thermal efficiency at 150 °C with
Solarlite DSG vacuum receivers
3.2 ha/32,000 m² total land area
required for solar field, Balance of Plant
(BOP) and control room
BOP can be designed for 10-20 minutes
buffer storage to overcome effect of clouds
and increase heat supply for the process
www.solarlite.de
- 20 -
SOLAR HEAT FOR DENIM FACTORY
 CAPEX: 3.13 million €;
SOLARLITE CST SOLUTION
Capacity (kWth)
# of collectors
5,000

1.5 M€ - solar collectors,
18

1.1 M€ - balance of plant BOP
(mechanical, electrical, control system,
piping and civil works)

0.53 M€ - Engineering, construction and
commissioning
Aperture area (m²)
9,936
Land area (m²)
32,000
Power for own usage (kWe)
40 - 60
Feed water temperature (°C)
80
Live steam temperature (°C)
150
Steam Tonnage (t/h)
7.7
Live steam supply
Saturated steam
Annual thermal yield (kWhth)
9,100,000
Annual steam generation (t/a)
15,000
www.solarlite.de
 OPEX: 24,000 €/a

Solar field mirror cleaning

Regular maintenance checks

Spare parts for collectors and BOP

Consumables like water, chemicals,
lubricant etc…
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CAPEX AND BENEFITS
SOLARLITE CST BENEFITS
Gas price ($/MMBTU)
12
Gas boiler efficiency (%)
80
Inflation on gas price
Inflation for fuel, electricity, O&M cost
3.7 %
2%
Over 10 years operation
O&M (€)
~ 378,000
Gas savings (€)
~ 5,715,000
EBITDA (€)
~ 5,337,000
CO2 savings (tons)
20,600
Over 25 years life time
O&M (€)
~ 1,100,000
Gas savings (€)
~ 19,250,000
EBITDA (€)
~ 18,150,000
CO2 savings (tons)
www.solarlite.de
51,500
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PROJECT „DUKE“
PLATAFORMA SOLAR
ALMERIA, SPAIN
DUKE is using nearly 1 km of solar parabolic troughs to generate steam with temperatures of up to 550 °C.
The SL 4600+ trough system is installed and shows how elegant technology can look like.
www.solarlite.de
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PULP & PAPER INDUSTRY EXAMPLE
TURKEY PROJECT DETAILS
www.solarlite.de
PROJECT
OBJECTIVE
• Construct a parabolic trough CST plant to generate
saturated steam for a pulp & paper industry
• Solar steam utilized to reduce Natural gas consumption and
thereby enabling chances to cut O&M costs
ENERGY
DEMAND
• 14.7 MWth of saturated steam to be supplied to the plant
for their purposes
• Solar field supplies 22.1 t/h of superheated steam at 8 bara
& 170 °C, feed water assumed to be 90 °C
PROJECT
LOCATION
• Tire, Turkey (38.1 °N, 27.73 °E)
• DNI resource varying from 1950 to 2050 kWh/m²/a
• Direct Normal Irradiance (DNI) of 2,003 kWh/m²/a obtained
from SoDa GIS is used without any data processing
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SOLAR FIELD CONFIGURATION
54 SL4600 collectors with
29,808 m² aperture area oriented
in North-South direction
75% and >65% collector
optical and thermal efficiency with
Solarlite DSG vacuum receivers
8.6 ha total land area required
for solar field, BOP etc…
BOP of solar field designed to
have 10-20 minutes buffer storage
to allow natural gas boiler to react
during cloudy/monsoon season
www.solarlite.de
- 25 -
SOLAR STEAM – SUMMARY

Solar field capacity: 14.7 MWth

For a feed water temperature of 90 °C, 22.1 t/h of saturated steam generated at 8 bar, 170 °C

2 years spare parts and one time investment for O&M equipments: 69,000 € (already included in solar
field CAPEX)

Typical annual OPEX: 54,000 € for the solar field and BOP

Power for solar field and BOP usage: 130 to 160 kWe

Annual thermal yield: 26.9 GWhth or 40,500 tons of saturated steam; solar fraction: 9%

Lifetime fuel savings for the industry: 69.4 million € (16.1 $/MMBTU gas price with 3% inflation
annually) – more than 7 times the benefit for the investment

Lifetime O&M costs of only 2 million € including 3% inflation annually (power for own
usage not considered)

LCOT25 years: ~ 1.8 €cents / kWhth (power for own usage and financing costs are not considered)
www.solarlite.de
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CAPEX AND BENEFITS
 CAPEX: 9.8 million €;
4.8 M€ - solar collectors, 3.5 M€ balance of plant BOP (mechanical,
electrical, control system, piping and civil
works), 1.5 M€ - Engineering,
construction and commissioning
www.solarlite.de

Solar field O&M includes – mirror
cleaning, maintenance checks, spare
parts, consumables etc…

Clients O&M savings account for
natural gas (price 16.1 $/MMBTU) +
10% (for other O&M savings)

Analysis period: 25 years, Annual
inflation assumed: 3%
- 27 -
PROJECT “TSE 1”
DIRECT STEAM GENERATION WITH PARABOLIC TROUGHS
www.solarlite.de
- 28 -
PAPER MILL EXAMPLE
ITALY PROJECT DETAILS
www.solarlite.de
PROJECT
OBJECTIVE
• Generate saturated steam for the a paper & pulp industry in
Italy
• To reduce dependency on fossil fuels, especially Natural gas
ENERGY
DEMAND
• 55 t/h of saturated steam at 15 bara to be supplied for the
overall production plant
• Solarlite recommend to install solar field generating 23 t/h
of steam to enable parallel operation with gas boilers
PROJECT
LOCATION
• Turin, Italy (45.25 °N, 7.535 °E)
• DNI resource varying from 1300 to 1400 kWh/m²/a
- 29 -
PAPER MILL EXAMPLE ITALY
SOLAR FIELD CONFIGURATION
72 SL4600 collectors with 24,288 m²
aperture area oriented in North-South
direction
11 ha total land area required for
solar field, Balance of Plant (BOP) and
control room
BOP steam separator can be designed
for 10-20 minutes buffer storage to
overcome effect of clouds and increase
steam supply security
www.solarlite.de
- 30 -
SOLAR STEAM SUMMARY

Solar field capacity: 15.6 MWth

With a feed water temperature of 85 °C, 23 t/h of dry saturated steam generated at 15 bara

2 years spare parts and one time investment for O&M equipments: 86,000 €

Typical annual OPEX: 62,000 € for the solar field and BOP

Power for solar field and BOP usage: 150 to 200 kWe

Annual thermal yield: 22.3 GWhth or 33,000 t/a; Fuel saved: 8 % annually

Lifetime fuel savings for the industry: 41.3 million € (0.355 €/m³ gas with 3% inflation annually)
– nearly 4 times the benefit for the investment

Lifetime O&M costs of only 2.3 million € including 3% inflation annually (power for own
usage not considered)

LCOT25 years: ~ 2.1 €cents / kWhth
www.solarlite.de
Lifetime CO2
Savings
224,000 t
- 31 -
CAPEX AND BENEFITS
 CAPEX: 11 million €; 5.8 M€ - solar
collectors, 3.5 M€ - balance of plant BOP
(mechanical, electrical, control system,
piping and civil works), 1.7 M€ Engineering, construction and
commissioning
www.solarlite.de

Solar field O&M includes – regular
maintenance work, spare parts,
consumables like water, chemicals

Client’s CAPEX account for boiler
investment

Clients Savings account for gas price +
20% (for gas and other O&M savings

Analysis period: 25 years, Annual
inflation assumed 3%
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Plugged to the sun
Solarlite CSP Technology GmbH
Schloss Duckwitz
17179 Duckwitz
Germany
Tel.:
Fax:
E-Mail:
Web:
+49-39972 / 56 97 - 0
+49-39972 / 56 97 - 10
[email protected]
www.solarlite.de
Copyright
All of the information offered - including excerpts - may only be disseminated or published in any other way with approval in writing from Solarlite CSP
Technology GmbH. Under no circumstances is it permitted to disseminate any downloaded information online or via other media, or to use it commercially.
- 33 -
www.solarlite.de