Accelerating the decarbonization of Industrial and ... … · LPG Fired Boiler • Customer - A...

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Accelerating the decarbonization of Industrial and Commercial sectors in India using Heat Pumps Aspiration Cleantech Ventures,India

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• Our Unique Selling Proposition(USP)

• Customers include

Pioneers of Industrial Heat Pumps

Technological Innovation

• High Temperature Heat Pumps : Successful operations of 90 Deg C Industrial Heat Pumps for more than a year

• R&D in CO2 based natural refrigerants with

• NTNU, Norway • IIT Madras, India

Financial Innovation

• Energy as a Service or ESCO

• Rental model

• Deferred Payment options

The Big Picture

India is a top Renewable Energy producer

Source : IRENA

China USA Germany India

Cumulative Renewable Energy Installed Capacity in GW – December 2018

Wind Solar PV

Global Total • Wind – 568 GW • Solar PV – 480 GW

India’s Electricity is getting Greener

1110,18 1172,98 1241,38 1303,37 1365,786

61,78 65,78 81,54 101,83 116,786

5,56% 5,61%

7,81% 8,55%

2014-15 2015-16 2016-17 2017-18 2018-19

Share of Renewable Electricity

Overall Generation (Billlion kWh) Renewable Generation (Billion kWh) % share of RE

Source : MNRE, CEA

But Industrial sector still relies heavily on Fossil Fuels..

Energy demand by fuel in selected end-use sectors in India

Source : International Energy Agency

Electrification and Decarbonization of everything (using RE) is the way forward..

– Transportation

– Electric Vehicles instead of IC Engines

– Consumer lifestyle

– Cooking (Appliances like microwave ovens, induction stoves, etc) instead of LPG and biomass

– Cleaning(Washing Machines) instead of manual cleaning

– Industrial – Hot Water generation using Heat Pumps, instead of fossil fuel burners

Decarbonization of Heat –Need for Hot Water(<100 Deg C) in Industrial applications

–Fuels that can be replaced

–Coal –Diesel –Kerosene –LPG –CNG –Electricity (induction based) –LDO

Decarbonization of Heat Fuels that can be replaced

• Coal

• Diesel

• Kerosene

• Liquified Petroleum Gas(LPG)

• Natural Gas

• Electricity (resistance based)

• Furnace Oil

Need for Hot Water(<100 Deg C) in Industrial applications

Decarbonization of Heat - Sources

Solar Thermal Heat Pump

Heat Pump Case Studies - Industrial Sector

Case Studies - Industrial

1. High Temperature for Surface Treatment Applications

a. Plating b. Phosphating

2. Combined Heating and Cooling in a Paint shop

3. Diesel Generator Head Preheating

4. Hot Water generation for Washing Glasses

5. Heat Pump assisted Wastewater Evaporization

6. Air Heating

1. High Temperature for Surface Treatment Applications – Plating and Phosphating

• Customer - A leading auto component manufacturer

• Application – Surface Cleaning

• Hot water requirement – • Plating - 7 pre-treatment tanks, and each tank to be maintained at 70-75 Deg C • Phosphating – 4 pre-treatment tanks, each tank to be maintained at 80-85 Deg C

• Source of heat replaced – Kerosene(SKO) Boiler consuming around 400 Ltrs of SKO per day

• Financial Model Innovation – Energy Services Performance Contracting (ESCO)

1. Heat Pumps – The details • Heat Pumps

• Condenser side of the heat pump replaced the boiler

• Evaporator side was used to recover the waste heat from oil coolers.

S. No. Description Plating Plant Phosphating Plant 1 Heat Pump Type 3 X Parallel Coupled Water Source 2 X Parallel Coupled Water Source 2 Total Heating Capacity 111 kW 136 kW Total Cooling Capacity 66 kW 79 kW 3 Power Consumption 41.7 kW 51 kW 4 COP 2.67 2.67

5 Heat Source Oil Cooler Return Line Oil Cooler Return Line (25-30 °C) (25-30 °C)

6 Heat Sink 7 Nos of Pretreatment Tanks 4 Nos of Pretreatment Tanks (70-75 °C) (80-85 °C)

7 Heating Medium Water Water

8 Heat Transfer Method Indirect Heating - Plate Heat Exchanger Indirect Heating - Plate Heat Exchanger

9 Refrigerant R1234ze(E) R1234ze(E) 10 Compressor Type High Temperature Scroll Compressor High Temperature Scroll Compressor 11 Backup Source Electrical Heaters Electrical Heaters

1a. Plating Shop – Performance Comparison

S. No. Description Plating Plant

Before HP After HP 1 Primary Energy Source SKO Fired Boiler Water Source Heat

2 Backup Energy Source Standby SKO Fired Boiler

Electrical Heaters

3 Heating Medium Thermic Oil Water 4 Heat Transfer Method Immersion Coil Heat

Exchanger Plate Heat Exchanger

5 Fuel/Energy Consumption per day

385 LPD 1050 kWh

6 Fuel/Energy Cost Rs. 65 /liter Rs. 6.3 /kWh 7 Energy Bill per year Rs. 83.42 L Rs. 21.73 L

1b. Phosphating Shop – Performance Comparison

S. No. Description

Phosphating Plant Before HP After HP

1 Primary Energy Source SKO Fired Boiler Water Source Heat Pump

2 Backup Energy Source Standby SKO Fired Boiler

Electrical Heaters

3 Heating Medium Thermic Oil Water 4 Heat Transfer Method Immersion Coil

Heat Exchanger Plate Heat Exchanger

360 LPD 1244 kWh

6 Fuel/Energy Cost Rs. 65/liter Rs. 6.3 /kWh

7 Energy Bill per year Rs. 78 L Rs. 21.62 L

Financial Innovation – Energy Services Contracting

• Term – 10 Years

• Billing – Based on kCal delivered

• Ownership of Assets – Aspiration Cleantech Ventures, will be transferred to customer at the end of the contract period.

• Operation and Maintenance – Aspiration Energy

• Savings Calculation – Against baseline set at the beginning of the contract

• To protect the downside, there is a minimum guaranteed billing

S. No. Description Painting Plant

1 Heat Pump Type 4 X Parallel Coupled Water Source

2 Total Heating Capacity 260 kW Total Cooling Capacity 172 kW 3 Power Consumption 102 kW 4 COP 2.67 5 Heat Source Electrodeposition Tank

(25-30 °C) 6 Heat Sink 4 Nos of Pretreatment Tanks

(60-70 °C)

7 Heating Medium Water 8 Heat Transfer Method Indirect Heating - Plate Heat Exchanger

9 Refrigerant R1234ze(E) 10 Compressor Type High Temperature Scroll Compressor

11 Backup Source LPG Fired Boiler

• Customer - A leading two-wheeler automobile

manufacturer

• Application – Surface Cleaning in Paint Shop

• Hot water requirement –4 pre-treatment tanks, each tank

to be maintained at 60-70 Deg C

• Source of heat replaced – Liquified Petroleum Gas(LPG)

Boiler consuming around 650 kg of LPG per day

• Combined Heating and Cooling

• Condenser side - replaced the fired boiler

• Evaporator side - replaced the chiller which was

used for electro deposition process.

S. No. Description

Painting Plant

Before HP After HP

1 Primary Energy Source LPG Fired Boiler Water Source Heat Pump

2 Backup Energy Source No Standby LPG Fired Boiler

3 Heating Medium Water Water

4 Heat Transfer Method Plate Heat Exchanger

Plate Heat Exchanger

650 kg/day + 700 kWh/day

1800 kWh

6 Fuel/Energy Cost Rs. 50 /kg Rs. 8 /kWh

7 Energy Bill per year Rs. 125.73 L Rs. 47.52 L

• Customer – Automotive parts manufacturer • Application – Diesel Generator Head Heating

• Hot water requirement –To reduce the startup

time of diesel generators, the engine heads are required to maintained at a temperature range of 60-70 °C.

• Source of heat replaced – Electric Heaters

S. No.

Description Before HP After HP

1 Application Engine Head Preheating 2 Energy Source Circulation Electrical

Heater Air Source Heat Pump

3 Heat required for Operation

32,680 kcal/hr 32,680 kcal/hr

4 Heating Medium Water Water 5 Heat Transfer Method Circulation Heater Plate Heat Exchanger 6 Heat Source Electrical Energy Ambient Heat 7 Heat Sink DG Engine Head DG Engine Head 8 Heater/Heat Pump

operating Temperature 75 deg. C 75 deg. C

9 Engine Head Water Temperature

63 deg. C 63 deg. C

10 Energy Consumption per day

348 kWh 145 kWh

11 Energy Cost Rs. 8 /kWh Rs. 8 /kWh 12 Energy Bill per year Rs. 9.19 L Rs. 3.83 L

• Customer – Manufacturer of Glasses • Application – Glass washing before the start of

tempering process

• Hot water requirement –Heating of cleaner solutions that are maintained at the temperature of 60 Deg C

S. No.

1 Application Glass Washer 2 Energy Source Immersion Electrical

12 kW 11 kW

4 Heating Medium Cleaner Solution Cleaner Solution 5 Heat Transfer Method Immersion Heater Direct Heating 6 Heat Source Electrical Energy Ambient Heat 7 Heat Sink Washer Tank Washer Tank 8 Heater/Heat Pump

192 kWh 72 kWh

5. Heat Pump Assisted Wastewater Evaporization

S. No.

1 Application Waste Water Evaporator 2 Energy Source Immersion Electrical

30 kW 28 kW

4 Heating Medium Water Water 5 Heat Transfer Method Immersion Heaters Direct Heating 6 Heat Source Electrical Energy Ambient Heat 7 Heat Sink Evaporator Evaporator 8 Heater/Heat Pump

operating Temperature

80 deg. C 80 deg. C

360 kWh 132 kWh

• Customer – An automotive parts manufacturer

• Application – Wastewater Evaporization

• Hot water requirement –80 deg C

6. Air Heating for Drying of Racks

S. No.

1 Application Air Heating – Paint Dryer X 2 Nos 2 Energy Source Diesel Fired Boiler Air Source Heat Pump 3 Heat required for

Operation 20,967 kcal/hr 24,080 kcal/hr

4 Heating Medium Water Water 5 Heat Transfer Method Air Heating Coil Air Heating Coil 6 Heat Source Diesel Ambient Heat 7 Heat Sink Paint Dryer X 2 Nos Paint Dryer X 2 Nos 8 Boiler/Heat Pump

operating Temperature 80-85 deg. C 80-85 deg. C

9 Air Temperature to be maintained

40-45 deg. C 40-45 deg. C

31.78 kg & 43.96 kWh 150 kWh

11 Energy Cost Rs. 78 /Liter Rs. 9 /kWh 12 Energy Bill per year Rs. 8.97 L Rs. 4.21 L

• Customer – Warehouse pallet racking and shelving system manufacturer • Application – Drying paints • Hot Air requirement –Air temperature at 40-45 Deg C for 2 dryers • Source of heat replaced – Diesel boiler

Heat Pump Case Studies - Commercial Sector

Commercial Case Studies

Hotels – Bathing application

– Liquefied Petroleum Gas(LPG) replacement at a Business Hotel

– Diesel replacement at a Tourist resort

Hospitals

– Liquefied Petroleum Gas(LPG) replacement at a major Hospital chain

1. Liquefied Petroleum Gas(LPG) replacement at a Business Hotel

Air Source Heat Pump

StorageTank55 °C

• Customer – Business Hotel with ~ 100 rooms spread over 9 floors

• Application – Bathing and Handwashing

• Hot Water requirement – 55 Deg C

• Source of heat replaced – Diesel boiler

1. Liquefied Petroleum Gas(LPG) replacement at a Business Hotel

S. No.

1 Application Hot Water Generation for Bathing/Handwashing 2 Energy Source LPG Fired Boiler Air Source Heat Pump 3 Heat required for

Operation 34,212 kcal/hr 24,080 kcal/hr

4 Heating Medium Water Water 5 Heat Transfer Method Immersion Coil Heat

Exchanger Direct Heating

6 Heat Source LPG Ambient Heat 7 Heat Sink Calorifier Tank Calorifier Tank 8 Heater/Heat Pump

operating Temperature 65-70 deg. C 55 deg. C

34 kg 95 kWh

10 Energy Cost Rs. 77 /kg Rs. 8 /kWh 11 Energy Bill per year Rs. 9.55 L Rs. 2.77 L

2. Diesel replacement at a Tourist resort

S. No.

1 Application Hot Water Generation for Bathing/Handwashing 2 Energy Source Diesel Fired Steam Boiler Air Source Heat Pump 3 Heat required for Operation 23,100 kcal/hr 24,080 kcal/hr

4 Heating Medium Water Water 5 Heat Transfer Method Immersion Coil Heat

Exchanger Direct Heating

6 Heat Source Diesel Ambient Heat 7 Heat Sink Calorifier Tank Calorifier Tank 8 Boiler/Heat Pump operating

Temperature 140-145 deg. C 55 deg. C

62.7 Liters 192 kWh

10 Energy Cost Rs. 62 /Liter Rs. 8.5 /kWh 11 Energy Bill per year Rs. 14 L Rs. 6 L

Heat Pump Vs Boiler Operating Cost/day

Heat Pump Operating Cost Average Boiler Operating Cost

– Tourist resort with 117 Rooms used diesel fired boiler to generate hot water for bathing/Handwashing.

– Heat Pump now provides heat to a centralized calorifier tank where the hot water is distributed to the different areas of the resort.

3. Liquefied Petroleum Gas(LPG) replacement at a major Hospital chain

S. No.

1 Application Hot Water for Bathing 2 Energy Source LPG fired Boiler Air Source Heat Pump 3 Heat required for

Operation 14 kW 14 kW

4 Heating Medium Water Water 5 Heat Transfer Method Direct Heating Direct Heating

6 Heat Source LPG Ambient Heat 7 Heat Sink Calorifier Tank Calorifier Tank 8 Heater/Heat Pump

12.6 kg 45 kWh

10 Energy Cost Rs. 77/kg Rs. 8 /kWh 11 Energy Bill per year Rs. 3.54 L Rs. 1.31 L

– Customer is a leading woman and child healthcare hospital that used LPG boiler to generate hot water for it’s maternity ward.

– Heat Pump now provides heat to a centralized calorifier tank where the hot water is distributed to all the rooms.

Common Challenges

Common Challenges 1. Design - Sizing

i. Difficulty in finding current energy consumption pattern

2. Operation & Maintenance Challenges

i. Handling of Pretreatment Solutions/Colloidal Solutions

ii. Choking of Heat Exchangers

iii. Oily/Dusty Evaporator Coil

iv. Unbalanced Heating and Cooling Demands

v. Insufficient Flow Rates

Heat Pump Sizing

– Main parameters required for Heat Pump Sizing: a. Fuel Consumption/Electrical Energy Consumption/Water Consumption rate b. Temperature Lift c. Ambient Temperature/Heat Source

– Constraints: a. No record of fuel consumption data b. Ambiguity in production rate c. Difficulty in measuring the above parameters during production hours d. Meeting the same heat transfer rate in the heat exchanger while running the heat pump

O&M Challenges 1. Handling of Pretreatment Solutions/Colloidal Solutions:

i. Pretreatment solutions are difficult to circulate through the heat

exchangers.

ii. Because of the impurities in the solution, frequent cleaning of heat exchangers is required.

2. Choking in Heat Exchangers i. In pretreatment tanks and industrial washers, the dust

particles or impurities in the solution settles over the heat exchanger plates during circulation. Eventually this leads to choking in the heat exchanger.

ii. Physical or chemical cleaning is required depending on the choking level and fluid used.

O&M Challenges

3. Oily/Dusty Evaporator Coil: i. In air source heat pump, Oily/dusty particles over the evaporator coil reduces the heat availability

for the heat pump.

ii. Monthly or Quarterly maintenance is required to have stable heat output.

O&M Challenges

4. Unbalanced Heating and Cooling Demands:

i. Cooling demand is less than Evaporator capacity. Overcooling at the source side will reduce the condenser heat rejection rate.

ii. When connecting heat pump with high capacity chiller, sudden cooling by the chiller on Evaporator will affect the condenser heat rejection rate.

5. Insufficient Flow Rates:

i. Insufficient flow rates will reduce the heat transfer rate.

Conclusion

– India is moving towards decarbonizing heat

– Heat Pumps have several applications in

– Industrial sectors

– Commercial sectors

– Heat Pumps also have their own set of Operation & Maintenace Challenges

– Lot of potential for collaborative Research and Development(R&D) of High Temperature Industrial Heat Pumps

– Business model innovations can also help grow the market

Thank you for your kind attention.

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