Solar Thermal Power in India: Experiences and Future
Rangan Banerjee
Forbes Marshall Chair Professor
Dept. of Energy Science and Engineering
IIT Bombay
Invited talk at Renewtech India 2015, April 29, 2015 Mumbai
Solar Power : Potential and Cost
Solar Insolation and area required
= 2500 sq.km
= 625 sq.km Source: World Energy Outlook – 2008, International Energy Agency
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Solar Concentrators
Arun Technology
CLFR TechnologyParabolic Trough
Scheffler paraboloid dish
Heliostat
3
Solar Thermal Technologies
Companies Operating temp.
Efficiency, η
Remarks
Parabolic Trough
Abener, Thermax, KIE Solatherm
350-400 ͦC Peak 14-20%11-16%Annual
Commercial
Linear Fresnel Reflector
KG Design, Areva 220-250 ͦC Peak 18%Annual 13%
Lower cost
Dish Gadhia Solar, Clique, WRST, Birla Terra Joule, ATE
200 - 700 ͦC Peak 30%Annual 12-25%
Solar heating cooking
HeliostatsSolar Tower
E-Solar (ACME)2.5 MW at Bikaner Sunborne
450-565 ͦC 23-25%7-20%
4
Estimated LCOE for existing and proposed Parabolic Trough and Solar Tower CSP Plants
Source: IRENA 2012
5
KG Design Services Private Limited (KGDS)
Solar thermal research centre in Coimbatore with 1400 m2 of collection area.
45 bar 257 C
Linear Fresnel Reflector
Solar Desalination plant
Solar biomass power plant cum desalination
Source: http://solar.kgisl.com 6
Integration with Heating & Cooling
applications
Boiler
“Built in India” design
Parabolic Concentrators
Agro-waste
Steam Driven Turbine
Completely IndigenousARCI, IIT B, NAL, IIT K, BARC
Agro-waste hybridizationHigh efficient conversion technologies
Project approval received in Dec 2009 with a project completion by June 2011. Total cost of R&D project is 9.11 Cr plus O&M costs
Solar IslandPower Island
Thermal Island
Vapor Absorption Cooling M/C
Organic
Rankine Cycle
Solar Accumulator
256 KW generation
Source: Thermax with permission
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Collaborative DesignBridge Technology Gap Through Collaboration
IIT Bombay
Fraunhofer
IIT Kanpur
DLR
NCL
NAL
ARCI
2Source: Thermax with permission
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Point focus fixed to the dishMaximized intercept factor
Coiled tube cavity absorberMinimized thermal losses
Automatic two-axes tracking
Facing the Sun, maximum insolation
169m2 or 104m2 Arun dish
Power capacity : 0.5 kWpeak / m2
Operating hours : 8 to 9 hrs / day
Daily output : 4 to 4.5 kWhth/day/m2
Capital cost : Rs. 21,000 / m2
Cost Parameter : Rs. 5,000 /(kWhth/day)Source: Clique Developments Ltd., Mumbai with permission 9
Solar Thermal Concentrator developed at ATE Enterprise
Process heating market for
commercial, small industrial
and rural applications (~10 kWt
at 1000 W/m2 insolation)
medium-scale paraboloid dish
with 15–30 m2 aperture area;
local vendor base and
manufacturing
Direct steam generation using
proprietary receiver
• Characterization of
thermal performance
• Measurement of mirror
reflectivity and effect of
ageing
• Remote monitoring
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Adhunik Global
• 6kW solar steam power plant• Fresnel type solar concentrators – 3 of 24m2 each -area of 96 sq mt.( Design from http://www.solarfire.org/)• Steam Engine 2 hp to 10 hp
Solar Oven
Source: http://www.tinytechindia.com/solar6kwtp.htm11
India One Dish Project
60m2 parabolic dish with fixed focus
Number of dishes : 770 nos. of 60m2
Electrical output : 1,0 MW el. (net. 22000 kWh/24hrs) Thermal output : 150 MW th. (24hrs) Solar field : 25 Acres Abu Road, RajasthanTotal mirror area : 45.000 m2
Turbine : 1,0 Mw el.
Source: http://www.india-one.net/abouttheproject.html
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Stirling engines seems to be
viable option
Major heat input should be
through gas flame or solar
energy
Choice of Capacity for Stirling
Engine
~ 96,000 villages to be
electrified in India
- For a group of 3-4 households
having enough cattle to supply
bio-gas for gas based systems
or hybrid systems
- Use for small capacity pumps
for irrigation application
Capacity needs to be at least 1.5
kWe
Stirling engines seems to be
viable DECENTRALIZED option
Cylinderhead
Safety valve
Charging line
Crankcase
Heat receiving tube
Tubes for water circulation
Design and development of Stirling engine for net 1.5 kW electrical output
0 200 400 600 800 1000 1200
292
294
296
298
300
302
Cyl
inde
r he
ad t
empe
ratu
re, K
Time, second
Cool down curve
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Solar TowerE-Solar – Acme partnership
First grid connected plant in India 2011
2.5 MW out of 10 MW installed Bikaner Rajasthan
Double-axis software-mirror tracking system Lightweight, small size 1 m2 flat mirrors
Plant output not stabilised – insolation, auxiliary consumption
http://acme.in/solar/thermal.html 14Non- operational?
Nokh (Godawari): 50 MW
Dhursar 125 MW Reliance/ Areva Megha, AP, 50 MW
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Strategy
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0% 100 %
Completely
Indigenous
Import Complete plant
Prototype
50 %
National Test Facility
National Testing facility – Facilitate technology
development
Objectives
National Test Facility (for solar thermal applications) • Development of facility for component testing and characterization.
• Scope of experimentation for the continuous development of technologies.
1MW Solar Thermal Power Plant• Design & Development of a 1 MW plant.
• Generation of Electricity for supply to the grid.
• Development of technologies for component and system cost reduction.
Development of Simulation Package• Simulation software for scale-up and testing.
• Compatibility for various solar applications.
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KG DS
Planned Mode
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Time Line
Jan. 2010
Nov. 2012
Evaluation Version (v1.0)
Released
Foundation Stone
Preliminary Version (v0.0)
Released
Sep. 2011
Final Version Ready
Aug. 2014
Sep. 7, 2009
Project Start
Jul. 2011
Steam Generation
from LFR
Oct. 2012
Jun. 21, 2013
Mar. 14, 2014
Steam Blowing
Turbine Rolling
Grid Synchronisation
Grid Feeding,Test Rig Ready
May 2014
Mar. 6, 2015
Project End
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Test Rig
Test Building
Dish Concentrator
User Interface: Main Window
Generation of user defined PFD using Simulator
Typical 50 MWe Solar Thermal Power Plant
Direct Steam Generation Process Heat Application
Simplified Process Flow Diagram
Cooling Water45 bar, 105°C1.09 kg/s
0.1 bar, 45.5°C1.78 kg/s
42 bar, 350°C1.93 kg/s
46.3 bar, 171°C2.22 kg/s
Steam Separator
44 bar, 256.1°C0.84 kg/s (Sat. Steam)
Pump-I
Preheater
Steam Generator
Pump-II
High Temperature Vessel
Low Temperature Vessel
17.5 bar, 232°C8.53 kg/s
13 bar, 393°C8.53 kg/s
PTC Field (8175m2)
Superheater
Pump-III
DeareatorPump-V
Pump-IV
Turbine
1 MWe
LFR Field (7020m2)
Pump-VI
Source: ISES, 2013
8175 m2 area – 3 MWth
Trough Field
LFR Field7020 m2 area – 2 MWth
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Arial view of 1 MWe Solar Thermal Power Plant and Test Facility by IIT Bombay
Plant Performance
0
100
200
300
400
500
600
700
800
10.00 11.00 12.00 13.00 14.00 15.00 16.00
DN
I
Time (h)
4th June 2014
DNI
Minute by minute DNI data for 4th June 2014
0
100
200
300
400
500
600
10.00 11.00 12.00 13.00 14.00 15.00 16.00
Pow
er O
utp
ut (k
W)
Time (h)
4th June 2014
Minute by minute turbine power output data for 4th June 2014
What did we learn?
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Overall
Specialisation- Sub Tasks – Difficult from scratch
1 MW – too small for CSP with present route
Industry interest in CSP research – declined-change in priorities- budgets
Catalysed CSP development – few consortium partners
Testing of one concentrator, new HTF fluid
Simulator – Evaluation licenses- Tata Power, Fichtner 28
Sequence of Commissioning Problems
Kartheek, N G R, et al 2013
Commissioning Experience
30Kartheek, N G R, et al 2013
System Problems
HTF Freezing: Unfreezes only in
summer.
UPS and Tracker failure:
Continuous Power supply
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10
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12
13
14
15
12:0
0 A
M
12:3
0 A
M
1:0
0 A
M
1:3
0 A
M
2:0
0 A
M
2:3
0 A
M
3:0
0 A
M
3:3
0 A
M
4:0
0 A
M
4:3
0 A
M
5:0
0 A
M
5:3
0 A
M
6:0
0 A
M
6:3
0 A
M
7:0
0 A
M
7:3
0 A
M
8:0
0 A
M
8:3
0 A
M
Am
bie
nt
Tem
per
atu
re (
oC
)
Time (hr: min)
Schematic of Oil System
TG
TG
Kartheek, N G R, et al 2013
Operational Problems
Leakages in
superheater
Receiver tube and
window glass: Spot
Welding, Continuous
power
Water entry in
Instrumented-air line:
NRV
Dry run of the BFP:
Level Switches
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Receiver Window Glass Breakage
Receiver Tube leakage
Kartheek, N G R, et al 2013
Temperature Transmitters showing Leakages
Leakage
from
Screwed
connection
Pump Seal Failure
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Equipment problems• NRV selection: Horizontal & Vertical line
• Instrument stub: No threaded parts
• Compressed air line: No threaded joints
• Communication failure
• Steam valves: Control, Manual handle,
Isolation
Control System HierarchyKartheek, N G R, et al 2013
What are the research directions? Gaps?
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Typical loop imbalance problem for 4th June 2014
0
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150
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250
300
350
400
10.00 11.00 12.00 13.00 14.00 15.00 16.00
Tem
pera
ture
( C
)
Time (h)
Loop 1 Loop 2 Loop 3
4th June 2014343°C
311°C
Castable ceramics storage: The castable ceramic is basedon a binder containing Al2O3.The binder is prepared underambient conditions and reactschemically to form a solid,stable matrix which enclosesthe aggregates iron oxides.
High temperature concrete storage:
In high temperature concrete,blast furnace cement is used asthe binder; iron oxides are usedagain as the main aggregate aswell as flue ash and again asmall amount of auxiliarymaterials.
Two-tank storage: The low vapour pressure of thenitrate salts allows vertical, field-erected tanks to be used. The largetanks, which operate atatmospheric pressure, are similarto commercial oil storage tanks.
Thermocline storage system:
Low-cost filler materials asthe primary thermal storagemedium, and molten nitratesalts as the direct heattransfer fluid.
Phase Change storage:The latent heat of fusion betweenthe liquid and solid states ofmaterials is rather highcompared to the sensible heat,storage systems utilizing phasechange material can be reduced insize compared to single-phasesensible heating systems.
(Brosseau, Hlava, and Kelly, 2004)(Herrmann, Kelly, and Price, 2004)
Steam accumulator storage:
A Steam accumulator is aninsulated steel pressure tankcontaining hot waterand steam under pressure. Itis a type of energy storagedevice.
(Eck, 2012)
(Tamme, Laing and Steinmann, 2004) (Laing, Steinmann, Tamme, and Richter, 2006)
(Michels, and Pitz-Paal, 2007)
Variation of Energy with storage capacity (Nandi, Bandyopadhyay and Banerjee, 2012)
Cost electricity Vs energy requirement for thermal generation(Nandi, Bandyopadhyay and Banerjee, 2012)
Ceramics Concrete
Two Tanks
PCM
Thermocline
5.00
7.00
9.00
11.00
13.00
15.00
1.00 1.02 1.04 1.06 1.08 1.10 1.12 1.14
Energy (MWh)
Cost
(U
S$/M
Wh)
Research Problems
Effect of dust, cleaning schedules
Tracking errors
Flow balancing
Alternative Storage
Control Strategies
Alternative HTF
Alternative mirror materials, vacuum, absorber tube
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Future
Facility – Enabling testing, training , research
Software – free to academic users
Handed over to NISE – March 2015
Limited industry interest
www.solar.energy.gov/sunshot/csp.html
Local Supply Chain – Solar Thermal
ESMAP, 2012, Local Supply Chain
Status Local Capability
ESMAP, 2012, Local Supply Chain
Action Plan
ESMAP, 2012, Local Supply Chain
Vendors – Solar Thermal
ESMAP, 2012, Local Supply Chain
Millman, Pune
Vendors – Power Block/EPC
ESMAP, 2012, Local Supply Chain
EU CSP Technology Roadmap 2014
End-Note
Facility – goal to enable design and development of future indigenous cost effective plants
Facility developed , not sure about future usage,
Attempted to influence/ seed interest –workshops/ training- yet sub-critical technology development efforts
Need for strategic technology development initiative nationally – Industry, researchers, Govt
Potential for cost reduction, integration with storage
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References
IRENA 2012: Renewable Energy Technologies: Cost Analysis Series, Concentrating Solar Power, Vol. 1: Power Sector, issue 2/5, IRENA 2012.
KGDS Renewable Energy Private Limited, http://solar.kgisl.com
Thermax- Sustainable Solutions in Energy and Environment , Pune, http://www.thermaxindia.com/
Clique Developments Pvt. Ltd., Mumbai, http://www.clique.in/
Sunshot Vision Study, U.S. Department of Energy, February 2012, www.solar.energy.gov/sunshot/csp.html
ESMAP, 2012: Development of Local Supply Chain: The Missing Link for Concentrated
Solar Power Projects in India, World Bank.
http://acme.in/solar/thermal.html
Adhunik Global, http://www.tinytechindia.com/solar6kwtp.htm
India One Solar Thermal Power Project, http://www.india-one.net/index.html
Kartheek N G R et al 2013: Experiences in Commissioning of a 1MWe Solar Thermal Power Plant in Gurgaon, Paper No. 339, Proceedings of 4th International Conference on Advances in Energy Research (ICAER 2013), IIT Bombay, Mumbai, December 10-12, 2013.
ISES 2013: Simulation of 1 MWe Solar Thermal Power Plant, Desai N.B., et aL. Proceedings of ISES Solar World Congress, Cancun, Maxico, November 3-7, 2013.
47
References
IEA, 2014: Technology Roadmap – Solar Thermal Electricity, International Energy Agency, 2014 edition.
World Energy Outlook – 2008, International Energy Agency, available online: http://www.worldenergyoutlook.org/media/weowebsite/2008-1994/WEO2008.pdf
Nandi, B.R., Bandyopadhyay, S., Banerjee, R., 2012. Analysis of High Temperature Thermal Energy Storage for Solar Power Plant. 3rd IEEE Int.Conf. Sust. Energy Technologies, Kathmandu, Nepal, 24-27.
Brosseau, D.A., Hlava, P.F., Kelly, M.J., 2004. Testing thermocline filler materials and molten salt heat transfer fluids for thermal energy storage systems used in parabolic trough solar power plants. ASME International Solar Energy Conference, Portland, Oregon, USA, 587-595.
Eck, M., 2012. Thermal Storage for STE Plants. 3rd SFERA Summer School, Almería German Aerospace Center Institute of Technical Thermodynamics
Herrmann, U., Kelly, B., Price, H., 2004. Two-tank molten salt storage for parabolic trough solar power plants. Energy 29, 883–893.
Laing, D., Steinmann, W.D., Tamme, R., Richter, C., 2006. Solid media thermal storage for parabolic trough power plants. Solar Energy 80, 1283–1289.
Michels, H., Pitz-Paal, R., 2007. Cascaded latent heat storage for parabolic trough solar power plants. Solar Energy 81, 829–837.
Tamme, R., Laing D, Steinmann, W.D., 2004. Advanced thermal energy storage technology for parabolic trough. Journal of Solar Energy Engineering ASME 126, 794–800.
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Acknowledgments
IITB Solar Power project team - J. K. Nayak, Santanu B., S. B. Kedare, Suneet Singh, M.Bhushan, S. Bharatiya, S. Doolla, U.N. Gaitonde, U.V. Bhandarkar, S.V. Prabhu, B.P. Puranik, A.K. Sridharan, B.G. Fernandes, K. Chatterjee, A.M. Kulkarni, RajkumarNehra, Kalpesh Karniik, Deepak Yadav, Satish Kumar, VikalpSachan, Pranesh K, Tejas Shinde, Kartheek NGR, Ranjeet Bhalerao, Nishith Desai
R.R. Sonde, Thermax, S.P. Vishwanathan, KGDSL, V. Sardeshpande– ATE, Clique
Bhaskar R Nandi, Balkrishna Surve, IIT Bombay
Thank youEmail: [email protected]
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