Integration of Advanced Solar Thermal Technology into Industrial Processes
Solar thermal systems are envronmentally-friendly technologies for replacing natural gas
ergSol, Inc.
Recipient
Fairfield, CA
Recipient Location
3rd
Senate District
11th
Assembly District
$1,199,905
Amount Spent
Completed
Project Status
Project Result
The integrated solar thermal system (ISTS) with high-performing evacuated tube collectors (ETC) was completed within the budget and is successfully operating since February 2020. The solar thermal system with energy storage has been integrated into the energy structure of a fully operating processing plant to provide on-demand solar thermal heat for the Clean-in-place (CIP) process. Hot water with zero carbon footprint is used in the bottling process for sanitizing and cleaning the production and cellar equipment. Annual energy data from the installed system showed a deviation to the expected results. The lower savings resulted from reduced or altered operations due to wildfire and operational plant changes. While there were real operating conditions significantly impacting the estimated energy baseline, the findings indicate that the ISTS is capable of delivering the expected performance with the water usage estimated to size the solar thermal system throughout the year. The final report is pending final review.
The Issue
Thermal energy is a ubiquitous need for industrial processes, making solar thermal water heating systems a promising clean, and environmentally friendly technology for reducing the reliance on natural gas. The employment and integration of solar thermal technologies for industries with high thermal energy demand is a sustainable solution for meeting the California carbon reduction goals and decreasing natural gas use. However, the marketplace currently lacks data on the costs, performance, reliability, and flexibility of its integration into current operational industries.
Project Innovation
Optimized use of thermal energy is widely applicable for industrial processes that require heat in various temperature ranges. The vast majority of industrial processes occur in a temperature range of 100˚Fahrenheit (F) to 300˚F. This temperature ”sweet spot” is standard in most industries, including food and beverage; dairy, poultry and agricultural products; pharmaceuticals; textiles; paper; metal surface treatment. All of these need pre-heated water for boilers, air conditioning, sanitation treatment, and other heat demanding processes. ergSol’s ETC collectors can provide more than 300°F temperature heat with high efficiency, making them appropriate for industrial process heat needs. Those ETCs represent localized, non-concentrating, non-tracking solar thermal design. They can be mounted flat on surfaces, leading to a small footprint for collector installation. Roof real-estate is often in short supply, and a smaller footprint per high-temperature BTU translates into more savings. ergSol’s innovative design was developed for a reliable, stable, and cost-efficient integration of the solar thermal system to increase energy efficiency, reduce emissions, and minimize production costs. The collectors were installed flush against the slightly sloped roof of the building. Adjacent to the building, a thermal energy storage tank was integrated into the design to extend the solar energy into the evening/early morning hours as well as for capturing the energy over the weekend. The prebuilt pump station in a container features a flexible modular design for easy maintenance access and installation efficiency. The minimum distance between the main components of the solar thermal system, such as collector field, storage tank, solar thermal pump station, and short pipe lengths, increases the overall efficiency of the system. The pre-fabricated heating system was made capable of mass production, scalability, and adaptability to diverse market needs.
Project Benefits
In this application, the integrated solar thermal system has the potential to achieve approx. 11,300 therms/year natural gas savings, considering a boiler efficiency of 96%. The project was designed to demonstrate the technical and economic feasibility of a commercial-scale ISTS to generate on-demand thermal energy for industrial processes, displacing part of the gas use. The technology’s applications are not limited to food processing and once commercialized, can provide carbon-free thermal energy for various customers in any climate zone.
The California food processing industry is one of the target markets for solar thermal applications. Energy, safety and security, global competition, water, regulations, and labor costs are some factors of concern for this industry. Energy — quality, reliability, and cost — is essential in retaining and growing the food processing industry in California. Those businesses can be most affected by high energy costs, price fluctuations, and even interruptions in utility services that can have significant effects on the cost and safety of the products. Reducing energy needs for food processors through effective implementation of localized solar thermal technology will provide food processors with the following benefits:
- OPEX cost reduction- Decrease the volatility of energy prices
- Carbon emissions reductions
- Compliance with local/state/federal policies and regulations
- Green Corporate Image
Key Project Members
Dr. Monika Weiss
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