Low-Cost Nontracking Asymmetric Shadeless Solar Thermal Collector for Industrial Process Heating
This project will develop a low-cost, high-efficiency solar thermal collector for industrial process heating.
Winston Cone Optics, Inc.
Recipient
Merced, CA
Recipient Location
Senate District
27th
Assembly District
$929,673
Amount Spent
Completed
Project Status
Project Result
The Recipient successfully completed the three arrays: 5 square meter prototype, 50 square meter pilot demonstration, and 91 square meter dairy demonstration. To date, the team has completed design, drawings, and test plans for the arrays, as well as a results report for the dairy demonstration. Project activities are currently halted due to loss of the host site and key project partner.
The Issue
The industrial sector is a major consumer, accounting for approximately one third of all fossil gas consumption in the state, where it is primarily used for process heating and indirect boiler heating in the manufacturing sector at temperatures between 100-200 C. While low and high temperature solar thermal technologies exist, this medium temperature range (100-200 C) has been historically underdeveloped. What is needed to support decarbonization is a solar technology that combines the low cost and low maintenance of non-tracking systems with the high efficiency of concentrating systems to achieve a levelized cost for 100-200 C heat that is competitive with fossil gas.
Project Innovation
This project will develop a low-cost, high-efficiency solar thermal collector for industrial process heating by using a unique asymmetric nonimaging optical design and scaling up the technology through iterative demonstrations at a testing facility and an industrial host site. The project team will be demonstrating a Non-tracking Asymmetric Shadeless design, which collapses the External Compound Parabolic Collector technology from a tilted collector into a collector with a flat horizontal aperture. Doing so provides a number of benefits, including cost reductions and performance enhancements, reducing capital and operations and maintenance (O&M) costs, while maximizing annual generation. The project is consistent with the California Energy Commission's mission of leading the state to a 100 percent clean energy future.
Project Benefits
In California, the industrial sector accounts for one-third of the total fossil gas consumption and roughly one-fourth of the state's greenhouse gas emissions. The vast majority of this consumed fossil gas is used for process heat or indirect boiler applications in the manufacturing industry. This project will help reduce fossil gas consumption for industrial process heating, resulting in air pollutant and greenhouse gas emission reductions. Advancing solar thermal technologies to reduce capital and O&M costs while maximizing annual generation will decrease the levelized cost of heat and increase market availability and adoption in industrial and commercial facilities.
Affordability
The team was planning to install a 500 square meter solar field on the rooftop, for a total installed cost of approximately $75,000. Each year, the solar field was estimated to generate ~350,000 kWh (11,945 therms), provide fossil gas savings ~411,764 kWh (14,053 therms), and provide gross savings of $10,400 per year (simple payback of 7.2 years). At a target installed cost of $150/m2, system affordability is a key ratepayer benefit.
Environmental Sustainability
Each square meter of installed collector area will avoid 329 lbs of equivalent carbon dioxide emissions annually. Each square meter of installed collector will generate 24 therms, thereby reducing fossil gas consumption by 28 therms per square meter annually (when replacing fossil gas burned in an 85% efficient boiler). This reduces dependence on gas infrastructure and the need for large-scale transmission and storage.
Subrecipients
The Regents of the University of California, Merced
Artic Solar, Inc. - Industrial Solar Thermal Solutions
Total Dairy Solutions
Match Partners
Winston Cone Optics, Inc.
