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AEPL ACADEMY
TRAINING SESSION
Leader in Industry scale solar thermal plants with over 2 MW installation and industrial
heat pump with over 200 kW
Rooftop solar installation for 40-120o C industrial processes
Industry’s best 95 °C Heat pump
Replace fossil fuel and reduce carbon emission with clean green solar energy
Technical expertise for hybridization
Unique PPA model for solar industrial heating
Proud Pioneers
About Aspiration Energy
Introduction to Solar Thermal
Thermosyphon System
Solar
Power
Free source of energy
Green energy
Reliable source
Non- conventional source
Available for 300 days per
year
Solar Power: Introduction
Solar Thermal
Concentrated
Fresnel
reflectors
Compound
Parabolic
Collectors
Parabolic
dish
Non-
concentrated
ETC FPC
Solar Power: Introduction
Solar Thermal System:
Industrial
Solar
Thermal
Modules with
Collectors
•1
Heat
Exchangers •2
Thermal
Battery
(Storage
Tanks)
•3
Pumps and
controllers •4
Typical solar thermal installation will consists of
Simple Solar Thermal
System
Flat Plate Collectors
Evacuated Glass
Tube Collectors
Thermo-siphon type
Heat Convection
Single Module ETC
type Solar Thermal
System
Evacuated Tube Collectors
Arrangement: U shaped copper
pipes fixed within the ETC
tubes. With an aluminum
insulation in between the
copper pipes and the ETC tube.
Advantage: More solar radiation
reflected towards the tube increase
the water temperature
ETC with U
Pipe
Arrangement: Parabola
shaped Aluminum reflectors
with ETC tubes fixed at their
focal point.
Advantage: more solar
radiation reflected towards
the tube increase the water
temperature
Compound Parabolic
Concentrator
Linear Fresnel Reflector
Parabolic Trough Collector
Other Solar Collectors
Parabolic Dish Collector
Collector efficiencies at different irradiances and temperature differences
Solar Heating For Industries
Industrial Processes suitable for Solar
Drying Electroplating
Bleaching Cleaning
Cooking Pickling
Degreasing Steaming
Evaporating Phosphating
Preheating Washing
Heat Pump - Background
Heat is the flow of energy from one body or substance to
another due to a difference in temperature.
Heat Pump - Background
First Law of Thermodynamics – Energy cannot be created or
destroyed. It exists in the universe in a fixed amount. It can
be stored, and can be transferred from one material to
another.
Second Law of Thermodynamics - energy generally cannot
spontaneously flow from a material at lower temperature to a
material at higher temperature.
Heat Pump - Background
Water does not move spontaneously, but can be pumped
from point A to point B, and can even be made to flow uphill
by a water pump, powered by an outside source of energy.
Likewise, energy can be relocated and elevated (from a
lower temperature to a higher temperature) by a heat pump.
THE IDEAL VAPOR-COMPRESSION REFRIGERATION CYCLE
The vapor-compression refrigeration cycle is the ideal model for refrigeration systems.
Schematic and T-s diagram for the ideal
vapor-compression refrigeration cycle.
This is the
most widely
used cycle for
refrigerators,
A-C systems,
and heat
pumps.
ACTUAL VAPOR-COMPRESSION REFRIGERATION CYCLE
Schematic and T-s diagram for the actual
vapor-compression refrigeration cycle.
An actual vapor-compression refrigeration cycle differs from the ideal one in several
ways, owing mostly to the irreversibilities that occur in various components, mainly due
to fluid friction (causes pressure drops) and heat transfer to or from the surroundings.
The COP decreases as a result of irreversibilities.
DIFFERENCES
Non-isentropic
compression
Superheated vapor at
evaporator exit
Subcooled liquid at
condenser exit
Pressure drops in
condenser and
evaporator
21
The Compressor
• The compressor is the heart of the
system. The compressor does just what
it’s name is. It compresses the low
pressure refrigerant vapor from the
evaporator and compresses it into a high
pressure vapor.
22
The Condenser
• The “Discharge Line” leaves the compressor
and runs to the inlet of the condenser.
• Because the refrigerant was compressed, it is a
hot high pressure vapor (as pressure goes up –
temperature goes up).
• The hot vapor enters the condenser and starts
to flow through the tubes.
• As the heat is removed from the refrigerant, it
reaches it’s “saturated temperature” and starts
to “flash” (change states), into a high pressure
liquid.
• The high pressure liquid leaves the condenser
through the “liquid line” and travels to the
“metering device”. Sometimes running through
a filter dryer first, to remove any dirt or foreign
particles.
23
Metering Devices
• Metering devices regulate how much liquid
refrigerant enters the evaporator .
• Common used metering devices are, small thin
copper tubes referred to as “cap tubes”,
thermally controller diaphragm valves called
“TXV’s” (thermal expansion valves) and single
opening “orifices”.
• The metering device tries to maintain a preset
temperature difference or “super heat”,
between the inlet and outlet openings of the
evaporator.
• As the metering devices regulates the amount
of refrigerant going into the evaporator, the
device lets small amounts of refrigerant out
into the line and looses the high pressure it has
behind it.
• Now we have a low pressure, cooler liquid
refrigerant entering the evaporative coil
(pressure went down – so temperature goes
down).
24
The Evaporator
• Low pressure liquid leaves the metering device
and enters the evaporator.
• Usually, a fan will move warm air from the
conditioned space across the evaporator finned
coils.
• The cooler refrigerant in the evaporator tubes,
absorb the warm room air. The change of
temperature causes the refrigerant to “flash”
or “boil”, and changes from a low pressure
liquid to a low pressure cold vapor.
• The low pressure vapor is pulled into the
compressor and the cycle starts over.
• The amount of heat added to the liquid to
make it saturated and change states is called
“Super Heat”.
• One way to charge a system with refrigerant is
by super heat.
1 kW
900 W
90%
How Efficient Is Electric Heater ?
Ambient Heat
Primary power
(Electricity)
Heat Pump
USABLE
ENERGY
Renewable
Energy
Conventional
Energy
Heat Pump
1 kW
1 - 2 kW 2- 3 kW
+ =
Heat
is
taken
in
from
the
ambient
The system pumps heat from a low
temperature reservoir to a high temperature
Heat Pump - Principle
Free Cooling
DO YOU NEED LIFE LONG FREE AC?
HEAT PUMP GIVES YOU FREE COLD WATER UPTO 7
DEG C WHILE SIMULTANEOUSLY PRODUCING HOT
WATER AROUND 55 DEG C
7 DEG C 55 DEG C
Air Source Heat Pump
Water Source Heat Pump
Water Source Heat Pump
Hot Water Tank
Air Conditioner
Water source heat pump
50℃
8℃
55℃
13℃
Industrial Application of
Solar Thermal and Heat Pump
Steam @ 2000C
250C
250C Steam @ 2000C
900C
Boiler Feed
Solar Assisted Boiler Feed
Component Washing
Industrial Washing Machine Pre-treatment Plants
Canteen Cooking
Dish Wash
Bathing & Hand Wash
Boiler Efficiency
&
Calorific Value
FUEL IN (100 Litres)
COLD WATER IN
STEAM / HOT
WATER OUT
(70%)
FLUE GAS OUT
+
OTHER LOSSES
(30%)
BOILER EFFICIENCY
BOILER EFFICIENCY = 70%
Boiler Efficiency
Through Fuel Consumption
Energy required = Fuel Consumption x Calorific Value x Boiler Efficiency
Energy
required for
Process
Fuel Consumption Boiler Efficiency
Fuel Calorific Value
= 20 x 9422 x 70%
= 1,31,908 kcal/hr
= 131908/860
Energy required = 154 kW
20 litres/hr
9422 kcal/l
70%
Calorific Values
Liquid Fuel
Fuel kJ/kg
kcal/kg
(0.239 x kJ/kg)
Specific Gravity kcal/litres
Diesel 44,800 10707.2 0.88 9422.3
SKO 46,200 11041.8 0.8 8833.4
FO 43,000 10277 0.92 9454.8
Gaseous Fuel
Fuel kJ/kg
kcal/kg
(0.239 x
kJ/kg)
Propane 50,350 12033.65
LPG 46,100 11017.9
Solid Fuel
Fuel kJ/kg
kcal/kg
(0.239 x
kJ/kg)
Coal 15,000 3585
Coke 28,000 6692
Fuel Calorific Value Litre/kg
Boiler
Efficiency
kW Litre/kg Fuel Price
Cost of Energy
Spent per kW (Rs)
kcal kW
Furnace oil 9454.84 11.00 per litre 60% 6.6 per litre 36 5.45
HSD 9422.3 11.00 per litre 60% 6.6 per litre 63 9.55
SKO 8833.3 10.30 per litre 60% 6.18 per litre 50 8.09
LPG 11017.9 13.00 per kg 60% 7.8 per kg 43 5.51
Propane 12033.7 14.00 per kg 60% 8.4 per kg 42 5.00
Coal/Coke 5250 6.00 per kg 60% 3.6 per kg 8 2.22
Briquette
(Sugarcane
husk)
3996 4.65 per kg 60% 2.79 per kg 4.5 1.61
Electricity 860 1 per unit 95% 0.95 per unit 8 8.42
Calorific Values
Fuel Consumption Measurement
Method Dedicated
Fuel tank
Common
Fuel Tank
Liquid
Fuel
Gaseous
Fuel
Flow meter
Level Indicator
Or
Dip Stick
LOAD CALCULATIONS - BASICS
Load Calculation
CALCULATION TYPES:
Through litres per day of water
• Canteen & Boiler Feed water application
Through Fuel Consumption
• Process heating & washing machine applications
Through Litres per day of Water
Q = m x Cp x ΔT
Canteen & Boiler feed application
Q = Energy required (kW)
m = Mass flow of water in LPD
Cp = Specific heat of water (kcal/kg K)
ΔT = Temperature difference (deg C)
Example:
10000 LPD has to be raised
from ambient to 80 deg C
Q = 10000 x 1 x (80 – 30)
= 500000 kcal
= 500000/860
= 581 kWh per day
Through Litres per day of Water
To design a storage, the main thing to keep in mind
We have to produce
24 hours energy
in
6 hours solar window
Through Litres per day of Water
LOAD ESTIMATION FOR SOLAR THERMAL SYSTEM
Effective Sunshine hours = 6 hours per Day
Solar Thermal Capacity =
𝐓𝐨𝐭𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 𝐩𝐞𝐫 𝐝𝐚𝐲
𝐄𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐒𝐮𝐧𝐬𝐡𝐢𝐧𝐞 𝐇𝐨𝐮𝐫𝐬
=581/6 = 97 kW
Through Litres per day of Water
LOAD ESTIMATION FOR HEAT PUMP SYSTEM
Effective working hours = 16 - 18 hours per Day
Heat Pump Capacity =
𝐓𝐨𝐭𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 𝐩𝐞𝐫 𝐝𝐚𝐲
𝐄𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐖𝐨𝐫𝐤𝐢𝐧𝐠 𝐇𝐨𝐮𝐫𝐬
= 581/16 = 36 kW
Through Litres per day of Water
Comparison of Solar Thermal VS Heat Pump Load
Solar Thermal Capacity = 97 kW
Heat Pump Capacity = 36 kW
Why the Capacity Required is Lesser for Heat Pump?
Heat pump runs for 16 hours whereas Solar Thermal needs to produce
the same energy in 6 hours
Is the Heat Pump Cheaper?
Yes, But there is a RUNNING COST. Heat pump consumes around 40 to
50% of Energy
TYPE - 2 Thru Fuel Consumption
Amount of Fuel consumed by the Boiler?
Boiler Efficiency?
Example:
Average Fuel consumed by the boiler per hour = 10 Litres of Diesel
Calorific value of Diesel = 11 kW per litre
Total energy = 110 kWh of Energy
With Boiler efficiency of 70%,
the effective Output per hour = 110*0.7 = 77 kW
TYPE-2: THRU FUEL CONSUMPTION
FUEL IN (10 Litres) or 110 kWh
COLD WATER IN
HOT WATER
OUT (70%) or
77 kWh
FLUE GAS OUT (30%)
BOILER EFFICIENCY
BOILER EFFICIENCY = 70%
Solar Capacity
Actual Energy
required for
Process
Solar Pipe
Heat Loss
Heat Loss will normally be 10% to 20%
APPLICATIONS &
LOAD ESTIMATION
Canteen Cooking
1
Hot Water For Canteen Cooking
Steam
Boiler
Steam Line (>100 degC)
To Canteen Utensils
for cooking
Feed water (25 degC)
To cook idly
Boil rice
With Solar
Steam
Boiler
Steam Line (>100 degC)
To Canteen Utensils
Pre-heated
Feed water (90 degC)
For cooking idly
To Boil rice
Rooftop Solar thermal
Installation assisting Boiler
From Solar
General Schematic
Solar thermal
Temperature required
Water quantity consumed/day
Hours of operation
Fuel used & Fuel cost
Fuel consumption (per hour/day)
Sample data
90 deg C
Temperature
10000 litres per day
Water
quantity
NA
Operation
Hours
Diesel
Fuel Used
Rs. 63/litre
Cost of Fuel
70 %
Boiler
Efficiency
Load Estimation
Q = m * Cp * (T2-T1)
Q – Heat energy required (kcal)
m – mass of water consumed for the application(LPD)
Cp – Specific heat capacity of water (1 kcal/kg k)
T2 – Temperature required for application (°C) or Water outlet temp
T1 – Ambient temperature of water (°C) or water inlet temp
We can achieve max temp up to 90°C from solar thermal
System Capacity Calculation
Effective sunshine hours = 6 hours/day
So, the Solar Thermal System Capacity = 755 / 6
=126 kW
SOLAR THERMAL SYSTEM
HEAT PUMP SYSTEM
Effective working hours considered = 18 hours/day
So, the Heat Pump Capacity = 755 / 18
= 42 kW
Description Solar Thermal
System
Heat Pump
System
Capacity 126 kW 42 kW
Project Cost Rs.63,00,000 Rs.21,00,000
Operational Cost/year Almost nil Rs.8,20,800
Net saving/year Rs.18,52,300 Rs.10,31,200
Payback 3.4 yrs 2.03 yrs
Simple payback - HEAT PUMP
Canteen Hand wash/Plate wash
2
Applications:
Plate Wash
Solar thermal Schematic
Heat Pump schematic
Boiler Feed
3
Boiler Feed
Steam
Boiler
Steam Line (>100 Deg C)
Pre-heated
Feed water (90 Deg C)
Rooftop Solar thermal
Installation
From Solar
To Process
applications
General Schematic
Process Treatment
4
Typical Process Treatment
Temperatures
During Sunshine hours the heat energy flows as shown through the red line, through
solenoid valves 2 and 3 (1 is off)
Integration Schemes
During Non-Sunshine hours the heat energy flows as shown through the blue line
through solenoid valve 1 (2 and 3 off)
Integration Schemes
Process heating application
Temperature required
Fuel Consumed
Hours of operation
Fuel used
Boiler Efficiency
Fuel Cost
Sample data
65 Deg C
Temperature
60 kg/shift of LPG
Fuel Consumed
70%
Boiler efficiency
8 hrs
Operation Hours
6, 8, 7.5, 9, 9, 8.5, 6, 6
Hourly Load
pattern/shift (kg/hr)
LPG
Fuel Used
Rs. 55/kg
Cost of Fuel
Load Estimation
Fuel Consumed per hour = 9 kg/hr (during peak load)
Calorific value of LPG = 12.8 kW/kg
Boiler Efficiency = 70%
Energy required for process = Fuel Consumption * Calorific value * Boiler efficiency
= 9 * 12.8 * 0.70 = 80.64 kW
Total Energy required for one hour = 80.64 kW
Solar Thermal Capacity
Accounting 10% piping losses = 89.6 kW
So, the Solar Thermal System capacity = 90 kW
Total committed running hours for Solar annually
= 6 hours / day x 300 days
= 1800 hours/yr
Industrial Washing Machine
5
Temperatures
Industrial Washing machine
Heat Pump Schematic - for Washing machine (Indirect Heating)
Washing Machine
Temperature required
Installed heater capacity
Hours of operation
Units consumed per hour
EB cost/unit
• 55 deg C
Temperature
• 36 kW heater
Installed heater capacity
•24
Operation Hours
•20 kWh
Units consumed per hour
•Rs. 8/kWh
EB Cost
Sample data
Load Estimation
Installed Heater Capacity = 36 kW
Units consumed / hour = 20 kWh
Units consumed per day = 20 * 24hrs
= 480 kWh
Heat load required = 20 kWh*0.95
= 19 kW
Accounting piping loss (15%)+Stand by time(15%)
= 19 kW + 2.85 kW + 2.85 kW
= 24.7 kW
Heat pump capacity selected = 28kW
* which delivers 28kWh per hour
Sizing of Pipes
• Flow Rate
• Velocity
• Pressure Drop
∝ to Flow rate
• More the flow
rate, more the
pressure drop
and vice versa
Pipe Selection Criteria
Which size to be selected??
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000
Pressure
Drop
in
m
(for
100
mtr
of
pipeline
length)
Flow Rate (LPH)
Pressure Loss in Pipe line for 100 mtr of Length - Pump Head
Calculation
1.5" Pipe Pressure Drop 2" Pressure Drop 2.5" Pressure Drop 3" Pressure Loss
Pressure Loss
Installation & Maintenance
Rooftop Analysis
Manifold arrangements
Glass tube fixing
Storage tank
Controller
Collector Fluid Maintenance
Collector maintenance
After Cleaning
Glass tube wreckage
Breakage Indication
Strainer Maintenance
Piping Maintenance
Tank maintenance
Heat Exchanger maintenance
Enclosure for equipment's
CASE STUDY
pH is a numeric scale used to specify the acidity or alkalinity
of an aqueous solution
Effects of pH
Acidity Alkalinity
Neutral
• pH below 6.5 causes erosion of material which results in leakage
• pH above 8.5 causes scale formation inside tube.
Fluid it transports
at what temperature
at what pressure it transports
commonly used material grades:
Mild Steel A53
Carbon Steel A106
Stainless Steel A312 tp304
Stainless Steel A312 tp316
Stainless Steel A312 tp316lL
CPVC
PPR
HDPE
PP
FRP
PVDF
Pipe Material Selection
Heat Load Calculation
http://www2.spiraxsarco.com/esc/heatloss_t
ankheating.aspx?shape=0
How much can Solar Save?
Wheels India
is saving
1,27,500 Litres
of Furnace Oil
which amounts to
51 Lakhs
per Year
Sona Koyo Steering
is saving
37,800 Litres
of Diesel
which amounts to
18.9 Lakhs
per Year
Ashok Leyland is benefited
< 1 year Payback
Case Study @ Wheels India
Conventional Heat
Source
Thermic Fluid
Boiler
Fuel Used Furnace oil
Application Pre-treatment
Temperature Range 60-75 ⁰C
Case Study @ Sona Koyo
Conventional Heat
Source
Hot water
generator
Fuel Used Diesel
Application Pre-treatment
Temperature Range 60-75 ⁰C
Case Study @ TVS Motors
Conventional Heat
Source
Electrical Heater
Application
Maintaining DG
Head temperature
Number of DG sets 4 nos.
Temperature Range 60-75 ⁰C
Electricity
Consumption
1200 kWh per day
Case Study @ Harita Seatings
Project Size 360 kW
Conventional Heat
Source
LPG
Application Pre-Treatment
Temperature Range 60-75 ⁰C
Fuel Savings 19,000 kg/year
CO2 Abatement 53,460 kg/year
Case Study @ Pidilite & Pfizer
Project Size 48 kW 42 kW
Conventional Heat
Source
Furnace Oil Electricity
Application Chemical Curing Sanitation
Temperature Range 60 ⁰C 60 ⁰C
Fuel Savings 8,700 Litres/year 81,000 kWh/year
CO2 Abatement 20,880 kg/year 32,400 kg/year
Case Study @ AL, Ennore
Existing Process
Conventional Heat
Source
Electrical Heater
Application Engine Head washing
Temperature Range 50-60 ⁰C
Electricity
Consumption
24 kWh per hour
After Heat Pump
Project size 28 kW
Present Consumption 12 kWh per hour
Units saved per year 86,400 kWh
Annual Carbon
Abatement
73, 440 kg
Case Study @ Brakes India
Existing Process
Conventional Heat
Source
Electrical Heater
Application
Small Auto
Components
Temperature Range 50-60 ⁰C
Electricity
Consumption
6 kWh per hour
After Heat Pump
Project size 14 kW
Present Consumption 2.5 kWh per hour
Units saved per year 12,500 kWh
Annual Carbon
Abatement
10, 200 kg
Case Study @ Lucas TVS
90 °C Heat Pump – Completed
Project Size 160 kW
Conventional Heat Source SKO
Application Pre-Treatment
Temperature Range 70 - 90 ⁰C
ZERO Investment from Customer
Rs. 8
per
MCal
Present
Cost
Rs. 5.5
per
MCal
Offered
Cost
Unique
PPA
Model
Be the proud
pioneer and save
the future…
>> Fast Forward to the Solar Future!! >>
Contact us @
info@aspirationenergy.com/044-42185301

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Presentation 1 Training Slides.pptx

  • 2. Leader in Industry scale solar thermal plants with over 2 MW installation and industrial heat pump with over 200 kW Rooftop solar installation for 40-120o C industrial processes Industry’s best 95 °C Heat pump Replace fossil fuel and reduce carbon emission with clean green solar energy Technical expertise for hybridization Unique PPA model for solar industrial heating Proud Pioneers About Aspiration Energy
  • 5. Solar Power Free source of energy Green energy Reliable source Non- conventional source Available for 300 days per year Solar Power: Introduction
  • 7. Solar Thermal System: Industrial Solar Thermal Modules with Collectors •1 Heat Exchangers •2 Thermal Battery (Storage Tanks) •3 Pumps and controllers •4 Typical solar thermal installation will consists of
  • 10. Evacuated Glass Tube Collectors Thermo-siphon type Heat Convection Single Module ETC type Solar Thermal System Evacuated Tube Collectors
  • 11. Arrangement: U shaped copper pipes fixed within the ETC tubes. With an aluminum insulation in between the copper pipes and the ETC tube. Advantage: More solar radiation reflected towards the tube increase the water temperature ETC with U Pipe
  • 12. Arrangement: Parabola shaped Aluminum reflectors with ETC tubes fixed at their focal point. Advantage: more solar radiation reflected towards the tube increase the water temperature Compound Parabolic Concentrator
  • 13. Linear Fresnel Reflector Parabolic Trough Collector Other Solar Collectors Parabolic Dish Collector
  • 14. Collector efficiencies at different irradiances and temperature differences
  • 15. Solar Heating For Industries Industrial Processes suitable for Solar Drying Electroplating Bleaching Cleaning Cooking Pickling Degreasing Steaming Evaporating Phosphating Preheating Washing
  • 16. Heat Pump - Background Heat is the flow of energy from one body or substance to another due to a difference in temperature.
  • 17. Heat Pump - Background First Law of Thermodynamics – Energy cannot be created or destroyed. It exists in the universe in a fixed amount. It can be stored, and can be transferred from one material to another. Second Law of Thermodynamics - energy generally cannot spontaneously flow from a material at lower temperature to a material at higher temperature.
  • 18. Heat Pump - Background Water does not move spontaneously, but can be pumped from point A to point B, and can even be made to flow uphill by a water pump, powered by an outside source of energy. Likewise, energy can be relocated and elevated (from a lower temperature to a higher temperature) by a heat pump.
  • 19. THE IDEAL VAPOR-COMPRESSION REFRIGERATION CYCLE The vapor-compression refrigeration cycle is the ideal model for refrigeration systems. Schematic and T-s diagram for the ideal vapor-compression refrigeration cycle. This is the most widely used cycle for refrigerators, A-C systems, and heat pumps.
  • 20. ACTUAL VAPOR-COMPRESSION REFRIGERATION CYCLE Schematic and T-s diagram for the actual vapor-compression refrigeration cycle. An actual vapor-compression refrigeration cycle differs from the ideal one in several ways, owing mostly to the irreversibilities that occur in various components, mainly due to fluid friction (causes pressure drops) and heat transfer to or from the surroundings. The COP decreases as a result of irreversibilities. DIFFERENCES Non-isentropic compression Superheated vapor at evaporator exit Subcooled liquid at condenser exit Pressure drops in condenser and evaporator
  • 21. 21 The Compressor • The compressor is the heart of the system. The compressor does just what it’s name is. It compresses the low pressure refrigerant vapor from the evaporator and compresses it into a high pressure vapor.
  • 22. 22 The Condenser • The “Discharge Line” leaves the compressor and runs to the inlet of the condenser. • Because the refrigerant was compressed, it is a hot high pressure vapor (as pressure goes up – temperature goes up). • The hot vapor enters the condenser and starts to flow through the tubes. • As the heat is removed from the refrigerant, it reaches it’s “saturated temperature” and starts to “flash” (change states), into a high pressure liquid. • The high pressure liquid leaves the condenser through the “liquid line” and travels to the “metering device”. Sometimes running through a filter dryer first, to remove any dirt or foreign particles.
  • 23. 23 Metering Devices • Metering devices regulate how much liquid refrigerant enters the evaporator . • Common used metering devices are, small thin copper tubes referred to as “cap tubes”, thermally controller diaphragm valves called “TXV’s” (thermal expansion valves) and single opening “orifices”. • The metering device tries to maintain a preset temperature difference or “super heat”, between the inlet and outlet openings of the evaporator. • As the metering devices regulates the amount of refrigerant going into the evaporator, the device lets small amounts of refrigerant out into the line and looses the high pressure it has behind it. • Now we have a low pressure, cooler liquid refrigerant entering the evaporative coil (pressure went down – so temperature goes down).
  • 24. 24 The Evaporator • Low pressure liquid leaves the metering device and enters the evaporator. • Usually, a fan will move warm air from the conditioned space across the evaporator finned coils. • The cooler refrigerant in the evaporator tubes, absorb the warm room air. The change of temperature causes the refrigerant to “flash” or “boil”, and changes from a low pressure liquid to a low pressure cold vapor. • The low pressure vapor is pulled into the compressor and the cycle starts over. • The amount of heat added to the liquid to make it saturated and change states is called “Super Heat”. • One way to charge a system with refrigerant is by super heat.
  • 25. 1 kW 900 W 90% How Efficient Is Electric Heater ?
  • 26. Ambient Heat Primary power (Electricity) Heat Pump USABLE ENERGY Renewable Energy Conventional Energy Heat Pump
  • 27. 1 kW 1 - 2 kW 2- 3 kW + = Heat is taken in from the ambient The system pumps heat from a low temperature reservoir to a high temperature Heat Pump - Principle
  • 28. Free Cooling DO YOU NEED LIFE LONG FREE AC? HEAT PUMP GIVES YOU FREE COLD WATER UPTO 7 DEG C WHILE SIMULTANEOUSLY PRODUCING HOT WATER AROUND 55 DEG C 7 DEG C 55 DEG C
  • 31. Water Source Heat Pump Hot Water Tank Air Conditioner Water source heat pump 50℃ 8℃ 55℃ 13℃
  • 32. Industrial Application of Solar Thermal and Heat Pump
  • 33. Steam @ 2000C 250C 250C Steam @ 2000C 900C Boiler Feed Solar Assisted Boiler Feed
  • 34. Component Washing Industrial Washing Machine Pre-treatment Plants
  • 39. FUEL IN (100 Litres) COLD WATER IN STEAM / HOT WATER OUT (70%) FLUE GAS OUT + OTHER LOSSES (30%) BOILER EFFICIENCY BOILER EFFICIENCY = 70% Boiler Efficiency
  • 40. Through Fuel Consumption Energy required = Fuel Consumption x Calorific Value x Boiler Efficiency Energy required for Process Fuel Consumption Boiler Efficiency Fuel Calorific Value = 20 x 9422 x 70% = 1,31,908 kcal/hr = 131908/860 Energy required = 154 kW 20 litres/hr 9422 kcal/l 70%
  • 41. Calorific Values Liquid Fuel Fuel kJ/kg kcal/kg (0.239 x kJ/kg) Specific Gravity kcal/litres Diesel 44,800 10707.2 0.88 9422.3 SKO 46,200 11041.8 0.8 8833.4 FO 43,000 10277 0.92 9454.8 Gaseous Fuel Fuel kJ/kg kcal/kg (0.239 x kJ/kg) Propane 50,350 12033.65 LPG 46,100 11017.9 Solid Fuel Fuel kJ/kg kcal/kg (0.239 x kJ/kg) Coal 15,000 3585 Coke 28,000 6692
  • 42. Fuel Calorific Value Litre/kg Boiler Efficiency kW Litre/kg Fuel Price Cost of Energy Spent per kW (Rs) kcal kW Furnace oil 9454.84 11.00 per litre 60% 6.6 per litre 36 5.45 HSD 9422.3 11.00 per litre 60% 6.6 per litre 63 9.55 SKO 8833.3 10.30 per litre 60% 6.18 per litre 50 8.09 LPG 11017.9 13.00 per kg 60% 7.8 per kg 43 5.51 Propane 12033.7 14.00 per kg 60% 8.4 per kg 42 5.00 Coal/Coke 5250 6.00 per kg 60% 3.6 per kg 8 2.22 Briquette (Sugarcane husk) 3996 4.65 per kg 60% 2.79 per kg 4.5 1.61 Electricity 860 1 per unit 95% 0.95 per unit 8 8.42 Calorific Values
  • 43. Fuel Consumption Measurement Method Dedicated Fuel tank Common Fuel Tank Liquid Fuel Gaseous Fuel Flow meter Level Indicator Or Dip Stick
  • 45. Load Calculation CALCULATION TYPES: Through litres per day of water • Canteen & Boiler Feed water application Through Fuel Consumption • Process heating & washing machine applications
  • 46. Through Litres per day of Water Q = m x Cp x ΔT Canteen & Boiler feed application Q = Energy required (kW) m = Mass flow of water in LPD Cp = Specific heat of water (kcal/kg K) ΔT = Temperature difference (deg C) Example: 10000 LPD has to be raised from ambient to 80 deg C Q = 10000 x 1 x (80 – 30) = 500000 kcal = 500000/860 = 581 kWh per day
  • 47. Through Litres per day of Water To design a storage, the main thing to keep in mind We have to produce 24 hours energy in 6 hours solar window
  • 48. Through Litres per day of Water LOAD ESTIMATION FOR SOLAR THERMAL SYSTEM Effective Sunshine hours = 6 hours per Day Solar Thermal Capacity = 𝐓𝐨𝐭𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 𝐩𝐞𝐫 𝐝𝐚𝐲 𝐄𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐒𝐮𝐧𝐬𝐡𝐢𝐧𝐞 𝐇𝐨𝐮𝐫𝐬 =581/6 = 97 kW
  • 49. Through Litres per day of Water LOAD ESTIMATION FOR HEAT PUMP SYSTEM Effective working hours = 16 - 18 hours per Day Heat Pump Capacity = 𝐓𝐨𝐭𝐚𝐥 𝐄𝐧𝐞𝐫𝐠𝐲 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 𝐩𝐞𝐫 𝐝𝐚𝐲 𝐄𝐟𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐖𝐨𝐫𝐤𝐢𝐧𝐠 𝐇𝐨𝐮𝐫𝐬 = 581/16 = 36 kW
  • 50. Through Litres per day of Water Comparison of Solar Thermal VS Heat Pump Load Solar Thermal Capacity = 97 kW Heat Pump Capacity = 36 kW Why the Capacity Required is Lesser for Heat Pump? Heat pump runs for 16 hours whereas Solar Thermal needs to produce the same energy in 6 hours Is the Heat Pump Cheaper? Yes, But there is a RUNNING COST. Heat pump consumes around 40 to 50% of Energy
  • 51. TYPE - 2 Thru Fuel Consumption Amount of Fuel consumed by the Boiler? Boiler Efficiency? Example: Average Fuel consumed by the boiler per hour = 10 Litres of Diesel Calorific value of Diesel = 11 kW per litre Total energy = 110 kWh of Energy With Boiler efficiency of 70%, the effective Output per hour = 110*0.7 = 77 kW
  • 52. TYPE-2: THRU FUEL CONSUMPTION FUEL IN (10 Litres) or 110 kWh COLD WATER IN HOT WATER OUT (70%) or 77 kWh FLUE GAS OUT (30%) BOILER EFFICIENCY BOILER EFFICIENCY = 70%
  • 53. Solar Capacity Actual Energy required for Process Solar Pipe Heat Loss Heat Loss will normally be 10% to 20%
  • 56. Hot Water For Canteen Cooking Steam Boiler Steam Line (>100 degC) To Canteen Utensils for cooking Feed water (25 degC) To cook idly Boil rice
  • 57. With Solar Steam Boiler Steam Line (>100 degC) To Canteen Utensils Pre-heated Feed water (90 degC) For cooking idly To Boil rice Rooftop Solar thermal Installation assisting Boiler From Solar
  • 59. Solar thermal Temperature required Water quantity consumed/day Hours of operation Fuel used & Fuel cost Fuel consumption (per hour/day)
  • 60. Sample data 90 deg C Temperature 10000 litres per day Water quantity NA Operation Hours Diesel Fuel Used Rs. 63/litre Cost of Fuel 70 % Boiler Efficiency
  • 61. Load Estimation Q = m * Cp * (T2-T1) Q – Heat energy required (kcal) m – mass of water consumed for the application(LPD) Cp – Specific heat capacity of water (1 kcal/kg k) T2 – Temperature required for application (°C) or Water outlet temp T1 – Ambient temperature of water (°C) or water inlet temp We can achieve max temp up to 90°C from solar thermal
  • 62. System Capacity Calculation Effective sunshine hours = 6 hours/day So, the Solar Thermal System Capacity = 755 / 6 =126 kW SOLAR THERMAL SYSTEM HEAT PUMP SYSTEM Effective working hours considered = 18 hours/day So, the Heat Pump Capacity = 755 / 18 = 42 kW
  • 63. Description Solar Thermal System Heat Pump System Capacity 126 kW 42 kW Project Cost Rs.63,00,000 Rs.21,00,000 Operational Cost/year Almost nil Rs.8,20,800 Net saving/year Rs.18,52,300 Rs.10,31,200 Payback 3.4 yrs 2.03 yrs Simple payback - HEAT PUMP
  • 69. Boiler Feed Steam Boiler Steam Line (>100 Deg C) Pre-heated Feed water (90 Deg C) Rooftop Solar thermal Installation From Solar To Process applications
  • 73. Temperatures During Sunshine hours the heat energy flows as shown through the red line, through solenoid valves 2 and 3 (1 is off) Integration Schemes
  • 74. During Non-Sunshine hours the heat energy flows as shown through the blue line through solenoid valve 1 (2 and 3 off) Integration Schemes
  • 75. Process heating application Temperature required Fuel Consumed Hours of operation Fuel used Boiler Efficiency Fuel Cost
  • 76. Sample data 65 Deg C Temperature 60 kg/shift of LPG Fuel Consumed 70% Boiler efficiency 8 hrs Operation Hours 6, 8, 7.5, 9, 9, 8.5, 6, 6 Hourly Load pattern/shift (kg/hr) LPG Fuel Used Rs. 55/kg Cost of Fuel
  • 77. Load Estimation Fuel Consumed per hour = 9 kg/hr (during peak load) Calorific value of LPG = 12.8 kW/kg Boiler Efficiency = 70% Energy required for process = Fuel Consumption * Calorific value * Boiler efficiency = 9 * 12.8 * 0.70 = 80.64 kW Total Energy required for one hour = 80.64 kW
  • 78. Solar Thermal Capacity Accounting 10% piping losses = 89.6 kW So, the Solar Thermal System capacity = 90 kW Total committed running hours for Solar annually = 6 hours / day x 300 days = 1800 hours/yr
  • 80. Temperatures Industrial Washing machine Heat Pump Schematic - for Washing machine (Indirect Heating)
  • 81. Washing Machine Temperature required Installed heater capacity Hours of operation Units consumed per hour EB cost/unit
  • 82. • 55 deg C Temperature • 36 kW heater Installed heater capacity •24 Operation Hours •20 kWh Units consumed per hour •Rs. 8/kWh EB Cost Sample data
  • 83. Load Estimation Installed Heater Capacity = 36 kW Units consumed / hour = 20 kWh Units consumed per day = 20 * 24hrs = 480 kWh Heat load required = 20 kWh*0.95 = 19 kW Accounting piping loss (15%)+Stand by time(15%) = 19 kW + 2.85 kW + 2.85 kW = 24.7 kW Heat pump capacity selected = 28kW * which delivers 28kWh per hour
  • 85. • Flow Rate • Velocity • Pressure Drop ∝ to Flow rate • More the flow rate, more the pressure drop and vice versa Pipe Selection Criteria
  • 86. Which size to be selected??
  • 87. 0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 Pressure Drop in m (for 100 mtr of pipeline length) Flow Rate (LPH) Pressure Loss in Pipe line for 100 mtr of Length - Pump Head Calculation 1.5" Pipe Pressure Drop 2" Pressure Drop 2.5" Pressure Drop 3" Pressure Loss Pressure Loss
  • 105.
  • 106.
  • 107. pH is a numeric scale used to specify the acidity or alkalinity of an aqueous solution Effects of pH Acidity Alkalinity Neutral • pH below 6.5 causes erosion of material which results in leakage • pH above 8.5 causes scale formation inside tube.
  • 108. Fluid it transports at what temperature at what pressure it transports commonly used material grades: Mild Steel A53 Carbon Steel A106 Stainless Steel A312 tp304 Stainless Steel A312 tp316 Stainless Steel A312 tp316lL CPVC PPR HDPE PP FRP PVDF Pipe Material Selection
  • 110. How much can Solar Save? Wheels India is saving 1,27,500 Litres of Furnace Oil which amounts to 51 Lakhs per Year Sona Koyo Steering is saving 37,800 Litres of Diesel which amounts to 18.9 Lakhs per Year Ashok Leyland is benefited < 1 year Payback
  • 111. Case Study @ Wheels India Conventional Heat Source Thermic Fluid Boiler Fuel Used Furnace oil Application Pre-treatment Temperature Range 60-75 ⁰C
  • 112. Case Study @ Sona Koyo Conventional Heat Source Hot water generator Fuel Used Diesel Application Pre-treatment Temperature Range 60-75 ⁰C
  • 113. Case Study @ TVS Motors Conventional Heat Source Electrical Heater Application Maintaining DG Head temperature Number of DG sets 4 nos. Temperature Range 60-75 ⁰C Electricity Consumption 1200 kWh per day
  • 114. Case Study @ Harita Seatings Project Size 360 kW Conventional Heat Source LPG Application Pre-Treatment Temperature Range 60-75 ⁰C Fuel Savings 19,000 kg/year CO2 Abatement 53,460 kg/year
  • 115. Case Study @ Pidilite & Pfizer Project Size 48 kW 42 kW Conventional Heat Source Furnace Oil Electricity Application Chemical Curing Sanitation Temperature Range 60 ⁰C 60 ⁰C Fuel Savings 8,700 Litres/year 81,000 kWh/year CO2 Abatement 20,880 kg/year 32,400 kg/year
  • 116. Case Study @ AL, Ennore Existing Process Conventional Heat Source Electrical Heater Application Engine Head washing Temperature Range 50-60 ⁰C Electricity Consumption 24 kWh per hour After Heat Pump Project size 28 kW Present Consumption 12 kWh per hour Units saved per year 86,400 kWh Annual Carbon Abatement 73, 440 kg
  • 117. Case Study @ Brakes India Existing Process Conventional Heat Source Electrical Heater Application Small Auto Components Temperature Range 50-60 ⁰C Electricity Consumption 6 kWh per hour After Heat Pump Project size 14 kW Present Consumption 2.5 kWh per hour Units saved per year 12,500 kWh Annual Carbon Abatement 10, 200 kg
  • 118. Case Study @ Lucas TVS 90 °C Heat Pump – Completed Project Size 160 kW Conventional Heat Source SKO Application Pre-Treatment Temperature Range 70 - 90 ⁰C ZERO Investment from Customer Rs. 8 per MCal Present Cost Rs. 5.5 per MCal Offered Cost Unique PPA Model
  • 119. Be the proud pioneer and save the future… >> Fast Forward to the Solar Future!! >> Contact us @ info@aspirationenergy.com/044-42185301