Design and Analysis of a Large Solar Industrial Heat Plant for Frito Lay in Modesto California

2007 ◽  
Author(s):  
Andy Walker ◽  
Chuck Kutscher ◽  
Al Halvorsen ◽  
Chris McKenna ◽  
Dave Chambers ◽  
...  
Keyword(s):  
Renewable Energy ◽  
Heat Exchanger ◽  
Steam Generator ◽  
Technical Assistance ◽  
Industrial Process ◽  
Hot Water ◽  
Solar Array ◽  
Design Recommendations ◽  
Process Heat ◽  
Technology Demonstration

Industry-specific technology demonstration projects are key to facilitating deployment of solar industrial process heat technologies. Frito Lay North America (FLNA) is pursuing installation of a solar industrial process heat plant at the manufacturing plant in Modesto CA. FLNA contracted with Industrial Solar Technology Corp. for design and installation of the system and with National Renewable Energy Lab for technical assistance. The US Department of Energy and California Energy Commission both facilitate private companies implementation of technology demonstration projects with incentives, tax policy, and technical assistance. The solar plant would include: 5,387 m2 (57,969 sf) of parabolic trough solar collectors; pipe from solar array to unfired steam generator; unfired steam generator (USG); hot water heat exchanger (HWHX); pipe from hot water heat exchanger back to array field; and associated pumps, bypass piping, and controls. Performance of each component of the solar heating system varies with changing conditions of intensity of the sunlight, position of the sun, and ambient temperature. Since each of these parameters change throughout the day and throughout the seasons an hourly simulation of one year’s performance is performed. The simulation is used to estimate annual energy delivery as well as to inform design recommendations. The solar array inlet temperature is solved for iteratively for each hour of the year based on an energy balance of the entire loop including all components. Nested within this iteration are iterations for the operating temperature of each of the 16 modules in series. Hourly direct beam solar radiation (W/m2) data for Modesto CA for 8 years from 1998–2005 was provided by the National Renewable Energy Laboratory Renewable Resource Data Center and the minimum year, average year, and maximum year were used in the analysis. Results indicate that the system would deliver between 3,898 MWh and 4,308 MWh per year (13.3 and 14.7 billion Btu/year) with an average of 4,044 MWh/year (13.8 billion Btu/year). This average estimate of 13.8 billion Btu/year agrees with the contractors proposal and also with methods described in the Industrial Process Heat Handbook published by NREL. The simulation is able to model more detail and inform design recommendations, such as bypassing the steam generator and only making hot water on winter days.

Cogeneration System Modeling Based on Experimental Results

2010 ◽  
Author(s):  
Flore Marion ◽  
Fred Betz ◽  
David Archer
Keyword(s):  
Heat Exchanger ◽  
Steam Generator ◽  
System Modeling ◽  
Primary Component ◽  
Performance Model ◽  
Operating Conditions ◽  
Hot Water ◽  
Plant Design ◽  
Absorption Chiller ◽  
Cogeneration System

A 25 kWe cogeneration system has been installed by the School of Architecture of Carnegie Mellon University that provides steam and hot water to its Intelligent Workplace, the IW. This cogeneration system comprises a biodiesel fueled engine generator, a steam generator that operates on its exhaust, a hot water heat exchanger that operates on its engine coolant, and a steam driven absorption chiller. The steam and hot water are thus used for cooling, heating, and ventilation air dehumidification in the IW. This cogeneration system is a primary component of an overall energy supply system that halves the consumption of primary energy required to operate the IW. This cogeneration system was completed in September 2007, and extensive tests have been carried out on its performance over a broad range of power and heat outputs with Diesel and biodiesel fuels. In parallel, a detailed systems performance model of the engine generator, its heat recovery exchangers, the steam driven absorption chiller, a ventilation and air dehumidification unit, and multiple fan coil cooling/heating units has been programmed making use of TRNSYS to evaluate the utilization of the heat from the unit in the IW. In this model the distribution of heat from the engine to the exhaust, to the coolant, and directly to the surroundings has been based on an ASHRAE model. While a computational model was created, its complexity made calculation of annual performance excessively time consuming and a simplified model based on experimental data was created. The testing of the cogeneration system at 6, 12, 18 and 25 kWe is now completed and a wealth of data on flow rates, temperatures, pressures throughout the system were collected. These data have been organized in look up tables to create a simplified empirical TRNSYS component for the cogeneration system in order to allow representative evaluation of annual performance of the system for three different mode of operation. Using the look up table, a simple TRNSYS module for the cogeneration system was developed that equates fuel flow to electricity generation, hot water generation via the coolant heat exchanger, and steam production via the steam generator. The different modes of operation for this cogeneration system can be design load: 25 kWe, following the thermal — heating or cooling — load, following the ventilation regeneration load. The calculated annual efficiency for the different mode is respectively 66% 68% and 65%. This cogeneration installation was sized to provide guidance on future cogeneration plant design for small commercial buildings. The new cogeneration TRNSYS component has been created to be applicable in the design of various buildings where a similar cogeneration system could be implemented. It will assist in selection of equipment and of operating conditions to realize an efficient and economic cogeneration system.

scholarly journals Global-Local Heat Demand Development for the Energy Transition Time Frame Up to 2050

Energies ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3814
Author(s):  
Dominik Keiner ◽  
Larissa D.S.N.S. Barbosa ◽  
Dmitrii Bogdanov ◽  
Arman Aghahosseini ◽  
Ashish Gulagi ◽  
...  
Keyword(s):  
Industrial Process ◽  
Energy Transition ◽  
Time Frame ◽  
Hot Water ◽  
Transition Time ◽  
Space Heating ◽  
Efficiency Gain ◽  
Domestic Hot Water ◽  
Heat Demand ◽  
Process Heat

Globally, the heat sector has a major share in energy consumption and carbon emission footprint. To provide reliable mitigation options for space heating, domestic hot water, industrial process heat and biomass for cooking for the energy transition time frame up to the year 2050, energy system modeling relies on a comprehensive and detailed heat demand database in high spatial resolution, which is not available. This study overcomes this hurdle and provides a global heat demand database for the mentioned heat demand types and in a resolution of 145 mesoscale regions up to the year 2050 based on the current heat demand and detailed elaboration of parameters influencing the future heat demand. Additionally, heat demand profiles for 145 mesoscale regions are provided. This research finds the total global heat demand will increase from about 45,400 TWhth in 2012 up to about 56,600 TWhth in 2050. The efficiency measures in buildings lead to a peak of space heating demand in around 2035, strong growth in standards of living leads to a steady rise of domestic hot water consumption, and a positive trend for the worldwide economic development induces a growing demand for industrial process heat, counterbalanced by the efficiency gain in already industrialised countries. For the case of biomass for cooking, a phase-out path until 2050 is presented. Literature research revealed a lack of consensus on future heat demand. This research intends to facilitate a more differentiated discussion on heat demand projections.

Experimental Investigation of Heat Transfer Enhancement by Using Different Number of Fins in Circular Tube

2018 ◽  
Vol 6 (3) ◽  
pp. 1-12
Author(s):  
Kamil Abdul Hussien
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Cold Water ◽  
Finned Tube ◽  
Hot Water ◽  
Copper Tube ◽  
Smooth Tube ◽  
Tube Heat Exchanger ◽  
Mass Flow Rates ◽  
Flow Heat

Abstract-The present work investigates the enhancement of heat transfer by using different number of circular fins (8, 10, 12, 16, and 20) in double tube counter flow heat exchanger experimentally. The fins are made of copper with dimensions 66 mm OD, 22 mm ID and 1 mm thickness. Each fin has three of 14 mm diameter perforations located at 120o from each to another. The fins are fixed on a straight smooth copper tube of 1 m length, 19.9 mm ID and 22.2 mm OD. The tube is inserted inside the insulated PVC tube of 100 mm ID. The cold water is pumped around the finned copper tube, inside the PVC, at mass flow rates range (0.01019 - 0.0219) kg/s. The Reynold's number of hot water ranges (640 - 1921). The experiment results are obtained using six double tube heat exchanger (1 smooth tube and the other 5 are finned one). The results, illustrated that the heat transfer coefficient proportionally with the number of fin. The results also showed that the enhancement ratio of heat transfer for finned tube is higher than for smooth tube with (9.2, 10.2, 11.1, 12.1 13.1) times for number of fins (8, 10, 12, 16 and 20) respectively.

scholarly journals Analysis and Optimization of a Novel Hexagonal Waveguide Concentrator for Solar Thermal Applications

Energies ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 2146
Author(s):  
Karunesh Kant ◽  
Karthik Nithyanandam ◽  
Ranga Pitchumani
Keyword(s):  
Industrial Process ◽  
Cost Effective ◽  
Solar Irradiation ◽  
Maintenance Cost ◽  
Solar Concentrator ◽  
Thermal Desalination ◽  
Process Heat ◽  
Solar Thermal Applications ◽  
The Cost ◽  
Operation And Maintenance Cost

This paper analyzes a novel, cost-effective planar waveguide solar concentrator design that is inspired by cellular hexagonal structures in nature with the benefits of facile installation and low operation and maintenance cost. A coupled thermal and optical analysis of solar irradiation through an ideal hexagonal waveguide concentrator integrated with a linear receiver is presented, along with a cost analysis methodology, to establish the upper limit of performance. The techno-economic model, coupled with numerical optimization, is used to determine designs that maximized power density and minimized the cost of heat in the temperature range of 100–250 °C, which constitutes more than half of the industrial process heat demand. Depending on the incident solar irradiation and the application temperature, the cost of heat for the optimal design configuration ranged between 0.1–0.27 $/W and 0.075–0.18 $/W for waveguide made of ZK7 glass and polycarbonate, respectively. A techno-economic analysis showed the potential of the technology to achieve cost as low as 80 $/m2 and 61 $/m2 for waveguide made of ZK7 glass and polycarbonate material, respectively, which is less than half the cost of state-of-the-art parabolic trough concentrators. Overall, the hexagonal waveguide solar concentrator technology shows immense potential for decarbonizing the industrial process heat and thermal desalination sectors.

scholarly journals Effect of Twisted Fin Array in a Triple-Tube Latent Heat Storage System during the Charging Mode

2021 ◽  
Vol 13 (5) ◽  
pp. 2685
Author(s):  
Mohammad Ghalambaz ◽  
Jasim M. Mahdi ◽  
Amirhossein Shafaghat ◽  
Amir Hossein Eisapour ◽  
Obai Younis ◽  
...  
Keyword(s):  
Energy Storage ◽  
Heat Exchanger ◽  
Latent Heat ◽  
Thermal Energy ◽  
Heat Storage ◽  
Hot Water ◽  
Melting Time ◽  
Latent Heat Storage ◽  
Tube Heat Exchanger ◽  
Storage Rate

This study aims to assess the effect of adding twisted fins in a triple-tube heat exchanger used for latent heat storage compared with using straight fins and no fins. In the proposed heat exchanger, phase change material (PCM) is placed between the middle annulus while hot water is passed in the inner tube and outer annulus in a counter-current direction, as a superior method to melt the PCM and store the thermal energy. The behavior of the system was assessed regarding the liquid fraction and temperature distributions as well as charging time and energy storage rate. The results indicate the advantages of adding twisted fins compared with those of using straight fins. The effect of several twisted fins was also studied to discover its effectiveness on the melting rate. The results demonstrate that deployment of four twisted fins reduced the melting time by 18% compared with using the same number of straight fins, and 25% compared with the no-fins case considering a similar PCM mass. Moreover, the melting time for the case of using four straight fins was 8.3% lower than that compared with the no-fins case. By raising the fins’ number from two to four and six, the heat storage rate rose 14.2% and 25.4%, respectively. This study presents the effects of novel configurations of fins in PCM-based thermal energy storage to deliver innovative products toward commercialization, which can be manufactured with additive manufacturing.

scholarly journals Self-Sufficiency and Energy Savings of Renewable Thermal Energy Systems for an Energy-Sharing Community

Energies ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 4284
Author(s):  
Min-Hwi Kim ◽  
Youngsub An ◽  
Hong-Jin Joo ◽  
Dong-Won Lee ◽  
Jae-Ho Yun
Keyword(s):  
Renewable Energy ◽  
Energy Storage ◽  
Thermal Energy ◽  
Thermal Energy Storage ◽  
Energy Systems ◽  
Hot Water ◽  
Pump System ◽  
Ground Source Heat Pumps ◽  
Self Sufficiency ◽  
Energy Sharing

Due to increased grid problems caused by renewable energy systems being used to realize zero energy buildings and communities, the importance of energy sharing and self-sufficiency of renewable energy also increased. In this study, the energy performance of an energy-sharing community was investigated to improve its energy efficiency and renewable energy self-sufficiency. For a case study, a smart village was selected via detailed simulation. In this study, the thermal energy for cooling, heating, and domestic hot water was produced by ground source heat pumps, which were integrated with thermal energy storage (TES) with solar energy systems. We observed that the ST system integrated with TES showed higher self-sufficiency with grid interaction than the PV and PVT systems. This was due to the heat pump system being connected to thermal energy storage, which was operated as an energy storage system. Consequently, we also found that the ST system had a lower operating energy, CO2 emissions, and operating costs compared with the PV and PVT systems.

scholarly journals Estimation of Energy Activity and Flexibility Range in Smart Active Residential Building

Smart Cities ◽  
2019 ◽  
Vol 2 (4) ◽  
pp. 471-495
Author(s):  
Viktor Stepaniuk ◽  
Jayakrishnan Pillai ◽  
Birgitte Bak-Jensen ◽  
Sanjeevikumar Padmanaban
Keyword(s):  
Renewable Energy ◽  
Energy Management ◽  
Storage Tank ◽  
Residential Buildings ◽  
Renewable Energy Sources ◽  
Hot Water ◽  
Active Management ◽  
Worst Case ◽  
And Storage ◽  
Storage Units

The smart active residential buildings play a vital role to realize intelligent energy systems by harnessing energy flexibility from loads and storage units. This is imperative to integrate higher proportions of variable renewable energy generation and implement economically attractive demand-side participation schemes. The purpose of this paper is to develop an energy management scheme for smart sustainable buildings and analyze its efficacy when subjected to variable generation, energy storage management, and flexible demand control. This work estimate the flexibility range that can be reached utilizing deferrable/controllable energy system units such as heat pump (HP) in combination with on-site renewable energy sources (RESs), namely photovoltaic (PV) panels and wind turbine (WT), and in-house thermal and electric energy storages, namely hot water storage tank (HWST) and electric battery as back up units. A detailed HP model in combination with the storage tank is developed that accounts for thermal comforts and requirements, and defrost mode. Data analytics is applied to generate demand and generation profiles, and a hybrid energy management and a HP control algorithm is developed in this work. This is to integrate all active components of a building within a single complex-set of energy management solution to be able to apply demand response (DR) signals, as well as to execute all necessary computation and evaluation. Different capacity scenarios of the HWST and battery are used to prioritize the maximum use of renewable energy and consumer comfort preferences. A flexibility range of 22.3% is achieved for the scenario with the largest HWST considered without a battery, while 10.1% in the worst-case scenario with the smallest HWST considered and the largest battery. The results show that the active management and scheduling scheme developed to combine and prioritize thermal, electrical and storage units in buildings is essential to be studied to demonstrate the adequacy of sustainable energy buildings.

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