Energy Analysis within Industrial Hydraulics and Correspondent Solar PV System Design

Energy efficiency and renewable energy use are two main priorities leading to industrial sustainability nowadays according to European Steel Technology Platform (ESTP). Modernization efforts can be done by industries to improve energy consumptions of the production lines. These days, steel making industrial applications are energy and emission intensive. It was estimated that over the past years, energy consumption and corresponding CO2 generation has increased steadily reaching approximately 338.15 parts per million in august 2010 [1]. These kinds of facts and statistics have introduced a lot of room for improvement in energy efficiency for industrial applications through modernization and use of renewable energy sources such as solar Photovoltaic Systems (PV).The purpose of this thesis work is to make a preliminary design and simulation of the solar photovoltaic system which would attempt to cover the energy demand of the initial part of the pickling line hydraulic system at the SSAB steel plant. For this purpose, the energy consumptions of this hydraulic system would be studied and evaluated and a general analysis of the hydraulic and control components performance would be done which would yield a proper set of guidelines contributing towards future energy savings. The results of the energy efficiency analysis showed that the initial part of the pickling line hydraulic system worked with a low efficiency of 3.3%. Results of general analysis showed that hydraulic accumulators of 650 liter size should be used by the initial part pickling line system in combination with a one pump delivery of 100 l/min. Based on this, one PV system can deliver energy to an AC motor-pump set covering 17.6% of total energy and another PV system can supply a DC hydraulic pump substituting 26.7% of the demand. The first system used 290 m2 area of the roof and was sized as 40 kWp, the second used 109 m2 and was sized as 15.2 kWp. It was concluded that the reason for the low efficiency was the oversized design of the system. Incremental modernization efforts could help to improve the hydraulic system energy efficiency and make the design of the solar photovoltaic system realistically possible. Two types of PV systems where analyzed in the thesis work. A method was found calculating the load simulation sequence based on the energy efficiency studies to help in the PV system simulations. Hydraulic accumulators integrated into the pickling line worked as energy storage when being charged by the PV system as well.

Discrepancies in solar irradiation data for Stockholm and Athens

The aim of this study is to evaluate the variation of solar radiation data between different data sources that will be free and available at the Solar Energy Research Center (SERC). The comparison between data sources will be carried out for two locations: Stockholm, Sweden and Athens, Greece. For the desired locations, data is gathered for different tilt angles: 0°, 30°, 45°, 60° facing south. The full dataset is available in two excel files: “Stockholm annual irradiation” and “Athens annual irradiation”. The World Radiation Data Center (WRDC) is defined as a reference for the comparison with other dtaasets, because it has the highest time span recorded for Stockholm (1964–2010) and Athens (1964–1986), in form of average monthly irradiation, expressed in kWh/m2. The indicator defined for the data comparison is the estimated standard deviation. The mean biased error (MBE) and the root mean square error (RMSE) were also used as statistical indicators for the horizontal solar irradiation data. The variation in solar irradiation data is categorized in two categories: natural or inter-annual variability, due to different data sources and lastly due to different calculation models. The inter-annual variation for Stockholm is 140.4kWh/m2 or 14.4% and 124.3kWh/m2 or 8.0% for Athens. The estimated deviation for horizontal solar irradiation is 3.7% for Stockholm and 4.4% Athens. This estimated deviation is respectively equal to 4.5% and 3.6% for Stockholm and Athens at 30° tilt, 5.2% and 4.5% at 45° tilt, 5.9% and 7.0% at 60°. NASA’s SSE, SAM and RETScreen (respectively Satel-light) exhibited the highest deviation from WRDC’s data for Stockholm (respectively Athens). The essential source for variation is notably the difference in horizontal solar irradiation. The variation increases by 1-2% per degree of tilt, using different calculation models, as used in PVSYST and Meteonorm. The location and altitude of the data source did not directly influence the variation with the WRDC data. Further examination is suggested in order to improve the methodology of selecting the location; Examining the functional dependence of ground reflected radiation with ambient temperature; variation of ambient temperature and its impact on different solar energy systems; Im pact of variation in solar irradiation and ambient temperature on system output.

Development of a ESES Solar Thermal Lab on Full Scale System

The main aim of this project is to develop an ESES lab on a full scale system. The solar combisystem used is available most of the time and is only used twice a year to carry out some technical courses. At the moment, there are no other laboratories about combisystems. The experiments were designed in a way to use the system to the most in order to help the students apply the theoretical knowledge in the solar thermal course as well as make them more familiar with solar systems components. The method adopted to reach this aim is to carry out several test sequences on the system, in order to help formulating at the end some educating experiments. A few tests were carried out at the beginning of the project just for the sake of understanding the system and figuring out if any additional measuring equipment is required. The level of these tests sequences was varying from a simple energy draw off or collector loop controller respond tests to more complicated tests, such as the use of the ‘collector’ heater to simulate the solar collector effect on the system. The tests results were compared and verified with the theoretical data wherever relevant. The results of the experiment about the use of the ‘collector’ heater instead of the collector were positively acceptable. Finally, the Lab guide was developed based on the results of these experiments and also the experience gotten while conducting them. The lab work covers the theories related to solar systems in general and combisystems in particular. 

Elbesparing med pelletkaminer och solvärme i direktelvärmda småhus

The aim of this study was to investigate how electricallyheated houses can be converted to using wood pellet and solarheating. There are a large number of wood pellet stoves on themarket. Many stoves have a water jacket, which gives anopportunity to distribute the heat to domestic hot water and aradiator heating system. Three typical Swedish houses with electric resistanceheating have been studied. Fourteen different system conceptsusing wood pellet stoves and solar heating systems have beenevaluated. The systems and the houses have been simulated indetail using TRNSYS. The houses have been divided in up to 10different zones and heat transfer by air circulation throughdoorways and open doors have been simulated. The pellet stoveswere simulated using a recently developed TRNSYS component,which models the start- and stop phases, emissions and thedynamic behaviour of the stoves. The model also calculates theCO-emissions. Simulations were made with one stove without awater jacket and two stoves with different fractions of thegenerated heat distributed in the water circuit. Simulations show that the electricity savings using a pelletstove are greatly affected by the house plan, the systemchoice, if the internal doors are open or closed and thedesired level of comfort. Installing a stove with awater-jacket connected to a radiator system and a hot waterstorage has the advantage that heat can be transferred todomestic hot water and be distributed to other rooms. Suchsystems lead to greater electricity savings, especially inhouses having a traditional layout. It was found that not allrooms needed radiators and that it was more effective in mostcases t use a stove with a higher fraction of the heatdistributed by the water circuit. The economic investigation shows that installing a woodpellet stove without a water jacket gives the lowest totalenergy- and capital costs in the house with an open plan (fortoday's energy prices and the simulated comfort criteria). Inthe houses with a traditional layout a pellet stove givesslightly higher costs than the reference house having onlyelectrical resistance heating due to the fact that less heatingcan be replaced. The concepts including stoves with a waterjacket all give higher costs than the reference system, but theconcept closest to be economical is a system with a bufferstore, a stove with a high fraction of the heat distributed bythe water circuit, a new water radiator heating system and asolar collector. Losses from stoves can be divided into: flue gas lossesincluding leakage air flow when the stove is not in operation;losses during start and stop phases; and losses due to a highair factor. An increased efficiency of the stoves is importantboth from a private economical point of view, but also from theperspective that there can be a lack of bio fuel in the nearfuture also in Sweden. From this point of view it is alsoimportant to utilize as much solar heat as possible. Theutilization of solar heat is low in the simulated systems,depending on the lack of space for a large buffer store. The simulations have shown that the annual efficiency ismuch lower that the nominal efficiency at full power. Thesimulations have also shown that changing the control principlefor the stove can improve efficiency and reduce theCO-emissions. Today's most common control principle for stovesis the on/off control, which results in many starts and stopsand thereby high CO-emissions. A more advanced control varyingthe heating rate from maximum to minimum to keep a constantroom temperature reduces the number of starts and stops andthereby the emissions. Also the efficiency can be higher withsuch a control, and the room temperature will be kept at a moreconstant temperature providing a higher comfort.

Evaluation of a high temperature solar thermal seasonal borehole storage

A solar thermal system with seasonal borehole storage for heating of a residential area in Anneberg, Sweden, approximately 10 km north of Stockholm, has been in operation since late 2002. Originally, the project was part of the EU THERMIE project “Large-scale Solar Heating Systems for Housing Developments” (REB/0061/97) and was the first solar heating plant in Europe with borehole storage in rock not utilizing a heat pump. Earlier evaluations of the system show lower performance than the preliminary simulation study, with residents complaining of a high use of electricity for domestic hot water (DHW) preparation and auxiliary heating. One explanation mentioned in the earlier evaluations is that the borehole storage had not yet reached “steady state” temperatures at the time of evaluation. Many years have passed since then and this paper presents results from a new evaluation. The main aim of this work is to evaluate the current performance of the system based on several key figures, as well as on system function based on available measurement data. The analysis show that though the borehole storage now has reached a quasi-steady state and operates as intended, the auxiliary electricity consumption is much higher than the original design values largely due to high losses in the distribution network, higher heat loads as well as lower solar gains.

European resarch school on large scale solar thermal - SHINE

The Solar HeatIntegration NEtwork (SHINE) is a European research school in which 13 PhDstudents in solar thermal technologies are funded by the EU Marie-Curie program.It has five PhD course modules as well as workshops and seminars dedicated to PhDstudents both within the project as well as outside of it. The SHINE researchactivities focus on large solar heating systems and new applications: ondistrict heating, industrial processes and new storage systems. The scope ofthis paper is on systems for district heating for which there are five PhDstudents, three at universities and two at companies. The PhD students allstarted during the early part of 2014 and their initial work has concentratedon literature studies and on setting up models and data collection to be usedfor validation purposes. The PhD students will complete their studies in2017-18.

Dynamic whole system testing of combined renewable heating systems : the current state of the art

Objective: For the evaluation of the energetic performance of combined renewable heating systems that supply space heat and domestic hot water for single family houses, dynamic behaviour, component interactions, and control of the system play a crucial role and should be included in test methods. Methods: New dynamic whole system test methods were developed based on “hardware in the loop” concepts. Three similar approaches are described and their differences are discussed. The methods were applied for testing solar thermal systems in combination with fossil fuel boilers (heating oil and natural gas), biomass boilers, and/or heat pumps. Results: All three methods were able to show the performance of combined heating systems under transient operating conditions. The methods often detected unexpected behaviour of the tested system that cannot be detected based on steady state performance tests that are usually applied to single components. Conclusion: Further work will be needed to harmonize the different test methods in order to reach comparable results between the different laboratories. Practice implications: A harmonized approach for whole system tests may lead to new test standards and improve the accuracy of performance prediction as well as reduce the need for field tests.

Evaluation of a PVT Air Collector

Hybrid Photovoltaic Thermal (PVT) collectors are an emerging technology that combines PV and solar thermal systems in a single solar collector producing heat and electricity simultaneously. The focus of this thesis work is to evaluate the performance of unglazed open loop PVT air system integrated on a garage roof in Borlänge. As it is thought to have a significant potential for preheating ventilation of the building and improving the PV modules electrical efficiency. The performance evaluation is important to optimize the cooling strategy of the collector in order to enhance its electrical efficiency and maximize the production of thermal energy. The evaluation process involves monitoring the electrical and thermal energies for a certain period of time and investigating the cooling effect on the performance through controlling the air mass flow provided by a variable speed fan connected to the collector by an air distribution duct. The distribution duct transfers the heated outlet air from the collector to inside the building. The PVT air collector consists of 34 Solibro CIGS type PV modules (115 Wp for each module) which are roof integrated and have replaced the traditional roof material. The collector is oriented toward the south-west with a tilt of 29 ᵒ. The collector consists of 17 parallel air ducts formed between the PV modules and the insulated roof surface. Each air duct has a depth of 0.05 m, length of 2.38 m and width of 2.38 m. The air ducts are connected to each other through holes. The monitoring system is based on using T-type thermocouples to measure the relevant temperatures, air sensor to measure the air mass flow. These parameters are needed to calculate the thermal energy. The monitoring system contains also voltage dividers to measure the PV modules voltage and shunt resistance to measure the PV current, and AC energy meters which are needed to calculate the produced electrical energy. All signals recorded from the thermocouples, voltage dividers and shunt resistances are connected to data loggers. The strategy of cooling in this work was based on switching the fan on, only when the difference between the air duct temperature (under the middle of top of PV column) and the room temperature becomes higher than 5 °C. This strategy was effective in term of avoiding high electrical consumption by the fan, and it is recommended for further development. The temperature difference of 5 °C is the minimum value to compensate the heat losses in the collecting duct and distribution duct. The PVT air collector has an area of (Ac=32 m2), and air mass flow of 0.002 kg/s m2. The nominal output power of the collector is 4 kWppv (34 CIGS modules with 115 Wppvfor each module). The collector produces thermal output energy of 6.88 kWth/day (0.21 kWth/m2 day) and an electrical output energy of 13.46 kWhel/day (0.42 kWhel/m2 day) with cooling case. The PVT air collector has a daily thermal energy yield of 1.72 kWhth/kWppv, and a daily PV electrical energy yield of 3.36 kWhel /kWppv. The fan energy requirement in this case was 0.18 kWh/day which is very small compared to the electrical energy generated by the PV collector. The obtained thermal efficiency was 8 % which is small compared to the results reported in literature for PVT air collectors. The small thermal efficiency was due to small operating air mass flow. Therefore, the study suggests increasing the air mass flow by a factor of 25. The electrical efficiency was fluctuating around 14 %, which is higher than the theoretical efficiency of the PV modules, and this discrepancy was due to the poor method of recording the solar irradiance in the location. Due to shading effect, it was better to use more than one pyranometer.

A user guide to simple monitoring and sustainable operation of PV-diesel hybrid systems : Handbook for system users and operators

This report contains a suggestion for a simple monitoring and evaluation guideline for PV-diesel hybrid systems. It offers system users a way to better understand if their system is operated in a way that will make it last for a long time. It also gives suggestions on how to act if there are signs of unfavourable use or failure. The application of the guide requires little technical equipment, but daily manual measurements. For the most part, it can be managed by pen and paper, by people with no earlier experience of power systems.The guide is structured and expressed in a way that targets PV-diesel hybrid system users with no, or limited, earlier experience of power engineering. It is less detailed in terms of motivations for certain choices and limitations, but rich in details concerning calculations, evaluation procedures and maintenance routines. A more scientific description of the guide can be found in a related journal article.

Variation of System Performance with Design and Climate for Combisystems in Sweden

In Sweden, 90% of the solar heating systems are solar domestic hot water and heating systems (SDHW&H), so called combisystems. These generally supply most of the domestic hot water needs during the summer and have enough capacity to supply some energy to the heating system during spring and autumn. This paper describes a standard Swedish combisystem and how the output from it varies with heating load, climate within Sweden, and how it can be increased with improved system design. A base case is defined using the standard combi- system, a modern Swedish single family house and the climate of Stockholm. Using the simulation program Trnsys, parametric studies have been performed on the base case and improved system designs. The solar fraction could be increased from 17.1% for the base case to 22.6% for the best system design, given the same system size, collector type and load. A short analysis of the costs of changed system design is given, showing that payback times for additional investment are from 5-8 years. Measurements on system components in the laboratory have been used to verify the simulation models used. More work is being carried out in order to find even better system designs, and further improvements in system performance are expected.

Provningsmetod för integrerade sol-biosystem : Årsverkningsgrad genom korttidsmätning

Test method for integrated solar- biomass systems - Long term prediction trough short term measurementsSP Technical Research Institute of Sweden and SERC, Dalarna University have in cooperation developed a test method for integrated solar and biomass systems. The test method is performed under six days including two summer days, two winter days and two spring/autumn days true to real weather conditions and loads for a single family house. The aim of the test method is to get information about a Combisystem’s annual performance and operation throughout a short term test. Seven different solar Combisystems have been tested within the project together with a pellet boiler without solar collectors. In addition to that a comparative testing has been performed at the two laboratories at SP and at SERC on the same Combisystem. The test method developed within the project has been proved to withstand the aim of the project, which is to be able to compare the performance between the systems. The test method is also suitable for identification of possible operation problems so they can be taken care of and consequently improves the system.The project and the system testing reveal that it is in general favorable to combine biomass pellets with solar heating. Pellet boilers has normally a low performance during the summer period but combined with a solar collector the boiler can be switch off during this period. There are however big differences in performance between the tested. The efficiency of the pellet boiler is highly dependent of the operating conditions and elements like heat losses from the system, system configuration and control strategy have great influence of the performance of the system and the emissions. On the other hand, the performance and the size of the solar collectors have a minor effect on the overall system performance. There is obviously a big potential for improvement of the system´s performance and the developed test method is an essential way to implement this perfection.

Replacing Finned Copper withCorrugated Stainless Steel, forthe Heat Exchangers of a SolarCombisystem Store : Performance and EconomicEvaluation

The importance of investigating cost reduction in materials and components for solar thermal systems is crucial at the present time. This work focuses on the influence of two different heat exchangers on the performance of a solar thermal system. Both heat exchangers studied are immersed helically coiled, one made with corrugated stainless steel tube, and the other made with finned copper tube with smooth inner surface.A test apparatus has been designed and a simple test procedure applied in order to study heat transfer characteristics and pressure drop of both coils. Thereafter, the resulting experimental data was used to perform a parameter identification of the heat exchangers, in order to obtain a TRNSYS model with its corresponding numerical expression. Also a representative small-scale combisystem model was designed in TRNSYS, in order to study the influence of both heat exchangers on the solar fraction of the system, when working at different flow rates.It has been found that the highest solar fraction is given by the corrugated stainless steel coil, when it works at the lowest flow rate (100 l/hr). For any higher flow rate, the studied copper coil presents a higher solar fraction. The advantageous low flow performance of stainless steel heat exchanger turns out to be beneficial for the particular case of solar thermal systems, where it is well known that low flow collector loops lead to enhanced store stratification, and consequently higher solar fractions.Finally, an optimization of the stainless steel heat exchanger length is carried out, according to economic figures. For the given combisystem model and boundary conditions, the optimum length value is found between 10 and 12 m.

Synsättet på förnyelsebara elkällor inom fastighetsbranschen

För mellan 40-50 år sedan så byggdes en miljon bostäder i Sverige. Idag har arbetet påbörjats med att renovera och restorera dessa bostäder, i samband med dessa åtgärder så görs även många åtgärder för att minska energianvändningen. Syftet med detta arbete var att ta reda på vad som var det mest ekonomiska valet av olika gröna elkällor. Även fastighetsägarnas egna tankar och uppfattningar ställs i relation till slutsatserna vid beräkningarna för att få en uppfattning om det stämmer överens. För att arbetet inte skulle bli för stort och krävande så gjordes dessa avgränsningar:  För att tiden skulle räcka till så avgränsades arbetet till Dalaregionen.  Arbetet har dessutom avgränsats till att bara undersöka ekonomin vid valet av de olika gröna elkällorna. Genom två olika undersökningar med mentometerknappar så kunde resultatet om fastighetsägarnas egna tankar och uppfattningar redovisas och analyseras. Vidare kunde fastighetsägarnas tankar och uppfattningar jämföras med beräkningarna och dessa slutsatser kunde då dras: Slutsatser:  Vindkraft var ej lönsam med dagens elpriser.  Av fastighetsbolag kunde det ses att deltagarna trodde olika på vad som gav bäst lönsamhet mellan vindkraft, solel eller grön el.