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.

Active cooling of low-concentrating hybrid PV/Thermal collectors

A series of measurements on the performance of solar cell string modules with low-concentrating CPC reflectors with a concentration factor C ˜ 4X have been carried out. To minimise the reduction in efficiency due to high cell temperatures, the modules were cooled. Four different way of cooling were tested:1) The thermal mass of the module was increased, 2) passive air cooling was used by introducing a small air gap between the module and the reflector, 3) the PV cells were cooled by a large cooling fin, 4) the module was actively cooled by circulating cold water on the back. The best performance was given with the actively cooled PV module which gave 2,2 times the output from a reference module while for the output from the module with a cooling fin the value was 1,8.Active cooling is also interesting due to the possibility of co-generation of thermal and electrical energy which is discussed in the paper. Simulations, based on climate data from Stockholm, latitude 59.4°N, show that there are good prospects for producing useful temperatures of the cooling fluid with only a slightly reduced performance of the electrical fraction of the PV thermal hybrid system.

PV-Wind Hybrid Systems for Swedish Locations

PV-Wind-Hybrid systems for stand-alone applications have the potential to be more cost efficient compared to PV-alone systems. The two energy sources can, to some extent, compensate each others minima. The combination of solar and wind should be especially favorable for locations at high latitudes such as Sweden with a very uneven distribution of solar radiation during the year. In this article PV-Wind-Hybrid systems have been studied for 11 locations in Sweden. These systems supply the household electricity for single family houses. The aim was to evaluate the system costs, the cost of energy generated by the PV-Wind-Hybrid systems, the effect of the load size and to what extent the combination of these two energy sources can reduce the costs compared to a PV-alone system. The study has been performed with the simulation tool HOMER developed by the National Renewable Energy Laboratory (NREL) for techno-economical feasibility studies of hybrid systems. The results from HOMER show that the net present costs (NPC) for a hybrid system designed for an annual load of 6000 kWh with a capacity shortage of 10% will vary between $48,000 and $87,000. Sizing the system for a load of 1800 kWh/year will give a NPC of $17,000 for the best and $33,000 for the worst location. PV-Wind-Hybrid systems are for all locations more cost effective compared to PV-alone systems. Using a Hybrid system is reducing the NPC for Borlänge by 36% and for Lund by 64%. The cost per kWh electricity varies between $1.4 for the worst location and $0.9 for the best location if a PV-Wind-Hybrid system is used.

Evaluation of a micro PV-Wind hybrid system in Nordic climate conditions

A one year data analysis for a micro PV-Wind hybrid system (0.52 kW + 1 kW), installed in Borlänge/Sweden is presented in this paper. The system performance was evaluated according the guidelines of the IEC 61724 standard. The parameters obtained allow a comparison with similar systems. The measurement data are also used to evaluate the sizing and operation of the hybrid system. In addition, the system was modelled in HOMER to study sizing options.

A computer study of the improvement of PV panel monthly outputs when the panel azimuth is changed thrice daily

The purpose of the calculations was to estimate the most suitable slopes and azimuths for three different positions per day of a solar panel in order to obtain the most possible energy from the PV panel compared with a stationary PV panel. The calculations were made in the computer program PV F-CHART.

A testing and demonstration facility for PV systems and components

A test and demonstration facility for PV and PV hybrid systems and system components has been designed and installed at Dalarna University in Sweden. The facility allows studies of complete PV systems or single components in a range of 0.1-10 kW. The facility includes two grid-connected PV systems, a PV Hybrid off-grid system, three emulators and the necessary measurement and control equipment. Tests can be done manually or automatically through programmed test procedures controlled that will be implemented in Labview. The facility shall be used by researchers, professionals of the industry and engineering students.

Energy Storage for a Grid-Connected PV-System: A Feasibility Study

The work presented in this thesis concerns the dimensioning of an Energy Storage System (ESS) which will be used as an energy buffer for a grid-connected PV plant. This ESS should help managing the PV plant to inject electricity into the grid according to the requirements of the grid System Operator. It is desired to obtain a final production not below 1300kWh/kWp with a maximum ESS budget of 0.9€/Wp. The PV plant will be sited in Martinique Island and connected to the main grid. This grid is a small one where the perturbations due clouds in the PV generation are not negligible anymore. A software simulation tool, incorporating a model for the PV-plant production, the ESS and the required injection pattern of electricity into the grid has been developed in MS Excel. This tool has been used to optimize the relevant parameters defining the ESS so that the feed-in of electricity into the grid can be controlled to fulfill the conditions given by the System Operator. The inputs used for this simulation tool are, besides the conditions given by the System Operator on the allowed injection pattern, the production data from a similar PV-plant in a close-by location, and variables for defining the ESS. The PV production data used is from a site with similar climate and weather conditions as for the site on the Martinique Island and hence gives information on the short term insolation variations as well as expected annual electricity production. The ESS capacity and the injected electric energy will be the main figures to compare while doing an economic study of the whole plant. Hence, the Net Present Value, Benefit to Cost method and Pay-back period studies are carried on as dependent of the ESS capacity. The conclusion of this work is that it is possible to obtain the requested injection pattern by using an ESS. The design of the ESS can be made within an acceptable budget. The capacity of ESS to link with the PV system depends on the priorities of the final output characteristics, and it also depends on which economic parameter that is chosen as a priority.

Evaluation of a Micro PV-Diesel Hybrid System in Tanzania

In April 2011 a monitoring system was installed to enable studies of the performance and the usage of a micro PV-Diesel Hybrid system at the Ihushi Development Center (IDC) near Mwanza in Tanzania. Estimations of the load have been obtained by a survey of installed appliances and interviews with users of installed equipment. The load profile obtained by measurements has been analyzed and compared to estimations of the energy use. Further, the system size and performance were studied.

Thermal Evaluation of a Solarus PV-T collector

Low concentrator PV-T hybrid systems produce both electricity and thermal energy; this fact increases the overall efficiency of the system and reduces the cost of solar electricity. These systems use concentrators which are optical devices that concentrate sunlight on to solar cells and reduce expensive solar cell area. This thesis work deals with the thermal evaluation of a PV-T collector from Solarus.Firstly the thermal efficiency of the low concentrator collector was characterized for the thermal-collector without PV cells on the absorber. Only two types of paint were on the absorber, one for each trough of the collector. Both paints are black one is glossy and the other is dull,. The thermal efficiency at no temperature difference between collector and ambient for these two types of paint was 0.65 and 0.64 respectively; the U-value was 8.4 W/m2°C for the trough with the glossy type of paint and 8.6 W/m2°C for the trough with dull type of paint. The annual thermal output of these two paints was calculated for two different geographic locations, Casablanca, Morocco and Älvkarleby, Sweden.Secondly the thermal efficiency was defined for the PV-T collector with PV cells on the absorber. The PV cells cover 85% of the absorber, without any paint on the rest of the absorber area. We also tested how the electrical power output influences the thermal power output of the PV-T collector. The thermal and total performances for the PV-T collector were only characterized with reflector sides, because of the lack of time we could not characterize them with transparent sides also.

Performance Evaluation of Different PV-Array Configurations under Weak Light Conditions and Partial Shadings

The paper analyses empirical performance data of five commercial PV-plants in Germany. The purpose was on one side to investigate the weak light performance of the different PV-modules used. On the other hand it was to quantify and compare the shading losses of different PV-array configurations. The importance of this study relies on the fact that even if the behavior under weak light conditions or the shading losses might seem to be a relatively small percentage of the total yearly output; in projects where a performance guarantee is given, these variation can make the difference between meeting or not the conditions.When analyzing the data, a high dispersion was found. To reduce the optical losses and spectral effects, a series of data filters were applied based on the angle of incidence and absolute Air Mass. To compensate for the temperature effects and translate the values to STC (25°C), five different methods were assessed. At the end, the Procedure 2 of IEC 60891 was selected due to its relative simplicity, usage of mostly standard parameters found in datasheets, good accuracy even with missing values, and its potential to improve the results when the complete set of inputs is available.After analyzing the data, the weak light performance of the modules did not show a clear superiority of a certain technology or technology group over the others. Moreover, the uncertainties in the measurements restrictive the conclusiveness of the results.In the partial shading analysis, the landscape mounting of mc-Si PV-modules in free-field showed a significantly better performance than the portrait one. The cross-table string using CIGS modules did not proved the benefits expected and performed actually poorer than a regular one-string-per-table layout. Parallel substrings with CdTe showed a proper functioning and relatively low losses. Among the two product generations of CdTe analyzed, none showed a significantly better performance under partial shadings.

COMPARISON OF PARTIAL SHADING LOSSES IN FREE FIELD PV-PLANTS WITH DIFFERENT ARRAY CONFIGURATIONS

A common problem when planning large free field PV-plants is optimizing the ground occupation ratio while maintaining low shading losses. Due to the complexity of this task, several PV-plants have been built using various configurations. In order to compare the shading losses of different PV technologies and array designs, empirical performance data of five free field PV-plants operating in Germany was analyzed. The data collected comprised 140 winter days from October 2011 until March 2012. The relative shading losses were estimated by comparing the energy output of selected arrays in the front rows (shading-free) against that of shaded arrays in the back rows of the same plant. The results showed that landscape mounting with mc-Si PV-modules yielded significantly better results than portrait one. With CIGS modules, making cross-table strings using the lower modules was not beneficial as expected and had more losses than a one-string-per-table layout. Parallel substrings with CdTe showed relatively low losses. Among the two CdTe products analyzed, none showed a significantly better performance.

Solar PV Powered Air Conditioner Analysis for an Office/Classroom in a Tropical Climate

This thesis focuses on using photovoltaic produced electricity to power air conditioners in a tropical climate. The study takes place in Surabaya, Indonesia at two different locations the classroom, located at the UBAYA campus and the home office, 10 km away. Indonesia has an average solar irradiation of about 4.8 kWh/m²/day (PWC Indonesia, 2013) which is for ideal conditions for these tests. At the home office, tests were conducted on different photovoltaic systems. A series of measuring devices recorded the performance of the 800 W PV system and the consumption of the 1.35 kW air conditioner (cooling capacity). To have an off grid system many of the components need to be oversized. The inverter has to be oversized to meet the startup load of the air conditioner, which can be 3 to 8 times the operating power (Rozenblat, 2013). High energy consumption of the air conditioner would require a large battery storage to provide one day of autonomy. The PV systems output must at least match the consumption of the air conditioner. A grid connect system provides a much better solution with the 800 W PV system providing 80 % of the 3.5 kWh load of the air conditioner, the other 20 % coming from the grid during periods of low irradiation. In this system the startup load is provided by the grid so the inverter does not need to be oversized. With the grid-connected system, the PV panel’s production does not need to match the consumption of the air conditioner, although a smaller PV array will mean a smaller percentage of the load will be covered by PV. Using the results from the home office tests and results from measurements made in the classroom. Two different PV systems (8 kW and 12 kW) were simulated to power both the current air conditioners (COP 2.78) and new air conditioners (COP 4.0). The payback period of the systems can vary greatly depending on if a feed in tariff is awarded or not. If the feed in tariff is awarded the best system is the 12 kW system, with a payback period of 4.3 years and a levelized cost of energy at -3,334 IDR/kWh. If the feed in tariff is not granted then the 8 kW system is the best choice with a lower payback period and lower levelized cost of energy than the 12 kW system under the same conditions.

System Integration of PV/T Collectors in Solar Cooling Systems

The demand for cooling and air-conditioning of building is increasingly ever growing. This increase is mostly due to population and economic growth in developing countries, and also desire for a higher quality of thermal comfort. Increase in the use of conventional cooling systems results in larger carbon footprint and more greenhouse gases considering their higher electricity consumption, and it occasionally creates peaks in electricity demand from power supply grid. Solar energy as a renewable energy source is an alternative to drive the cooling machines since the cooling load is generally high when solar radiation is high. This thesis examines the performance of PV/T solar collector manufactured by Solarus company in a solar cooling system for an office building in Dubai, New Delhi, Los Angeles and Cape Town. The study is carried out by analyzing climate data and the requirements for thermal comfort in office buildings. Cooling systems strongly depend on weather conditions and local climate. Cooling load of buildings depend on many parameters such as ambient temperature, indoor comfort temperature, solar gain to the building and internal gains including; number of occupant and electrical devices. The simulations were carried out by selecting a suitable thermally driven chiller and modeling it with PV/T solar collector in Polysun software. Fractional primary energy saving and solar fraction were introduced as key figures of the project to evaluate the performance of cooling system. Several parametric studies and simulations were determined according to PV/T aperture area and hot water storage tank volume. The fractional primary energy saving analysis revealed that thermally driven chillers, particularly adsorption chillers are not suitable to be utilizing in small size of solar cooling systems in hot and tropic climates such as Dubai and New Delhi. Adsorption chillers require more thermal energy to meet the cooling load in hot and dry climates. The adsorption chillers operate in their full capacity and in higher coefficient of performance when they run in a moderate climate since they can properly reject the exhaust heat. The simulation results also indicated that PV/T solar collector have higher efficiency in warmer climates, however it requires a larger size of PV/T collectors to supply the thermally driven chillers for providing cooling in hot climates. Therefore using an electrical chiller as backup gives much better results in terms of primary energy savings, since PV/T electrical production also can be used for backup electrical chiller in a net metering mechanism.

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.