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Abstract
A large number of industrial processes demand thermal energy in the temperature range of 80240 C. In this temperature range, solar
thermal systems have a great scope of application. However, the challenge lies in the integration of a periodic, dilute and variable solar
input into a wide variety of industrial processes. Issues in the integration are selection of collectors, working uid and sizing of components. Application specic congurations are required to be adopted and designed. Analysis presented in this paper lays an emphasis on
the component sizing. The same is done by developing a design procedure for a specic conguration. The specic conguration consists
of concentrating collectors, pressurized hot water storage and a load heat exchanger. The design procedure follows a methodology called
design space approach. In the design space approach a mathematical model is built for generation of the design space. In the generation
of the design space, design variables of concern are collector area, storage volume, solar fraction, storage mass ow rate and heat exchanger size. Design space comprises of constant solar fraction curves traced on a collector area versus storage volume diagram. Results of the
design variables study demonstrate that a higher maximum storage mass ow rates and a larger heat exchanger size are desired while
limiting storage temperature should be as low as possible. An economic optimization is carried out to design the overall system. In economic optimization, total annualized cost of the overall system has been minimized. The proposed methodology is demonstrated through
an illustrative example. It has been shown that 23% reduction in the total system cost may be achieved as compared to the existing design.
The proposed design tool oers exibility to the designer in choosing a system conguration on the basis of desired performance and
economy.
2008 Elsevier Ltd. All rights reserved.
Keywords: Design space; Industrial applications; Pressurized hot water storage; System integration; Solar thermal; Optimization
1. Introduction
A large number of industrial processes demand thermal
energy in the temperature range of 80240 C (Proctor
and Morse, 1977; Kalogirou, 2003). Solar thermal at plate
collectors are not suitable for very high temperature applications. For high temperature applications, dierent solar
concentrators may be employed. A number of solar indus-
0038-092X/$ - see front matter 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.solener.2008.02.011
687
Nomenclature
collector area, m2
heat exchanger area, m2
surface area of the storage tank, m2
collector cost coecient including accessories
and piping, Rs/m2
Chx
capital cost of heat exchanger, US$/kW/C
COM
annual operation and maintenance cost, US$/y
CF
fuel price, US$/kg
Cpc
specic heat of cold stream uid, J/kg C
Cph
specic heat of hot stream uid, J/kg C
CR
cost function of auxiliary water heater, US$/kW
Cst
storage system cost coecient including piping
and insulation, US$/m2
CRFc capital recovery factor of collector and storage
systems, y1
CRFaux capital recovery factor of auxiliary heater, y1
CRFhx capital recovery factor of heat exchanger, y1
(CV)F caloric value of fuel, J/kg
Dst
average storage tank diameter, m
F
solar fraction over a specied time horizon, estimated
Fs
solar fraction over a specied time horizon, desired
FR
collector heat removal factor
h/d
height to diameter ratio of the storage tank
Ibn
beam normal solar radiation intensity, W/m2
IT
solar radiation intensity on tilted surface, W/m2
k
thermal conductivity of storage tank insulation,
W/m K
mc
cold stream mass ow rate of heat exchanger,
kg/s
mh
hot stream mass ow rate of heat exchanger, kg/s
mL
desired load mass ow rate, kg/s
mst
storage mass ow rate to heat exchanger, kg/s
N
number of transfer units of heat exchanger
n
expected life of collectors and storage, y
nL
number of hours of load/day
naux
expected life of auxiliary heater, y
P
cold or hot uid temperature eectiveness
Pd
storage tank design pressure, bar
Ps
saturation pressure corresponding to the limiting storage temperature.
Pmax
maximum storage tank operating pressure, bar
qaux
auxiliary energy required, W
Qaux
auxiliary energy required over a specied time
horizon, J
qL
desired hot water load, W
QL
desired hot water load over a specied time horizon, J
qLs
load met by solar energy or energy extracted
from the storage, W
QLs
load met by solar energy over a specied time
horizon, J
Ac
A
Ast
Ccoll
qs
Qs
qstl
R
Ra
Rb
r
T
TAC
Ta
Tci
Tco
Tco,min
Thi
Tho
TL
TR
Tst
Tsti
Tstf
t
tins
tt
tca
UA
Ust
UL
Vst
Greek symbols
h
incident angle
gaux
eciency of auxiliary heater
go
average optical eciency of the concentrator
q
density of working uid, kg/m3
qt
density of storage tank material, kg/m3
rd
design hoop stress for storage tank material,
MPa
(sa)
average transmittance absorptance product
Abbreviations
AUX auxiliary
HX
heat exchanger
ISO
organization for international standards
LDO light diesel oil
LMTD logarithmic mean temperature dierence
US$
united states dollar
688
dT st
Ac I T F R sa F R U L T st T a
dt
qLs U st Ast T st T a
Solution of dierential equation (1) enables one to calculate the storage temperature (Tstf) at the end of a time step:
Ac I T F R sa Ac F R U L T stf T a qLs U st Ast T stf T a
Ac I T F R sa Ac F R U L T sti T a qLs U st Ast T sti T a
Ac F R U L U st Ast t
exp
qC p V st
3
For a given type of collector, storage and load characteristics, Eq. (3) uniquely predicts the storage temperature over
a period of time. The storage temperature is a function of
collector area and storage volume. In this analysis, it is
Load pump
Flat plate Solar
Collectors
Storage
Tank
Tst
Load
Pump
Make up
water
By varying the collector area and the storage volume, different feasible designs may be obtained. For illustration,
a case of unity solar fraction is described. Unity solar fraction suggests that the entire thermal demand has to be met
by the solar energy. For satisfying the entire thermal demand, storage tank temperature during the time of the demand must be greater than the desired load temperature:
120
Storage temperature, C
T st 6 100 C
80
solar fraction
60
Load
Temp.60 C
ISO
Load
profile
40
20
10
12
14
16
18
20
22
24
Time,h
Fig. 2. Load and storage temperature prole over a typical day.
10000
Storage volume,cu.m
Since, water at the atmospheric pressure, is used as a working uid, the storage tank temperature has to be less than
100 C:
T st P T L
689
Volume
limits for
a given
area
1000
b
Feasible design region
(Design space)
100
m
10
Vmin
1
75
A min
100
125
150
175
200
225
250
Collector area,sq.m
Fig. 3. Design space for F = 1.
minimum collector area design. The design occurs at a collector area of 76 m2 and storage volume of 28 m3. Any
decrease in the collector area from m will not meet the
desired hot water demand.
It may also be noted that there exists a minimum as well
as a maximum storage volume for a given collector area.
For example, a constant collector area line (Ac = 111 m2)
in Fig. 3 intersects the limiting curves at a and b. Point
a indicates a minimum limit on storage volume of
2.6 m3,while point b indicates a maximum limit of
1227.2 m3. Beyond point b, thermal losses from the storage
tank will dominate resulting into a loss of solar fraction.
Similarly, there exists a minimum as well as a maximum
collector area for a given storage volume. It is illustrated
in Fig. 3 through points m and o. The line segment ma in Fig. 3 signies the Pareto optimality curve.
The region bounded by the limiting curves includes all
feasible designs of the system and is called the design space
(Kulkarni et al., 2007). Similar to the above procedure, the
design space can be identied by tracing constant solar
Table 1
Solar system parameters
Location
Load
Collectors
Storage
690
fraction lines for other solar fractions. Any objective function involving the capital and the operating costs of the system may be chosen for optimization of the overall system.
A more elaborate treatment of design space is given by
Kulkarni et al. (2007). Application of the design space
approach has been demonstrated for solar thermal system
operating up to 100 C. A large number of industrial and
commercial applications demand solar thermal energy
beyond 100 C. Utility of the design space methodology
is therefore, improved and extended for systems operating
beyond 100 C.
The limiting storage temperature determines the maximum operating pressure of the system and the thickness
of the storage tank. For simplication, it is assumed that
the type of heat exchanger and its size may be characterized
and selected on the basis of UA product. UA product represents the output of a heat exchanger for a unit logarithmic temperature dierence (LMTD). Design procedure
proposed here uses UA product as a heat exchanger sizing
parameter. A mathematical model of the system is developed in the following section.
3.2. Mathematical model of the system
Energy balance of a well mixed storage tank can be
expressed as
qC p V st
dT st
qs qLs qstl
dt
Pressurized
hot water
Storage
mst
Solar
Concentrator
Thi
Load
pump
Tco
HX
AUX
Load
Tst = Thi
Tho
Tci
mc
characteristic equation for a solar collector. For high temperature applications and for concentrating collectors, this
may not always be suitable. For such systems, a second or
higher order characteristic equation may be more suitable.
For more accurate results, a non-linear characteristic equation should be used instead of (9). The proposed methodology is independent of the nature of the characteristic
equation. However, for the system, for which the methodology is demonstrated, it has been observed that an accurate non-linear characteristic equation does not improve
the system sizing signicantly (Kulkarni, 2008).
Solar ux incident on the aperture of a tracking concentrator is calculated as
I T I bn cos h
10
Combining Eqs. (8) and (9) with Eq. (7), energy balance of
the tank can be expressed as
qC p V st
dT st
Ac I T F R go F R U L T st T a
dt
qLs U st Ast T st T a
11
12
13
14
15
T ho T st P T st T ci
16a
16b
17
With known P and R, the cold process stream outlet temperature can also be determined:
T co T ci PRT st T ci
18
QL
nL tmc C pc
19
By knowing the hot stream outlet temperature, solar contribution to the load during a time step may be determined.
In Eq. (19), desired load (QL) over a time horizon (a day)
and duration of load in nL time steps (number of hours)
is specied. The load is assumed to be uniformly distributed over the time steps. Cold stream mass ow rate (mc)
and inlet temperature (Tci) are assumed to be constant in
this analysis. No auxiliary energy will be required if
Tco P Tco,min. In all the cases, hot stream ow rate is controlled in such away that cold stream outlet temperature
does not exceed Tco,min. This ensures eective utilization
of the solar energy. Auxiliary energy is required if Tco <
Tco,min and the same is determined as
qaux mc C pc T co;min T co
20
System parameters are evaluated on the basis of initial storage temperature (Tsti). Final storage temperature at the end
of a time step t is obtained by solving Eq. (11) numerically:
t
Ac I T F R go Ac F R U L T sti T a
T stf T sti
qC p V st
21
mh C ph T sti T ho U st T sti T a
The nal storage temperature at the end of a time step will
be the initial temperature for the next time step. Storage
temperature prole over a day is thus, obtained. The maximum storage temperature (Tst,max) observed in a day is
identied. In this model, the maximum storage operating
pressure is the saturation pressure of water corresponding
to the maximum storage temperature. The correlation proposed by Chopey (2004) is used to determine the saturation
pressure of water corresponding to the maximum storage
temperature.
In the industrial practice, the design pressure pd for the
pressure vessel is usually taken to be 1.5 times the maximum operating pressure Ps. Storage tank thickness is calculated using the hoop stress equation (Brownell and
Young, 1959).
tt
for R 6 1
691
pd Dst
tca
4rd
22
692
800
700
600
500
400
300
200
100
0
10
12
14
16
18
Table 2
Input data for pressurized hot water storage system example
Location
Load
Collectors
Storage
Heat exchanger
693
Table 3
Eect of maximum storage mass ow rate on the system performance at a xed system size of Ac = 180 m2, Vst = 4 m3, UA = 6000 W/C, Tst,max = 160 C
Maximum storage mass
ow rate, kg/s
Average collector
eciency
Average HX eectiveness
during load period
Solar
fraction
2
3
4
5
6
7
8
10
114.18
112.62
111.9
111.61
111.41
111.27
111.16
111.02
39.72
40.01
40.14
40.2
40.25
40.28
40.3
40.33
63.09
56.14
52.35
50.63
49.44
48.58
47.91
46.97
0.8859
0.893
0.8963
0.8978
0.8988
0.8995
0.9
0.9008
Storage volume,cu.m
1000
100
2 kg/s
3 kg/s
4 kg/s
5 kg/s
6 kg/s
Table 4
Eect of heat exchanger size on system performance at a xed system size
of Ac = 180 m2, Vst = 4 m3, mst,max = 3 kg/s and Tst,max = 160 C
UA, W/C
Average storage
temperature during
load period, C
Solar
fraction
2000
2600
3000
4000
6000
8000
10 000
136
127.8
123.8
118.7
112.6
110.1
108.6
15.2
23.7
28.1
41.5
56.1
67.6
74.8
0.78
0.82
0.84
0.86
0.89
0.90
0.91
7 kg/s
10
203
206
209
212
215
218
221
224
Collector area,sq.m
volume, corresponding to the unity solar fraction for dierent storage mass ow rates, are highlighted in Fig. 6. It
may be noted that the storage mass ow rate does not have
a signicant impact on the storage volume. However, the
minimum collector area requirement decreases signicantly
with increasing maximum storage ow rate. Higher values
of storage mass ow rates are therefore, desired. It may be
noted that the higher mass ow rate of the storage water
requires more electrical power required to pump it through
the heat exchanger. Appropriate hydraulic analysis may be
performed to select the maximum storage mass ow rate.
3.3.2. Eect of heat exchanger size (UA)
At a xed system size, Table 4 shows the eect of heat
exchanger UA value on the system performance. As heat
exchanger UA value increases the heat exchanger eectiveness increases and the average storage temperature during
load decreases. This results in an improvement in the solar
fraction and a reduction in the minimum collector area
requirement (Fig. 7). In Fig. 7, the eect of heat exchanger
size, on the design space for unity solar fraction is revealed.
The limiting storage temperature lines for dierent heat
exchanger sizes are separately drawn. The minimum storage volume requirements i.e., the intersections of the constant unity solar fraction curves with the limiting storage
temperature lines are depicted by points a to f. The minimum collector area requirements are represented by points
1000
Storage volume,cu.m
100
2600 W/C
10000 W/C
a1 b1
c1
d1
e1
10
b
Limiting
storage
temperature
lines
f1
f
a
1
190
200
210
220
230
240
250
Collector area,sq.m
Fig. 7. Eect of heat exchanger sizing parameter on the design spaces at
unity solar fractions at Tst,max = 160 C, mst,max = 3 kg/s.
694
Storage volume,cu.m
1000
Unity solar fration curves at
UA = 6000 W/C
Constant unity solar fraction curves
mst,max = 3 kg/s
100
120C
e
130 C
d
10
140 C
205
210
215
220
225
230
235
240
245
27
1
200
26
As the storage temperature decreases, the duty of the auxiliary heater has to be increased to fulll the demand. There
is a practical limit on the provision of auxiliary heater
capacity. It is not benecial to operate the system at very
low storage temperatures. A lower limit on storage temperature is therefore, provided. The cold process stream inlet
temperature should ideally serve as a lower limit. Due to
nite size of the heat exchanger, a certain temperature difference (dT) is maintained. At any instant of time, storage
temperature should be above the minimum specied limit.
The constraint is stated as
T st P T ci dT
Limiting storage
temperature lines
150 C
160 C
250
Collector area,sq.m
Fig. 8. Eect of maximum storage temperature on the design space for
unity solar fraction at UA = 6000 W/C and mst,max = 3 kg/s.
28
On the hot stream side, it is assumed that there is a minimum temperature dierence between the inlet and the outlet temperature. Corresponding to this minimum
temperature dierence, a maximum storage ow rate exists:
Value
200 C
85 C
90 C
6 kg/s
8000 W/C
2000 W/C
29
ms 6 ms;max
Storage volume,cu.m
10000
0.6
0.7
0.8
0.9
Discount rate, r%
Life of collectors and storage, n years
Life of heat exchanger, years
Life of auxiliary heater, naux years
Collector cost coecient, Cc US$/m2
Storage tank material cost US$/kg
Storage tank cost coecient per m3 US$/mm
of wall thickness
Tank insulation price, Cins US$/m2
F=1
m
10
a
1
100
Table 6
Economic parameters adopted for optimization
1000
100
695
130
160
190
220
250
280
310
340
370
Collector area,sq.m
Fig. 9. Entire design space with optimized storage volume.
10.75
15
5
10
333
1.1
59
3 (for a slab thickness
of 25.4 mm)
555
89
0.9
75%
696
Table 7
Economic optimum designs at dierent solar fractions
Solar fraction
Collector area, m2
Storage volume, m3
Heat exchanger UA value, W/C
Maximum storage temperature, C
Maximum operating pressure, bar
Tank thickness, mm
Total cost, US$/y
System capital cost, US$/y
Operating (fuel) cost, US$/y
1.00
207
17
8000
119
2
31
14 763
14 763
0
0.90
176
12
6226
119
2
28
14 217
12 704
1513
0.80
156
8
5117
123
2
28
14 251
11 226
3025
0.87
170
11
5840
121
2
28
14 180
12 187
1993
2=3
30
Annual repair and maintenance cost of the collector and
storage is taken as 2% of the capital cost while that of
the heat exchanger is taken as 3% of its capital costs. For
the case study, the auxiliary heater operates on light diesel
oil. Auxiliary heater rating Ra is determined from the period of the maximum auxiliary energy demand.
The mathematical model described in Section 3.2 is
transformed into an economic optimization formulation.
All the input parameters and constraints remain the same
as in Tables 2 and 5 respectively. The objective function
is minimization of total cost by varying collector area, storage volume, heat exchanger UA value and storage mass
ow rates within a specied range and results are shown
in Table 7.
It may be observed from Table 7 that reduction in the
solar fraction reduces the collector area, the storage volume, and the heat exchanger size requirement. There is a
marginal increase in the maximum storage temperature
(and corresponding operating pressure) with a reduction
in solar fraction. It is interesting to note that the tank
thickness decreases even if there is an increase in the storage temperature. The decrease in tank thickness is attributed to a reduction in the storage volume (22). As the
solar fraction decreases, capital cost decreases while operating cost increases. A trade o between the capital and
0.60
116
5
3748
127
2
26
14 888
8839
6049
0.50
97
4
3082
127
2
24
15 248
7687
7561
15400
0.70
136
5
4483
127
2
27
14 535
9998
4537
15200
15000
14800
14600
14400
14200
14000
0.5
0.6
0.7
0.8
0.9
Solar fraction
Fig. 10. Variation of total cost with solar fraction.
the operating costs yields a solar fraction with the minimum total cost of the system. Fig. 10 shows the variation
of total cost with solar fraction. For the given constraints,
the global economic optimum is observed at a total cost of
US$14 180/y and at a solar fraction of 0.87. A comparison
of the optimum design with the existing design is shown in
Table 8.
In actual practice, commercial concentrating collectors
are available only in discrete sizes. The type of concentrating collector used for this study is available at a xed size of
160 m2. The entire economic optimization is performed wit
a xed collector size of 160 m2. Table 8 also shows an optimized design with a xed collector area of 160 m2. Existing
design consists of 160 m2 of collector area, 5 m3storage volume, heat exchanger UA value of 3500 W/C and the storage tank thickness of 160 mm. The existing design gives a
solar fraction of 0.78 and the annualized system cost of
Table 8
Comparison of global economic optimum with existing design
Solar fraction
Total cost, US$/y
Solar system Capital cost, US$/y
Auxiliary heater Capital cost, US$/y
Operating (fuel)cost
Collector area, m2
Storage volume, m3
Heat exchanger UA value, W/C
Maximum storage temperature, C
Maximum operating pressure, bar
Tank thickness, mm
Optimum design
Existing design
0.87
14 180
8537
3650
1993
170
11
5840
121
2
28
0.78
18 956
10 833
4740
3383
160
5
3500
200
16.00
160
0.82
14 213
7125
4427
2661
160
9
5572
122
2.1
27
200
Temperature, C
160
140
120
100
80
60
Minimum storage
temperature ,90 C
40
20
0
0
10
12
14
16
18
20
Table 9
Range of system designs encompassing 2% increase in the minimum total
cost
Solar fraction
Total cost, US$/y
System capital cost, US$/y
Operating (fuel) cost
Collector area, m2
Storage volume, m3
Heat exchanger UA value, W/C
Maximum storage temperature, C
Maximum operating pressure, bar
Tank thickness, mm
0.71
14 471
10 085
4386
138
6
4554
127
2
27
0.978
14 461
14 126
334
200
14
7448
121
2
30
5. Conclusions
Storage temperature
profile
180
697
22
24
Time,h
Fig. 11. Storage temperature prole with optimum system size,
Ac = 148 m2, Vst = 7 m3.
698
of solar energy in industrial processes. The study demonstrates the possibility of application of design space methodology to a variety of industrial process heat
congurations in an eective way.
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