H2020 HyCool Project: Industrial Refrigeration using a Hybrid System based on Solar Heat
- Type Project
- Status Filled
- Execution 2018 -2022
- Assigned Budget 5.818.971,87 €
- Scope Europeo
- Main source of financing H2020
- Project website HyCool
The first phase involved component optimization and the final design of the full-scale modular hybrid solar heat pump, as well as its manufacturing and commissioning. This phase basically involved numerical modeling of the hybrid heat pump to optimize its performance through appropriate modularity and optimized control logic; the initial design of a hybrid heat pump optimized for solar industrial applications; experimental testing of a hybrid heat pump module under controlled laboratory conditions to develop a performance map; and the final review of the full-scale hybrid heat pump design based on the results of the experimental testing campaign.
The modeling and definition of system components, energy flows, and storage capacities had to be executed during this period to define the overall system design, including energy sources, steam consumers, cooling loads, and storage capacities, as well as how these components are physically connected to each other. Visualization of the system integration and the hybrid heat pump had to begin in M5.
During this period, other tasks have been carried out, such as the development of a characterization protocol for adsorbent materials, with the aim of accurately estimating their performance. It is necessary to determine their thermal diffusivity, heat capacity, adsorption behavior, vapor transport properties, and heat of adsorption at different temperatures and pressures.
The overall progress of the project has reached almost 100%, with the exception of the system integration visualization and hybrid heat pump, as well as the final designs at two demonstration sites (pending solar field details). The following table presents the progress toward meeting the project objectives. For each objective identified in the Description of Action (DoA), the status of its technical completion and the corresponding Work Plan are presented.
Table 1: Project objectives and status in the period (M1-M18)
WP State Target
Obtaining a valid configuration for both pilots (GIV and DEBO)-WP2-WP3-WP5-(100%)
First design of the modular heat pump-WP3-(100%)
Hydraulic diagram and specification of each demonstration site-WP5-(100%)
Requirements and indicators of hybrid solar system-WP2-(100%)
Key Performance Indicators (KPI)-WP2-(100%)
Final design of the full-scale modular hybrid solar heat pump-WP3-(100%)
Manufacture of HHP-WP3-(100%)
Modeling and defining system components, energy flows and storage capacities - WP5 - (100%)
Visualization of the system integration and the hybrid heat pump-WP5-(85%). System integration complete.
Development of the characterization protocol for adsorbent materials (WP4, 100%).
Final projects at two demonstration sites (WP6, 85%). Solar field details finalized.
To assess the expected results of Hycool, a Key Performance Indicator (KPI) methodology has been proposed, which is detailed in section D.2.5 "Key Performance Indicators and Process Levels." This product compiles, organizes, and classifies the KPIs that can be used for Hycool process applications. The aforementioned KPIs are based on the literature and the experience of the partners responsible for system development within the Hycool project. Therefore, careful monitoring of compliance with the already identified KPIs is necessary to demonstrate the potential of Hycool technology when the installed systems are operational.
The objective of the HyCool Project is to expand the current use of solar thermal energy in industrial processes. To this end, it proposes the combination of a novel Fresnel solar thermal collector (FCSP) system with specially designed hybrid heat pumps (HHPs) (a two-in-one combination of adsorption heat pumps and compressor) for a wider output temperature range (solar heating and cooling -SHC-) and a wide range of design and operating configurations to increase the implementation potential of the proposed solar thermal energy in industrial settings.
In summary, the main advantages of the HyCool system are:
- Greater flexibility: The combination of two systems allows HHPs to accept both electricity and heat from solar systems as driving force, creating a strong synergistic effect that will be used to generate cooling, while the solid sorbent (the main component of the adsorption heat pump) can be adapted to specific working environments.
- Greater efficiency: HHPs powered by solar and waste heat, and integrated into industrial thermal/electric processes in a real plant, can achieve COP values twice as high as those of conventional heat pumps.
The mission of the HyCool project is to increase the current use of solar heat in industrial processes and, to this end, the project proposes the coupling of novel Fresnel CSP solar thermal collectors (FCSP) with specially built hybrid heat pumps (HHP) (a "two-in-one" combination of adsorption-based heat pumps and compressor) for a wider output temperature range (solar heating and cooling -SHC-), and to provide a wide range of operational and design configurations to better adapt to each case, thus increasing the implementation potential of the proposed Solar Heat in industrial environments. The two main features of the HyCool System are Flexibility and Efficiency and will allow different strategies for a technically and economically viable system. During the Capital Expeditions phase, simplicity will be sought by pursuing ease in optimizing the design configuration, modular construction and ITS for commissioning. During the operating expenses, the optimal balance between operational flexibility and HyCool system efficiency will be sought to maximize HyCool's profitability in each individual case. The proposed pilots will then demonstrate both opposing strategies in two selected key leading industrial sectors: the Food Case Pilot targets small, specialized food industries in high-solar irradiation areas with process cooling needs. Here, narrow configurations aim to optimize efficiency, so a simple system will be selected to achieve maximum results depending on the operating conditions. The Chemical Case Pilot targets multi-process industries in high-solar irradiation areas with steam and cooling needs. Here, a more complex configuration aims to optimize operational flexibility, so a more complex system will be implemented, capable of switching between different options depending on the weather, season, and production schedule. Finally, special consideration will be given to building trust during HyCool communication and results dissemination throughout the project.
Considering the described STO 2, the expected results could be summarized as a reduction in energy consumption compared to conventional heat pump systems of up to 75%, an HHP electrical COP of 6, an efficiency increase of up to 25% (also considering the auxiliaries of the entire system) and a reduction in operational GHG emissions of up to 90%.
The different KPIs to be proposed will address the following aspects: Energy characteristics (absolute power values, storage capacities, etc.), Energy efficiency (instantaneous and integrated energy yield, for the entire system, for each module), Cost efficiency (e.g. investment, maintenance costs, ROI conditions), Space efficiency (compactness, spatial constraints), Impact on comfort (conditions of use and maintenance, thermal impact characterization), Environmental impact (life cycle considerations, renewable energy share) and Robustness, reliability, autonomy. At the machine level, these KPIs will include: COP, EER, cooling power density, cost per unit of cooling power, life cycle objectives.
IMPACT:
The initiative will generate solutions that demonstrate that solar thermal energy can be a reliable energy source for industrial processes, offering significant opportunities for market adoption of this renewable energy source and for the decarbonization of industrial processes.
Boosting innovation capacity: Innovation capacity is the ability of organizations to commercialize new ideas, products, and services, and includes technical, management, and resource aspects.
Competitiveness, growth, and job creation in the EU: The industrial market remains virtually intact, despite the fact that 45% of total heat from industrial processes is produced in the low-to-medium temperature range. The lists of industries and processes most suitable for solar thermal energy are well documented, so the project focuses on initial demonstrations in the chemical and food industries. The potential of this market is undeniable: it represents billions of euros and hundreds of thousands of jobs.
Benefits for society: The flexibility of the HyCool solution, its storage, and its ICT control system align with demand response concepts and emerging smart grid trends. This increases the likelihood and willingness of industrial companies to participate in such programs, which is key to a more reliable distribution and transmission network overall. On the consumer side, consumers express a preference for sustainable buildings and products.
- VEOLIA SERVEIS CATALUNYA SOCIEDAD ANONIMA UNIPERSONAL
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