Opportunities for Solar for Industrial Process Heat in the United States
Figure data for report on opportunities for solar technologies to provide industrial process heat in the United States (NREL/TP-6A20-77760).
02 PETROLEUM↗
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Parabolic Trough Collector Cost Update for Industrial Process Heat In The United States
Despite great potential, the worldwide adoption of concentrating solar thermal (CST) collectors for solar industrial process heat (SIPH) is modest. Industrial process heat (IPH) demands for heat and steam are typically below 300 degrees C, where CST collectors can provide the needed heat. Parabolic trough collectors (PTCs) are the most deployed CST technology for SIPH applications. This paper is focused on the United States, and a summary of known operating parabolic trough plants is shown. A previous analysis of a modern PTC in 2016 found that for SIPH applications, the installed solar field cost could be $200/m2 (2016$). Recent advances in PTC design and manufacturing have led to reduced cost per square meter of aperture area, and for a field of 510 solar collector assemblies (SCAs), the installed cost was $120/m2 (2020$). On one hand, the results from this study showed that the solar field cost for large solar fields (510 SCAs or ~804,000 m2) would increase to $184/m2 (2023$) due to post pandemic inflation and increase in metal prices. On the other hand, medium SIPH sized fields (90 SCAs or ~142,000 m2) cost analysis indicated an installed cost could be $197/m2 (2023$). When small SIPH fields (12 SCAs or ~19,000 m2) are considered, this jumps to $297/m2 (2023$). These are cost estimates for the Installed Cost of the solar fields using the United States 2023$ steel prices. When Chinese steel is used for comparison, the installed cost could be between $162 - $210/m2 for the range of SIPH sizes.
concentrating solar thermal↗
Impact of process temperature on the cost of concentrating solar thermal industrial process heat
Not Available
14 SOLAR ENERGY↗
Solar energy for industrial process heat
Findings of study of potential use for solar energy utilization by California dairy industry, prove that applicable solar energy system furnish much of heat needed for milk processing with large savings in expenditures for oil and gas and ensurance of adequate readily available sources of process heat.
Barbieri, R. H.↗
System Advisor Model (SAM) Improvements for Emerging Solar Thermal Applications
The System Advisor Model (SAM) is an open-source tool developed by NREL to simulate the techno-economic performance of technologies like photovoltaics, solar thermal, wind, and geothermal. NREL has recently completed, active, and planned projects to improve the solar thermal models in SAM and its underlying code base to represent emerging component technologies, systems, and applications. This poster describes new capabilities in the SolarPILOT optical modeling tool, supercritical carbon dioxide (sCO2) power cycles, and solar industrial process heat.
14 SOLAR ENERGY↗
Dynamic optimization with flexible heat integration of a solar parabolic trough collector plant with thermal energy storage used for industrial process heat
There is an increasing need to reduce fossil fuel consumption used for industrial process heat to slow the effects of climate change. Using solar thermal heat is a viable way to replace fossil fuel use, but solar industrial process heat plants have limited implementation due to large upfront costs and inefficiencies from the inherent variability from solar energy. Having more flexible and optimized control over these plants can enable them to be more efficient. Here in this work, a solar industrial process heat plant with thermal energy storage that can flexibly collect and deliver heat to two industrial processes (flexible heat integration) is dynamically modeled with control setpoints found by a dynamic optimization method. The optimized case can increase the solar efficiency of the plant by 7.5% on average relative to a base case. The results show that it is best to collect heat at lower temperatures for all but ideal solar conditions, only medium to high quality heat should be stored in large quantities, and exchanging heat with a lower temperature heat sink is generally more efficient. The optimized case is able to reduce the levelized cost of heat of the plant to $31.83/MWh th compared to a base case value of $34.10/MWh th . The optimized case can reduce emissions by 22.2% compared to a plant which uses only natural gas. This work shows that dynamic optimization with flexible heat integration can be a cost-effective way to increase efficiency so that more of these types of plants can be implemented.
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The Role of Concentrating Solar-Thermal Technologies in a Decarbonized U.S. Grid
The National Renewable Energy Laboratory’s Solar Futures Study explores the roles solar energy technologies could play in the future U.S. energy markets under different scenarios. This report discusses the role of concentrating solar-thermal (CST) technologies in those future scenarios with an emphasis on concentrating solar-thermal power (CSP), which refers to converting thermal energy to electricity. The report begins with an overview of the CSP resource and market status. Next we discuss the results from the grid-scale capacity planning modeling under future scenarios considered in the Solar Futures Study, focusing on the results for CSP and presenting several sensitivity model results not discussed in the main report. We then discuss likely CST research and industry directions over the next decade. Finally we discuss three potential future markets for CST beyond electricity generation -- industrial process heat, solar fuels production, and electric thermal energy storage.
14 SOLAR ENERGY↗
Large area transparent refractory aerogels with high solar thermal performance
Application of transparent silica aerogels in low-temperature solar thermal systems has led to major improvements in performance. In high temperature concentrating solar thermal (CST) systems, aerogels have yet to demonstrate the necessary scalability, durability, and performance to support their widespread deployment. Here, large-area transparent refractory aerogel tiles are synthesized and shown to achieve a record-high receiver figure-of-merit (FOM) at high temperatures. The work leverages a scaled-up process for sol–gel synthesis to control the density of the aerogels for improved solar transmittance and adapts a previous atomic layer deposition (ALD) technique with the aid of predictive reaction-transport modeling. After aging for 10 days at 700 °C, the large-area tiles exhibit a solar-weighted transmittance of 95.6 % and a thermal emittance of 0.31, corresponding to a FOM of 80 % at 100 suns and 700 °C. The observed sintering rates at 700 °C are comparably low to earlier one-inch aerogels, suggesting long-term stability under relevant operating conditions. Furthermore, the study indicates that refractory aerogels are scalable materials for efficient photothermal conversion at high temperatures.
Aerogels↗
Hybrid Solar Heat Generation Modelling and Cases: Preprint
Renewable thermal energy systems (RTES) harness renewable energy sources to provide services for space heating and cooling, district heating, domestic hot water, and industrial process heat (IPH). The use of low-pressure steam generated by the combustion of fossil fuels is common today to provide process heat for industrial facilities. Solar IPH (SIPH) technologies could economically replace the steam or heat needs at many industrial sites by providing high-temperature pressurized hot water, a heat transfer fluid (HTF) such as synthetic-oil, or direct steam (Kurup and Turchi, 2015). RTES could be hybridized with technology options or combined with the existing heat supply (e.g. fuels), to give options for targeted IPH application and the reduction of fuel consumption. This work has tested hybrid system modelling approaches. Initial results show when a natural gas (NG) burner that feeds an IPH application of 300°C, has both air and NG streams pre-heated with a solar field/RTES exit temperature of 180°C (via an HTF), a 13% NG offset is possible. NG offsets reach up to 26%, when the RTES exit temperatures are at 300°C for a given annual capacity factor of 24%. This can be even higher with addition of thermal energy storage (TES).
43 PARTICLE ACCELERATORS↗
Analysis for Industrial Decarbonization: A National View
This presentation provides a brief summary of existing national-scale industrial analysis of electrification, solar process heat, and hydrogen for combustion applications.
decarbonization↗
Guideline for Characterizing and Evaluating a Candidate Project Site for Solar Thermal Applications
This document presents a structured procedure for characterizing and evaluating candidate project sites for concentrating solar power (CSP) and solar heat for industrial processes (SHIP) applications. The objective is to provide project developers, researchers, and other stakeholders with a consistent, technology-agnostic framework for early-stage site assessment, enabling informed decision-making prior to significant investment in project development. Site selection is a critical factor in project success or failure for both CSP and SHIP projects. Key factors such as solar resource availability, land characteristics, environmental and regulatory constraints, infrastructure availability, and community context are determined by the choice of project site and can materially impact project performance, cost, schedule, and overall viability. This procedure is designed to systematically evaluate these factors, identify potential fatal flaws, and prioritize the most favorable candidate sites for further development. The process begins with rapid screening-level evaluation, using publicly available data to assess solar resource, land availability and suitability, zoning and land-use compatibility, and exclusion zones such as protected lands or sensitive habitats. Sites that meet the minimum screening criteria advance to a more detailed characterization. Subsequent sections of this report provide guidance for a next-level assessment of the most important technical and environmental parameters, including: 1) Solar resource quality, variability, and uncertainty using multiyear datasets and, where appropriate, on-site measurement campaigns; 2) Meteorological conditions such as wind, temperature, extreme weather events, and soiling impacts; 3) Land characteristics including slope, shading, and geotechnical conditions; and 4) Environmental and regulatory considerations, including permitting processes, endangered species, cultural resources, and visual impacts. The procedure also addresses infrastructure and integration considerations, including: 1) Grid interconnection requirements for CSP power generation projects; 2) Electrical and operational integration for SHIP facilities; 3) Water availability, quality, and permitting constraints, which are particularly critical for CSP in arid regions; and 4) Site access, construction logistics, and availability of workforce and supporting services. Recognizing the importance of social and economic context, the procedure includes evaluation of community engagement factors, such as stakeholder sentiment, proximity to sensitive visual receptors, workforce development opportunities, and local economic incentives. The outputs of these assessments are synthesized in a cost and risk evaluation, translating site characteristics into expected impacts on capital cost, operating cost, schedule, and technical risk. This is complemented by screening-level performance modeling, including 8760 simulations and long-term projections, to quantify expected energy or thermal output, assess variability thereof, and support comparison between candidate sites. Finally, the procedure provides high-level guidance on a structured go/no-go decision framework, categorizing sites based on identified risks and constraints, and outlining a clear path forward to feasibility studies and front-end engineering design for viable projects. By standardizing the site characterization process across both CSP and SHIP applications, this guideline aims to: 1) Improve consistency and transparency in early-stage project evaluation; 2) Reduce development risk and avoid investment in nonviable project sites; 3) Support collaboration between developers, researchers, and public agencies; and 4) Accelerate successful deployment of concentrating solar technologies for both power generation and industrial process heat.
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Improved SIPH Thermal Particles for Decarbonization of Chemical Production
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03 NATURAL GAS↗
Agricultural and industrial process heat
The application of solar energy to agricultural and industrial process heat requirements is discussed. This energy end use sector has been the largest and it appears that solar energy can, when fully developed and commercialized, displace from three to eight or more quads of oil and natural gas in U.S. industry. This potential for fossil fuel displacement in the agricultural and industrial process heat area sector represents a possible savings of 1.4 to 3.8 million barrels of oil daily.
Dollard, J.↗
Ultra-High Operation Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing: Test Facility & Performance Evaluations
Solar Heat for Industrial Processes (SHIP) cavity receivers are capable of generating electricity or industrial process heat by absorbing thermal energy from solar radiation, focused on a small area. The concentration of solar radiation on the small area of the receiver enables the achievement of high temperatures (ranging from 400°C to 1,100°C) of a working fluid, thus making the SHIP technology thermodynamically comparable with conventional power plants. A volumetric receiver consists of a porous structure-generally made of silicon carbide or metal, which absorbs solar radiation and converts it into heat energy. Heat energy from the porous materials is then transferred to the fluid following through them. A volumetric receiver acts as a convective heat exchanger, transferring heat to the fluid through convection. Open-loop volumetric receivers work with air at atmospheric pressure and are suitable for single-cycle or multi-cycle energy plants. A Model Based Systems Engineering (MBSE) approach was used to develop a test bed at Sandia national Laboratories (SNL) capable of demonstrating an open-loop volumetric air receiver developed by General Electric Aerospace (GE Aerospace). This paper presents the development of the various MBSE methods, test bed, and testing operations for the GE air receiver, which was experimentally demonstrated to achieve 1,350°C for over 3 hours of operation and an approximate 70% receiver efficiency. By being able to achieve such high temperatures >1,000°C, this work provides the potential to support many SHIP industrial use cases.
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Solar energy for process heat: Design/cost studies of four industrial retrofit applications
Five specific California plants with potentially attractive solar applications were identified in a process heat survey. These five plants were visited, process requirements evaluated, and conceptual solar system designs were generated. Four DOE (ERDA) sponsored solar energy system demonstration projects were also reviewed and compared to the design/cost cases included in this report. In four of the five cases investigated, retrofit installations providing significant amounts of thermal energy were found to be feasible. The fifth was rejected because of the condition of the building involved, but the process (soap making) appears to be an attractive potential solar application. Costs, however, tend to be high. Several potential areas for cost reduction were identified including larger collector modules and higher duty cycles.
French, R. L.↗
Renewable Thermal Energy Systems Designed for Industrial Process Solutions in Multiple Industries
Industrial decarbonization is a key area that must be accelerated, to foster the removal of fossil fuels from the provision of heat, especially at low temperatures less than 300 degrees C. This paper looks at the results of two case studies for understanding the economics and potential for renewable thermal energy systems (RTES), particularly in hybrid configurations to provide industrial process heat (IPH). The first case study looks at heat pumps for district heating, and the second, the use of linear Fresnel collectors (LFCs) coupled with phase change material (PCM) thermal energy storage (TES) for direct steam generation (DSG). Using district heat as an input for the heat pump, three cases were run harvesting energy from ambient water (5 degrees C), sewage water (20 degrees C), and a solar collector (35 degrees C). Accounting for elevated costs of infrastructure for each heat source, the levelized cost of heat (LCOH) of the first case study ranged from $4-$15 per million British Thermal Units (MMBTU). For the second case study modeling LFCs with PCM and TES, the results show that a LCOH of $9-$15 per MMBTU is possible, depending on the direct normal irradiance.
concentrated solar thermal↗
Renewable Thermal Energy Systems Designed for Industrial Process Solutions in Multiple Industries: Preprint
Industrial decarbonization is a key area that must be accelerated, to foster the removal of fossil fuels from the provision of heat, especially at low temperatures less than 300 degrees C. This paper looks at the results of two case studies for understanding the economics and potential for renewable thermal energy systems (RTES), particularly in hybrid configurations to provide industrial process heat (IPH). The first case study looks at heat pumps for district heating, and the second, the use of linear Fresnel collectors (LFCs) coupled with phase change material (PCM) thermal energy storage (TES) for direct steam generation (DSG). Using district heat as an input for the heat pump, three cases were run harvesting energy from ambient water (5 degrees C), sewage water (20 degrees C), and a solar collector (35 degrees C). Accounting for elevated costs of infrastructure for each heat source, the levelized cost of heat (LCOH) of the first case study ranged from $4-$10 per million British Thermal Units (MMBTU). For the second case study modeling LFCs with PCM and TES, the results show that a LCOH of $9-$15 per MMBTU is possible, depending on the direct normal irradiance.
concentrated solar thermal↗
Analysis and Optimization of a Novel Hexagonal Waveguide Concentrator for Solar Thermal Applications
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.
14 SOLAR ENERGY↗