Solar Compound Parabolic Collector (CPC) at Hatsun Agro Product Limited, Salem
Project Overview
Hatsun Agro Products (HAP) Limited - Salem plant requires a large quantity of hot water at a temperature of 90- 95℃ for ice cream processing as well as boiler feed water.
The plant requires 35000 L of hot water at a temperature of 90- 95℃ for the process heat in ice cream making and around 40000 L to 50000 L for the boiler feed water every day
The hot water for processing is produced using steam with a plate heat exchanger (PHE)
The average coal consumption/day is 11.3 tons in the 8-ton boiler
SUN BEST Solution
Based on the energy demand, 220 numbers of CPC 18 collectors, each 3.28m2 area are installed to provided 25,000 to 30,000 litre hot water of around 90 -950 C
Each bank of 110 CPCs is connected in a pressurized primary loop with expansion tank, pump, auto refilling water and a plate heat exchanger.
The secondary loop consists of cold storage water and pump coupled to the plate heat exchanger. The primary loop works at 2-3 bar pressure heating water to 110-1200C
The cold water passes through the PHE and get heated up to a temperature of 95 Deg C and it is taken to the process.
The requirement of hot water for processing starts early morning at 4 AM and a few times during day and also in the night. Hence a 21 KL storage has been designed.
Challenges
The distance of process application from the storage is 300 m and drop of 30C was observed during this transfer; this drop is minimized by insulating the pipes.
The roof is very tall. Due to the 15m height of the roof, the installation team had a major hardship during installation. The team worked in a safe and efficient manner
Benefits
A savings of 672 kg/day or 201 tonnes/year was recorded
The system is expected to give a saving of 7262 tonnes of CO2 in 15 years
Forest cover savings of 16920 acres over 15 years.