The SHIP2FAIR technologies and control approach will be demonstrated in four different EU countries with different irradiation values and energy/economic scenarios. In addition, solar heat will be exploited in four different processes showing wide SHIP2FAIR replicability all around Europe.
The demonstration campaign will be boosted by the realization of the “SHIP2FAIR Replication Tool” which will be able to evaluate the techno-economic feasibility of new SHIP installation in agro-food sector starting from few energy consumption and process detail data, towards the promotion of SHIP technologies particularly among SMEs.
The demonstration campaign is going to involve three very big and well known EU players in their food sector: RAR (Sugar), ABC (Ham and “charcuterie”), M&R (Drink and distillery) and an SME (RODA) representing the winery industry. The demo-site owners are strongly committed to the project idea (and its future replication in the rest of their plants) and will promote the project and its results among both industrial stakeholders and general public, being interested in the further replication at other plants of their group.
Synergies with the experience of other centres in SHIP projects will be enhanced as well as the study of exploiting the project results in other locations. During SHIP2FAIR project, it will be boosted the participation of interested stakeholders in conferences and meetings. During these events it will be transferred project results and knowledge regarding how solar heat integration in industrial process can create, capture and deliver value for the different market actors. These synergies will engage professionals and managers on training developed during SHIP2FAIR and will activate the replication and exploitation strategy as well as market beyond Europe.
SHP2FAIR methodology has been designed to develop its results for a general scenario, and then addressing the particular challenges present in each demo-site use case. This premise will allow that the replication to other sectors and use cases is feasible and cost-effective, ensuring that the final objective of spreading the SHIP projects along EU is achieved in the temporal framework indicated in the Exploitation roadmap of the project.
SHIP2FAIR provides a path to overcome those challenges, thus, exploiting the untapped potential of SHIP technologies:
- SHIP economic competitiveness,
- the relatively low prices of fossil fuels charged to the industry due, in some cases to governmental subsidies, and
- the complexity of the integration in existing industrial processes
Within SHIP2FAIR, this objective is understood as a twofold goal: on the one hand, the Replication Tool aims to maximize the solar fraction at process level under cost-effective conditions; on the other, the replicability of the results across at the agro-sector sector level and beyond is enabled by a process centred approach together with the consideration of multiple solar technologies, including storage. It is expected that the solar fraction at process level may reach between 11,2% at RAR and 39% at RODA. At the end of the SHIP2FAIR, 4 industries will have an operational installation of SHIP and 10 industries will have a concept engineering with a feasibility study. It is expected that, in the 5 years after the project ends, the partners will have implemented over 100 SHIP projects in the EU (75% in the agro-food sector and 25% in other sectors).
The main aspects in which the innovation takes places within SHIP2FAIR are: (1) the design and development of the Replication Tool, (2) the solar technologies involved, (3) the solar heat integration in the industrial processes, (4) the control strategies and systems for operating the complete industry and (5) the capacity building programme linked to the project.
SHIP2FAIR involves two solar heating technology providers in the consortium, one of linear Fresnel (ISG) and one of ultra-high vacuum FPC (TVP). In addition, a reduced deployment of FPC will be considered in the smallest demo-site.
To select the best solution for each of the for demo-sites, a preliminary study has been developed (These technologies will be suitable for a large spectrum of process heat temperature (50-250 ºC)):
- Linear Fresnel Collectors for RAR and M&R plants, as these collectors are more suitable for steam production and they have a high demand, so, if SHIP2FAIR is successful, future enlargements are possible.
- Ultra high-vacuum FPC for ABC plant, as they show a high production rate for the location weather conditions and the process requirements.
- Conventional FPC for RODA, since other options required too high upfront costs for such a small plant, so the most cost effective and simple technology has been considered, since the objective of the demo-site will be to test both the replication and the Control Tool. In addition, solar field visual impact is a key factor for wine cellars, and therefore FPC collectors are especially suitable as their impact is minimum.
Nevertheless, the final solution about the implementation is to be made during the project execution, once there is more accurate information about cost, characteristics and production rates of each collector technology, and depending on the demo-sites requirements.
SHIP2FAIR aims at demonstrating Solar Heat Industrial Process (SHIP) in industrial environment, towards a strong penetration and spread of these systems in the agro-food industrial sector encouraging the replication also in other process heat sectors through two dedicated tools (SHIP2FAIR Control and Replication Tools), a best practices guide for developing SHIP projects from scratch and a capacity building program for both professionals and students interested in the sector.
Several small SHIP projects exist in Europe with heat costs between €38 and €120 per MWh19, considering different temperature range and economic/energy scenarios. At present, solar heat can mainly be used for processes ranging from 20°C to 100°C20, so SHIP2FAIR targets to promote the penetration and the affordability of higher temperature technologies. This objective will bring several impacts (social, environmental, technical economical) at local, national and European level in accordance to some EU directive and initiatives in the field of more environmentally sustainable industries and renewable heating.
SHIP2FAIR project will be performed by a multidisciplinary and well-balanced consortium integrated by 4 research organizations, 6 large companies and 3 SME, 2 associations, one from the energy research and one from the agro-food sector, from 8 different European countries, thus ensuring a wide international covering and enhancing the project impact.
Partners of SHIP2FAIR consortium can be identified within 4 groups that cover the whole value chain: Innovation developers, implementation partners, End-users and other added-value partners as companies, energy utilities and agro-food industries associations.
SHIP2FAIR project is the key to integrate solar heat from renewable energy in the Agro-food industrial processes, thanks to competitive and environmentally friendly solar technologies, innovative business lines and a user-friendly approach. These assets are being integrated and improved during the life of this four-years- project in four real industrial places of the Agro-food sector. These industrial sites will install a demo-site each, and up to a 40% of the heat demand will be covered by solar power. Why SHIP2FAIR focuses on the agro-food sector?
Agro–food sector, which is the largest manufacturing sector and the leading employer.
- SHIP2FAIR targets to promote the penetration and the affordability of higher temperature technologies.
- SHIP2FAIR aims to validate through a long demonstration campaign of 18 months, the technological and economic reliability of SHIP technologies for the agro-food sector with process temperatures in the range between 50°C and 250°C.
- SHIP2FAIR proposes technologies and control schemes applicable to both newly built and already existing industrial plants and able to cooperate with traditional process heating systems.
Besides, SHIP2FAIR aims to demonstrate specific reliability targets such as:
- Minimum lifetime certified at its nominal efficiency: 20 years.
- Solar efficiency (yearly average): between 37% at M&R and 54% at RODA.
- Solar fraction: between 11,2% at RAR and 39% at RODA.
- Maintenance costs: maximum increase of 5% compared to fossil fuel based solutions.
SHIP project is an industrial process, the solar heat installation and other existing heat generation sources.
- Use cases and boundary conditions definition
- SHIP2FAIR Replication Tool feasibility analysis and Concept Engineering
- Solar Heat integration and thermal optimization
- Operation monitoring and control strategies. SHIP2FAIR Control Tool.
- Demo-sites engineering and commissioning
- Demonstration, evaluation and fine-tuning
- Dissemination, training and showcases
- What is the Replication Tool?
A software to determine what features a SHIP project should have, and what metrics can be used to measure its quality or performance. The Replication Tool also has a powerful engine to simulate different scenarios. Based on these assets and the analysis of what you need and your preferences, as a user, the Replication Tool will help to improve different aspects of SHIP projects, such as selecting the most profitable option to minimise fossil fuel usage. And the cherry on the cake: thanks to the intuitive interface of the Replication Tool, you don’t need to study a Master to use it.
- What is the Control Tool?
The control tool will consist of a set of algorithms and is the empowering part that adds intelligence to the technologies and allows them to reach their full potential. Being the connecting component between the solar collectors and the SHIP plant, the Control Tool combines knowledge about the future solar radiation and industrial processes. This will help to determine the optimal operating strategy for the solar plant and existing heating producers so that emissions and costs are kept low while the process quality remains high.
The control algorithms run on a modern information and communication infrastructure (ICT), which electronically connects all the components and allows the operators to check in on their processes from all over the world via an Internet interface.
Combined with machine learning methods to continuously adapt to new inputs and measurements from both the plant and the solar collectors, the control tool will bring SHIP projects into an efficient future.
- What is the Capacity Building program approach?
SHIP2FAIR trains professionals and the future workforce of the renewable energy field to include the SHIP Tools & skills in their current and future work.
- What is the overall SHIP Guide?
The fundamental guide to create your SHIP project from scratch, including guidelines, best practices and tips learnt from the SHIP2FAIR flagship projects. An all-in-one manual with an answer for everyone interested in implementing a SHIP project.
The flagship projects of SHIP2FAIR will be implemented in four industries chosen thanks to the visibility of their brand -wines Roda, sugar RAR, delicatessen Loste Tradi-France and spirits from Martini & Bacardi-. And above all, they were chosen because their industrial processes show a number of common threads, which can be improved via the SHIP Replication & Control Tools and transferred afterwards with these improvements to other industries.