Global Ecovillage Network - Oceania & Asia Documents

. DOCUMENTS The Energy Required to Manufacture Renewable Energy Technologies
. REFERENCES

by Peter Jolly & Richard O'Sullivan  

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.
This paper was presented at the Solar 89 Conference. Australia & New Zealand Solar Energy Society.


Peter Jolly.
Energy Laboratory
Mechanical Engineering
The University of Queensland
St. Lucia. 4067, Australia

Richard O'Sullivan.

Applied Physics
Royal Melbourne Institute of Technology
Melbourne,
Australia




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It should be noted that the trends and conclusions made in this analysis may not be accurate in the future as energy conversion efficiencies are continually being improved with advances In technology.

While it may be argued that fossil fuel technologies are nearing their maximum efficiencies, renewable energy technologies, due to their relative newness, can expect greater improvements in the ensuing decades. For example evacuated tubes offer great potential to produce medium/high grade heat while only having modest material energy requirements.


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For example :
orders of manufacture

order
1 direct energy use
2 capital energy and fuel production energy
3 capital energy and fuel production energy to provide plant and fuel for order two



Hot water heating accounts for approximately 35-40% of the energy consumed by a domestic residence.

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SOLAR 89 CONFERENCE
Australian and New Zealand Solar Energy Society


ABSTRACT
This paper presents comparative data on the fossil fuel energy required to manufacture, Install and operate a solar hot water system and a RAPS System with their fully fossil fuelled counterparts.

The results show that both renewable energy technologies use much less energy than their counterparts to accomplish the same task over their lifecycle.

In the case of hot water heating solar energy Is more than 2000% energy efficient in Darwin and 250% efficient In Hobart.

The analysis shows that minimising the fossil fuel running energy requirements maximises the overall life cycle energy efficiency. This conclusion Infers we should consider using systems with higher solar fractions than previously recommended.

The paper highlights the shortcomings of comparing technologies solely on a cost basis.

INTRODUCTION ACKNOWLEDGMENTS
ENERGY ANALYSIS RULES HOT WATER HEATING
REMOTE AREA POWER SUPPLY SYSTEMS CONCLUSIONS

INTRODUCTION

Often in debate on energy matters the question arises as to whether a certain technology requires more energy for its manufacture than it will produce during its lifetime.

Proponents of renewable energy technologies should be ready to answer such questions and be able to compare these technologies with fossil fuel technologies.

Comparing technologies on present economic grounds would be very short-sighted as the growing environmental movement will demand other criteria to be used which will include damage to the environment. cleanup costs and perhaps a resource tax.

This paper will use existing data to compare the energy required to manufacture, install and operate a flat plate solar hot water heater and a RAPSS (Remote Area Power Supply System) with their fossil fuel counterparts.

The study is only a preliminary one, pointing the way for a detailed follow-up study.


ENERGY ANALYSIS - SOME GROUND RULES

In order to assess the energy required to manufacture, Install and operate a device, such as a solar hot water heater, it is necessary to identify all the individual components and processes associated with the system. Several difficulties can arise when performing this analysis;

  • Which figures do you believe?
    Difficulty arises in determining the energy required to manufacture a given component.
    For example, the energy required to produce copper sheet varies greatly depending on the grade of ore used.
  • Further, recycled metals, such as aluminium,
    require less than twenty times the energy compared to "new" metals [3].
  • Where do you draw the system boundary?
    Production of a particular product, such as copper sheet, can involve many processes. These Include mining, smelting, casting and rolling with each step requiring inputs of capital energy (infrastructure), fuels, transport, labour..... and cat food f or the mine manager's cat!


Boustead and Hancock [2] describe a method of analysis which isolates various "orders" associated with the manufacture of a given commodity.

Actual analysis is seldom carried beyond order two, since further orders usually make an insignificant contribution to the overall energy consumption.

(see Sheridan,[4])


In the analysis presented here we are interested in comparing the total life cycle energy required by a fossil fuel system with a renewable energy system to achieve the same task.

Mathematically, the representation used in this analysis is as follows;
(equation 1)

T = C + nM + nR

  • Where,
    T = Total primary energy (fossil fuel) used to perform the task over the life of the device (kWh)
  • C = Total energy required to manufacture and install the device (kWh)
  • M = Energy used in the maintenance of the device (kWh/y)
  • R = Annual fossil fuel operating requirements (kWh/y)
  • n = Life of device (y)

HOT WATER HEATING

Comparing the total life cycle energy required to provide hot water by electricity and solar energy.

This analysis compares the life cycle energy requirements of an electric boosted standard flat plate solar collector with an all electric system. One of the authors (O'Sullivan and Meldrum [5]) has undertaken a detailed study to determine the manufacturing energy requirements of a standard solar hot water system.


Table 1 summarises the total life cycle energy requirements for the two systems for capital cities in Australia.

  • The maintenance (M) energy requirements are assumed negligible.
  • The last column in the table is the ratio of the life cycle energy requirements of the all electric system to the solar boosted system.
  • The efficiency of conversion of primary energy into electric heat (n) has been assumed to be 25%.
  • No allowance has been made for the energy required to construct and maintain a grid electricity system and the energy required to mine the fuel used to power the system.
  • Thus all claims made about the energy attractiveness of solar water heating are conservative.
  • Table 1.
    Comparison of the total life cycle energy required to provide hot water by electricity and solar energy.

    . Area1
    (m2)
    Solar1
    Fraction
    Capital
    Energy2
    (kWh)
    Ambient
    water3
    temp
    (¡c)
    Solar
    System4
    (kWh)
    Electric System5
    (kWh)
    Ratio7
    Adelaide
    Brisbane
    Darwin
    Hobart
    Melbourne
    Perth
    Sydney
    4
    4
    3
    5
    5
    4
    4
    0.74
    0.81
    0.97
    0.65
    0.67
    0.77
    0.76
    3,728
    3,728
    2,796
    4,660
    4,660
    3,728
    3,728
    18.0
    21.7
    27.1
    14.06
    15.2
    19.5
    19.0
    77,914
    53,382
    9,586
    113,605
    104,812
    67,117
    70,651
    253,741
    229,748
    194,730
    279,681
    271,899
    244,014
    247,257
    3.3
    4.3
    20.3
    2.5
    2.6
    3.6
    3.5
    .
    See Note 4
    F is calculated from:
    (equation 2)

    F = Cp M(Tr - Ta)(1 - f)n

                       ne

    Where,

    • Cp Specific heat of water (4100 J/kg)
    • M = Mass of water used by the household per year (94,900 kg)
    • Tr = Required water temperature (57¡ C)
    • Ta = Ambient water temperature (¡ C)
    • f = Solar fraction
    • n = Life of system (15 years)
    • ne = Efficiency of conversion of primary energy into electric heat (25%).






    A comparison of the life cycle energy requirements of a fossil fuel powered system and a photovoltaic assisted system.
    1_1clear.gif (43 bytes)Equation 3 assumes identical maintenance requirements for both systems. This assumption may not be valid as pointed out by Berrill and Jolly [8] although should effect the present analysis very little.

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    (equation 11)

    ne = 100
             1 - f

    Where:
    f = solar fraction

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    ACKNOWLEDGMENTS

    The authors would like to thank the following persons who helped supply information.

    Ken Gutherie, Trevor Berril, Martin Greene, Graham Morrison, Charles Gay, Neville Jones, Peter Freise and Norman Sheridan.


    . .


    Notes:-
    1. Taken from Australian Standard 2002-1987 for a four person household.

    2. Capital energy includes collector, tank and Installation taken from O'Sullivan and Meldrum [5]. The figure of 3,728 kWh Is for solar systems using copper, (e.g. aluminium, plastic) have somewhat different energy requirements [5]. The figure of 3,728 kWh does Include 5% for maintenance, which Is reasonable, even though maintenance has been neglected in the energy consumption figures for the electric system, since solar collectors require more maintenance than all-electric systems.


    3. Calculated from data compiled by Szokolay [6] using methods presented by Lee and Gutherie [7]. The average temperatures given In the table were reduced by 5¡ C, when calculating the backup energy requirements for the solar systems, to account for lower solar fractions in winter.

    4. The total fossil fuel backup (F) - see formula @ left coloumn.
    The energies given apply to solar systems using the thermosiphon principle to circulate water through the collectors and tank. If the tank is not mounted above the collectors, electrically pumped circulation is required. This increases the fossil fuel backup by an amount approximately equal to the capital energy requirement (e.g. 3,500 kWh for a collector area of 4 sq m).


    5. The all electric systemiIs assumed to have a storage volume the same size as the solar system. The tank manufacturing energy requirements are 833 kWh.


    6. The average ambient water temperature for Hobart was assumed to be 14¡ C as data was not available.


    7. Column five divided by column six.







    REMOTE AREA POWER SUPPLY
    SYSTEMS (RAPSS)

    A typical RAPS System has a generator, solar array, battery and AC/DC inverter.

    In order to compute the total capital energy requirements of the system (C) it is necessary to acquire specific manufacturing data on all system components including the diesel generator, batteries, inverter, controllers and the renewable energy devices.

    A comparative analysis was undertaken which computes the difference (D) between the life cycle energy requirements of a fossil fuel powered system and a photovoltaic assisted system.

    An expression for D can be written as follows;

    (equation 3)

    D = nndRf - Cs - nndRs

    where,

    • Cs = Capital energy required to manufacture and install a photovoltaic array (kWh)
    • Rf = Average daily running energy requirements of the fossil fuel system (kWh/d)
    • Rs = Average daily fossil fuel requirements of the solar assisted system (kWh/d)
    • n = Life of system (y)
    • nd = Number of days operation per year
      (365 d/y)

    A further equation can be written by performing an energy balance on the system;
    (equation 4)

    ng Rf = ng Rs + fL

    where,

    • f = Solar fraction (fraction)
    • L = Average daily energy supplied to the batteries (kWh/d)
    • ng = Diesel generator efficiency (fraction)

    The capital energy requirements (Cs) can be written as follows;

    Cs= Ca Pa

    where,

    • Ca = Photovoltaic array energy construction requirements (kWh/peak watt)
    • Pa = Nominal power output of array (W)
            =  fL 1000                  (equation 6)

                    N
    • N = Average peak sun hours (h/d)

    Combining equations (3) to (6) gives,
    (equation 7)

    D = fL [ nnd - 1000 Ca]
                 [  ng
               N    ]

    For:

    • D   >  0,
    • Ca <  N  nnd
                1000 ng
      (equation 8)

    Substituting typical values of:
    N = 5, n = 15,
    nd= 365 and ng =  0.35
    requires Ca
    < 78 kWh/W.

    If this condition is met then the solar assisted system will consume less fossil fuels over its lifetime compared to an all diesel system.

    A detailed analysis performed by ARCO Solar [9] using data from a DOE/JPL report [10] has shown that the energy required to manufacture a typical module is 3.3 kWh/W.

    An allowance for transportation of the modules has been accounted for by assuming modules are transported on average 1000 km requiring 5500 kJ/tonne-km [5].

    A typical module weighs 0.2 kg/peak watt, increasing Ca to 3.6 kWh/W. Using this figure the energy payback period has been calculated from Equation 8 for the capital cities in each state. (See Table 2).

    The percentage energy savings (S) of the solar assisted system can be calculated from the following equation assuming the capital energy requirements are small;
    (equation 9)

    S    =        D       x 100
               nnd L          1

    ~
               100 f
                 ng

    Table 2. Energy payback for photovoltaic assisted RAPS Systems.

    Peak sun hours Payback (y)
    Adelaide
    Brisbane
    Darwin
    Hobart *
    Melbourne
    Sydney
    Perth
    * estimate
    5.04
    5.39
    5.95
    3.50
    3.97
    5.19
    4.72
    0.68
    0.64
    0.58
    0.99
    0.87
    0.67
    0.73

     

    DISCUSSION OF RESULTS

    The analysis performed on hot water systems has shown that the capital energy requirements (C) are small compared to the running energy requirements, except for a solar system in Darwin.

    In Darwin, however, the capital energy requirement for a solar system is just over 1% of the total energy consumed by an all-electric system and the net energy savings are maximised due to the high solar fraction. Of course as the solar fraction is decreased the fossil fuel backup becomes more significant although It still remains below 40% of the energy consumed by an all-electric system even for Hobart assuming the conditions given in Table 1.

    This means that a more detailed analysis of the capital energy requirements is not necessary.

    The energy efficiency is defined as follows;

    (equation 10)

    ne = Total   life  cycle energy of  all electric  system   x    100    Total life cycle energy of solar/electric system          1

    Equation 11 allows a quick estimate of the energy efficiency and shows that highest efficiencies will be achieved by maximising the solar fraction. This equation also implies that if we wish to minimise fossil -fuel consumption then we should be recommending much higher solar fractions than the present Australian Standards [ 11] .

    For the analysis of RAPSS it has been shown that the energy required to manufacture photovoltaic modules is small compared to the fossil fuel running costs.

    For all areas In Australia it has been shown that energy savings result In less than one year (Table 2) if a solar assisted system is used.

    Further analysis is required to determine whether the capital energy required to manufacture the entire RAPSS is small compared to the running energy requirements. If it is found to be the case then Equation 9 holds, indicating the adoption of high solar fractions if one desires to minimise overall energy consumption.

    If a similar analysis is performed for wind turbines it is very likely the same conclusions will be reached as wind turbines, located at good sites, have energy payback periods of about two years (Christensen [12]). The principles outlined in this article can be used to analyse other tasks such as house heating, transportation etc.

    6. CONCLUSIONS

    The present analysis has clearly shown, for the technologies discussed, that renewable energy devices consume much less energy over their life time compared to fossil fuel powered systems performing the same task. If the minimisation of energy consumption and pollution were a societal goal then we should be actively promoting the use of renewables.

    REFERENCES

    1. Chapman, P. Fuel's Paradise. Penguin, 1975.

    2. Boustead, I. and Hancock, G.H.
    Handbook of Industrial Energy Analysis.
    Ellis Horwood Publishers, 1979.

    3. Personal Communication with the Brisbane City Council Recycling Officer, M. Taylor July 1989.

    4. Sheridan, N. Industrial Energy Analysis. Presented at the Seminar, Improving Profits Through Energy Management, held at the Bardon Professional Development Centre on April 6, 1982, Brisbane.

    5. O'Sullivan, R.A. and Meldrum, R.T.
    Net Energy Analysis of Flat Plate Solar Water Heaters. Energy Authority of N.S.W., April 1984.

    6. Szokolay, S.V.
    Climatic Data and its Use in Design. Published by RAIE Education Division, 1982.

    7. Lee, T.
    Refinement of Estimates of Cold Water Inlet Temperature of Hot Water Volumetric Demand for Use In Solar Water Heating Performance Prediction. Presented at the Annual ANZSES Conference, Melbourne, 1988.

    8. Berrill, T. and Jolly, P.G.
    Effect of Energy Source/Task. Matching on Life Cycle Cost of RAPSS. Presented at the Annual ANZSES Conference, Canberra 1987.

    9. Gay, C. F.
    Energy Payback Calculations. ARCO solar, Inc. June 1989.

    10. New Processes for Photovoltaic Manufacture. DOE/JPL Report 954334.

    11. Australian Standard 2002-1987, Appendix D. 12. Christensen, B. Facts to Persuade The Disbelievers. Windpower Monthly, December. 1988.

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