TTK Prestige India

	General information

Name	TTK Prestige India
Country installed	India
Address	TTK Prestige Ltd, SF NO 234/1, Pollachi Road, Myleripalayam Pirivu, Coimbatore 641032, Tamilnadu, India
Industry sector, NACE code	C - Manufacturing
Solar thermal system owner / operator	M/s. TTK Prestige Ltd
Solar thermal engineering company	M/s. Sun Best, Theni
Process integration engineering company	M/s. Sun Best, Theni
Year of operation start	2007

	Technical parameters

Collector technology	flat plate collector
Collector name
Installed collector area (gross), m²	768.0
Installed collector area (aperture), m²
Installed collector area (absorber), m²	384.0
Installed thermal power (estimated), kW_th	537.6 (Default value calculated by multiplying the gross collector area by 0.7 kW_th/m²)
Solar collector loop heat transfer fluid	water
Solar energy storage	other
Storage volume, m³	32
Kind of conventional heat source	other
Kind of fuel used	other

	Process

Solar thermal energy used for	Hot water requirement in washing plant for degreasing of cooker vessels
Unit operation	other process heating
Point of Solar Heat Integration	B2) Heating of process medium (please specify)
--> Integration how and where	Solar heated water is circulated in heat exchanger to keep bath ( 2000 L x 4 nos) temperature around 60 Deg C
--> Temperature range process	For each unit there are two numbers of 2 KL insulated SS 304 solar water tanks and each tank connected to 24 solar panels for heating one 2000 liter water bath. The water in the solar panel is heated by thermo siphon effect. The first tank output is given as input to the second tank. Though it is a closed loop system to offset evaporation losses make up soft water line is connected to the first tank. There are two number of 1000 liter soft cold water tank fixed 10 feet above the solar collector. The solar hot water output taken to the lower end of heat exchanger (SS 316 L). The heat exchanger outlet is connected to a pump which is connected to the cold water inlet of the first 2 KL tank. There are two sensors - first one in the water bath and anther sensor in the solar insulated tank. Whenever the temperature goes below 55 Deg C, the pump will be start to push the water, so that hot water will flow through the heat exchanger. The hot water line fully insulated to avoid temperature losses.
--> Temperature range solar loop (min/max), C°

	Economic parameters

Total investment costs (excl. VAT), €	91,930.00 (Turnkey costs including solar collectors, piping, support construction, storage, design, commissioning reduced with subsidies)
Solar loop (excl. VAT), €	(Solar collectors, piping, support construction)
Solar energy storage (excl. VAT), €
Others (excl. VAT), €	(Design, commissioning, others)
Process integration (excl. VAT), €
Subsidy, € or % of total investment costs	30643 Subsidy availed from MNRE
Cost for fuel replaced, €/MWh_fuel
Calculated solar thermal system life time, a	15
Annual useful solar heat delivery, MWh/a
Specific annual useful solar heat delivery, MWh/am²
Specific investment costs, €/m²	119.7
Solar fraction, %	85

	Lessons learned

Initiative	Dr C Palaniappan – MD of Sun Best was known to the company basing on his earlier successful work on solar air heater – the co. had requested him to initiate this project.
Integration methodology	The conventional fuel per day is 75 litre of diesel ( net calorific value 10500 kcal/litre). Operating hrs 12 hrs/day. Conventional system efficiency reported by the company 80%. Average solar radiation at the site: 4.97 KW/m2/day. Overall efficiency of solar water heater: 40%. Energy demand = 75 (litre) X 10500 ( kcal) X 0.8/860 = 732 KWH. Solar collector needed = 4.97 (KW/m2/day) X 0.4 = 368 sq.m or 184 panels of 2 sq.m each. We have chosen 192 panels or 384 sq.m for nearest standard value
Crucial Interfaces	Designing of heat exchanger and coupling with the system. Experiences / lessons learned: initially iron heat exchanger was installed and at a later stage the same is converted into SS 316 L heat exchanger for better result.
Construction / Commissioning	Nearly 4 such large projects on water heating had been executed by our group – we were able to solve many issues.
Operation / Performance	During sunny days the system performed well. Cloudy days and partial rainy days, problems faced in raising the bath temperature to the needed vlaue.
Recommendations	Basing on our experience and also to avoid a conventional boiler starting In the late hours to meet a low percentage of thermal load that could not be supplied by solar due to low radiation, 3kw x3 Nos of electrical immersion heaters are introduced in each 2kl tank so that the solar storage tank temperature could be maintained 10 degree Celsius above the bath temp.

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