High-energy industries like mining, transport, and logistics face complex challenges in electrification and the transition away from fossil fuels.
Fraunhofer Chile drives innovation with bespoke solutions that leverage the most efficient technologies available for every specific scenario.
Since 74% of energy consumed in the industrial sector corresponds to heat, the development of cost-efficient clean thermal energy technologies is fundamental for decarbonization.
At Fraunhofer, our team of research engineers specializes in analyzing energy systems integrated into industrial processes. Our capabilities include data analysis, advanced sensor integration, and shading analysis, among other critical skills required for these complex projects.
Solar Heat for Industrial Processes (SHIP) is an innovative method for harnessing solar thermal energy. These systems utilize an array of solar collectors to capture radiation and transfer it to a heat transfer fluid, such as water or thermal oil. To ensure continuous operation even without direct sunlight, the heated fluid is typically stored in thermal tanks before being distributed. This stored energy directly supplies industrial operations—such as steam production, water heating, and drying—thereby significantly reducing reliance on fossil fuels and their associated carbon emissions.
Implementing SHIP systems offers numerous benefits. Beyond reducing the industrial carbon footprint, they lower long-term operational costs by utilizing a free, renewable energy source. Furthermore, diversifying an industry’s energy mix increases resilience against fossil fuel price fluctuations.
However, implementation also presents challenges. Initial investment can be significant, and feasibility relies heavily on factors such as solar radiation levels, available space for collectors, and specific industrial heat demand. Moreover, precise engineering and design are essential to efficiently integrate SHIP systems into existing industrial processes.
Industrial heat generation through SHIP represents a compelling opportunity for industries to reduce their environmental footprint by leveraging abundant solar energy. With ongoing technological advancements and adequate support, SHIP systems are poised to play a significant role in the transition toward a sustainable, low-carbon future.
Low and medium temperature SHIP
Globally, it is estimated that 67% of energy consumed by the industrial sector is used for heat. Of this, 51% falls within the low (T < 150°C) and medium (150°C < T < 400°C) temperature ranges.
These temperatures can be achieved using flat plate and concentrating solar technologies, enabling heat delivery to a wide variety of production processes in industries such as food and beverage, agriculture, chemicals, mining, and pulp and paper.
According to scenarios from the Long-Term Energy Planning (PELP), at least 35.8% of Chile's primary energy consumption corresponds to heat, with a high dependency on fossil fuels. This indicates that Chile has significant potential to decarbonize its energy mix, a potential further amplified by the country's exceptional solar irradiation levels.
High temperature SHIP
Energy-intensive heavy industries—such as iron, steel, cement, glass, and chemical manufacturing—require high-temperature processes (> 400°C). Aside from low and medium-temperature needs, 49% of total industrial heat energy is required for these high-temperature applications.
Currently, these sectors are dominated by fossil fuel combustion due to limited alternatives. Alongside replacing fuels with greener options like green hydrogen, integrating solar heat is a promising pathway.
While current solar concentration systems can reach these temperatures, testing heat transfer media and storage systems for each specific process remains necessary. The greatest challenge for solar energy integration is meeting continuous 24/7 energy demand economically, without compromising process parameters or product quality.
The industrial sector is Chile's largest energy consumer, accounting for 40% of total consumption. More than half of this is dedicated to process heat generation, with one-third specifically required for high-temperature processes.
Northern Chile is home to the majority of copper, salt, and metallic/non-metallic mining operations, as well as cement production facilities. As the world’s largest copper producer and the country with the highest solar potential globally, Chile is uniquely positioned.
With an average DNI of 2920–3650 kWh/m²/year, integrating solar energy can significantly contribute to industrial decarbonization and the achievement of 2030/2050 sustainability goals.
The decarbonization of the industrial energy mix requires the integration of clean energy sources, such as wind or solar thermal, which can be deployed at a competitive cost and with high availability.
Concentrated Solar Power (CSP) stands out as one of the premier global alternatives for increasing both the share of renewable electricity generation and 24/7 energy storage capacity.
These two features are essential for accelerating the integration of renewable energy into the power grid, mitigating energy curtailment, and providing system stability.
Concentrated Solar Power (CSP) is a technology that utilizes mirrors or lenses to focus a large amount of sunlight onto a small area. This concentrated light is converted into heat, which is subsequently used to generate electricity.
As of 2022, approximately half of the world's operational CSP capacity (6.3 GWe) utilizes molten salt storage.
The advantages of using solar salts as a heat transfer and storage medium lie in their low carbon footprint during production—resulting in a low environmental impact—as well as their high volumetric heat capacity. Furthermore, their ability to operate at high temperatures significantly enhances cycle efficiency.
Globally, over 80% of CSP projects planned through 2025—predominantly hybrid systems—are expected to feature molten salt storage. Given the significant potential of solar salts, it is crucial to consider their application in future CSP plants, particularly in combination with hybrid projects.
