SOLAR ENERGY RESEARCH at IOC-R&D Centre, Faridabad Dr. D.K. Tuli General Manager (Alternate Energy)

Coverage Solar Energy Research Plan of IOC-R&D –Approach –Line of action (strategy) –Basic research Solar Power Generation Plans of IOC –Solar Lanterns & other products –Solar hydrogen dispensing station –Large scale solar farms

Three-Pronged Approach 1.Infrastructure & Expertise Creation 2.Product Development & Technology Evaluation 3.Basic Research Projects

R&D Strategy - Infrastructure & Expertise Creation –Set-up laboratory facility for testing of lanterns and other solar energy driven products –Testing facility for solar panels –Up-gradation of laboratory facility To certification level –Discussions with TUV, Germany and Fraunhaufer, Germany For Solar Cell Research For Solar Thermal Research

Targeted Areas of Expertise Solar PV Testing of Modules & Components of PV Systems – Mechanical, Electrical, Environment & Other Related Tests Energy yield assessments – Study of local irradiation data & system details and long term yield forecasts compilation using simulations Site Condition Evaluation – Actual energy yield at the site including shadowing/seasoning and type of plant (off or on grid, pump systems etc) Technology advisory services – Based on global technology evaluation and relevant standards/regulations Plant monitoring, output energy yields checks and evaluation – Data logging and analysis capabilities Damage & fault assessment – Determination and analysis of damages & malfunctions of the systems including required repairs

Necessity for Comprehensive Testing Why? Prolonged exposure to weather and extreme temperature conditions Sturdiness of insulating materials Performance of wires Extent of current leakages Fire and health hazards For Whom ? -Grid tied systems -Government rebates and tax incentives -House insurance -Off-grid systems -Current leakages -Durability

Benefits of Comprehensive Testing Facilities Setting up of complete laboratory facility –Can be utilized for all R&D purposes as well as for certification purpose Sole Indian party status and second Asian certification country after Japan If utilized for certification, can earn extra revenue All collaborative basic research efforts shall be helped by leveraging the lab facility successfully and the pace of development will be enhanced by aggressive institution/industrial collaborations

Basic research areas: Advanced coatings Improved reflectors Advanced thermal collectors High temperature resistant thermic fluids Applied research areas: Hydrogen generation through solar thermal route Advanced solar systems for refinery steam pre-heating solar assisted biomass gasifiers air heating & drying etc. Targeted Areas of Expertise Solar Thermal

Hydrogen through Solar Energy

–Technology / product tie-ups –for LED lanterns & other appliances development –for panels –for solar thermal products –IITs & CSIR labs such as CMERI, CEERI, CAZRI etc –Existing technology evaluation and data generation Actual field evaluation exercise on controlled basis on a 10 KWp size plant complete with data management facilities –Power generation & data logging to evaluate all possible commercial PV technologies amongst following : »Mono and/or multi c-Si »a-Si »CPV »CIGS »CdTe – Activity can be extended further for all remaining cell technologies under incubation R&D Strategy Product Development & Technology Evaluation

Basic research for Improved Solar Systems R&D Strategy – Basic Research Outsourcing & Collaboration Focus on 3rd & 4th Generation PV Cells Solar thermal systems leading up-to hydrogen generation

Solar Lanterns from IndianOil Made for poor, adored by rich…….a viable solar power generation for India

Kerosene use - Market Surveys Puri & Bhubaneswar ParameterUnitPuri Sea beachNolia basti, PuriUnit-12, BBSR Target segment Mostly small shops (39/500) Mostly fishermen (49/700) Slums (36/200) IncomeRs./day (Range) 200/- (50-500) 110/- (75-200) Not divulged Kerosene consumption ltr/month (Range) 40 (10-70) 20 (7-35) 23 (10-60) SKO price Rs./ltr (Range) 27/- (23-30) (20-30) 25/- (25-28) Monthly SKO spend Rs./mont h (Range) 1071/- ( ) 515/- ( ) 574/- ( ) Amount ready to pay for SL Rs./day (Range) 4.10 (3-5) 4.70 (3-12) 4.60 (3-5)

The hows & whys of solar lights Brighter than kerosene lights –15-20 times better quality light lumens vs lumens (kerosene ‘dibri’) No smoke –Virtual elimination of soot-related health hazard Cheaper than kerosene lights No moving parts, very little maintenance Near-zero heat –Can sit very close to lamp: boon to villagers & shopkeepers Above all, endless source of energy Solar light brighter, healthier & cheaper than kerosene lamps

Solar lighting options for the poor & middle class 1. Central charging station with lanterns on rental for low- income villagers –Regular income for the rural entrepreneur –Micro-financing by MFI/RRB/CB for purchase of lanterns by the poor 2. Solar lights with small panels for relatively well-off villagers –Direct purchase & use 3. Village adoption 3 options Options 1 & 2 practical for both urban & semi-urban customers Low-income areas Shops/mandis (marketplace) Emergency lights Options 1 & 2 practical for both urban & semi-urban customers Low-income areas Shops/mandis (marketplace) Emergency lights

Solar Charging Station (SCS) Solar charging stations –At RO/KSK/LPGD or Any central location Direct charging during the day –Batteries inside the lanterns The Concept D(PBD) inaugurating SCS, Sathla KSK Rooftop solar panels, Sathla KSK

Solar Charging Station (SCS) Customers pay rent for lantern & a fee for charging lantern on a daily/monthly basis –Every evening, Customers bring the discharged lantern and take a charged lantern with them –Alternatively, the charging station owner arranges for delivery & collection of lanterns The Concept

IndianOil’s Solar Charging Station KSK, Sathla, UP

IndianOil’s Solar Lantern Charging Rack KSK, Chokoni, UP

IndianOil’s Solar Lantern in use Ujhari village, Gajraula, Bareily DO Sweet shops using IndianOil’s solar lanterns A chemist shop using IndianOil’s solar lanterns

Solar Lantern’s Specifications ParametersMNRE IndianOil PV module2.5 – 5 (Wp)2.5 – 4.5 (Wp) BatteryUpto 12V4 – V Electronic efficiencyMin 80% Average duty cycle per day 4 hours Central charging  Upto 6 hrs in full brightness  Upto 8 hrs in dimmer Stand alone mode = 4 hrs Autonomy14 hours Lux (1’)V=105 H=32(*) Three categories

INDIANOIL’s Solar Lanterns (Proposed Target Specifications ) ParametersSolar LampSolar LanternsSolar Petromax PV module2.5 Wp 4.5 Wp8 Wp BatteryUpto 3.5 6/12 V 5 6 V V Electronic efficiency Min 80% Average duty cycle per day Central charging  5-6 hrs in full brightness  7-8 hrs in dimmer Stand alone mode = 4 hrs Central charging  5-6 hrs in full brightness  7-8 hrs in dimmer Stand alone mode = 4 hrs Central charging  5-6 hrs in full brightness  7-8 hrs in dimmer Stand alone mode = 4 hrs Autonomy Lux (1’)V = H =15-25 V = H = V > 190 H > 65

IOC-R&D Plan & Targets ( ) New product development –Rural usage Lanterns Solar powered fans Pump sets Street lights –Urban usage Home lighting systems Fans Garden lights Mobile chargers Street lights Inverters Captive power generating sets –Miscellaneous (Industrial including commercial buildings) usage Cookers Power generating units Demo Projects –Installation of solar powered systems within R&D –Extending support to install solar systems in sister divisions –Setting up some proven technological units in the country as demo units to leap-frog the technical know-how ~ 50+ MW (12000 ROs x 6 W/d x 200 days x 4 years) Solar Mission target = 200 MW for of-grid by 2013

Development of Solar based HCNG dispensing station at Delhi during Commonwealth Games  To gain experience with onsite Solar Hydrogen Production infrastructure and Hydrogen HCNG utilization in automotive vehicles  To study performance, emission, reliability and safety aspects of hydrogen powered vehicles  To demonstrate Hydrogen / HCNG powered vehicles for public awareness and acceptance during Commonwealth Games Project Objectives

Work Plan IOC will set up on-site Solar Photovoltaic / Electrolyser based hydrogen dispensing station. The station will comprise the following Solar photovoltaic panels Electrolyser Hydrogen compressor Hydrogen Storage Blender & Dispenser

Infrastructure Required S.No.DescriptionSpecification 1Solar Photovoltaic System 25 kW (Peak- 50 kWp) Output : 100 V (DC) 2Electrolyser 5 Nm3/hr Purity; % 3H 2 Compressor Suction Pressure: 5-10 bar Discharge Pressure: ~450 bar 4H 2 StoragePressure 450 bar 5HCNG BlenderBlending Range: 0-50% (v/v) 6DispenserHCNG : bar Hydrogen : 350 bar

Facility Creation Product Development & Evaluation Basic Research Medium term Long term Short term GOAL Future Fuels A progressive & profitable energy centre of repute having international level research facilities, development expertise and certification accreditations

Basic Research on New Generation PV Cells Possibilities: Multi junction devices –Stacks of single junction cells in descending order of band-gap –Top cell captures high-energy photons and passes rest on to lower band-gap cells New materials / material technologies –Nano PV cells –Dye sensitized cells –Polymer cells Concentrator PV –Concentrates and utilizes maximum sun power

PV Cells…..theoretical projections PROS: Multi junction is one of the approach to exceed single junction efficiencies For 50% efficiency, it is mentioned that 5 junctions shall be needed assuming 80% absorption is possible CONS The tandem approach is limited by the availability of stable materials of desired band gaps Concentration possess challenges in acceptance angle and thermal management as the degree of concentration is increased # Junctions in Cells1 Sun µMaximum Concentration µ 1 Junction30.8%40.8% 2 Junction42.9%55.7% 3 Junction49.3%63.8% n Junctions68.2%86.8%

Hydrogen generation through Solar Energy –Comparative study of PV & Thermal route Building Integrated PhotoVoltaic –Emerging & promising area Polymeric Materials and chemicals used in solar panels – Polymeric films – Adhesives Hybrid Systems –Fuel cells –Combustion engineering Solar Energy Some Interdisciplinary Areas of R&D

Type Testing – SOLAR PV Terminal Robustness Tensile and/or torque test on electrical terminations to assess the ability to withstand the normal stresses associated with handling and insulation IEC IEC IEC UL , 28 IEEE & Static Mechanical Load Test Determines the ability of the module to withstand wind, snow, ice, or other static load IEC IEC IEC UL IEEE Impact Test Assesses the adequacy of the system to withstand impact forces UL Surface Cut Susceptibility Verifies if the covering surface can withstand surface cuts UL IEEE IEC Junction Box Securement Verifies if junction box can withstand tensile pull forces UL Hail Impact Test Simulates hail impact to determine the ability to withstand and survive severe hailstorm conditions IEC IEC IEC ASTM E-1038 & E 822 IEEE & MECHANICAL TESTS

Type Testing – SOLAR PV Thermal Cycling Rapid cycling of temperature extremes between -40 C and + 85C for 200 cycles at 6 hours per cycle to test the ability to withstand thermal mismatch, fatigue or other stresses caused by rapid, non-uniform or repeated changes of temperature IEC IEC IEC UL IEEE & ASTM E Humidity Freeze Cycling Rapid cycling of both temperature and humidity extremes similar to thermal cycling with additional high 10 cycles per 24 hour. Determines the ability to withstand high temperature and high humidity followed by freezing temperatures IEC IEC IEC UL IEEE & ASTM E Damp Heat Test +85C & 85% RH for 1000 hours to test the ability to withstand the effects of long-term penetration of humidity IEC IEC IEC IEEE & ASTM E ENVIRONMENTAL TESTS

Type Testing – SOLAR PV Ground Path Continuity / Bonding Path Resistance Verifies electrical continuity between all exposed conductive parts and the grounding point under high current condition IEC IEC UL IEEE IEEE ASTM E Electrical Isolation (Including wet/dry hipot, leakage current and dielectric voltage withstand tests) Measures the quality of electrical insulation under various conditions. Verifies the adequacy of electrical insulation between all active parts of the power generating circuit and the frame or the outside world IEC IEC /10.5 IEC UL /26/27 IEC ASTM E /7.2 IEEE ,5.5,5.6 IEEE ,5.5,5.6 Bypass / Blocking Diode Terminal Test (Non- intrusive) Assesses the adequacy of thermal design and relative long-term reliability of bypass/blocking diodes used to limit the detrimental effects of system hot- spot susceptibility IEC IEC IEC IEEE IEEE Impulse Voltage Verify the insulation’s ability to withstand over-voltage UL ELECTRICAL TESTS

Type Testing – SOLAR PV Temperature Coefficients Determines the effect of temperature on the current, voltage and peak power output of the module IEC IEC Temperature Tests Verify the system to withstand high heat without showing signs of stress or deformation IEC UL Visual Inspection Visually inspect system for damage and compliance with design criteria IEC IEC IEC IEC IEEE & ASTM E 1799 OTHER TESTS

Learning from the Workshop Solar PV and Solar Thermal are two distinct and separate areas of solar energy research Traditionally, solar thermal was more in use quantitatively, while solar PV is now spreading far & wide Total installed solar thermal capacity in world ~ 500 MW Total installed solar PV capacity in world ~ 15 GW At present, installing solar thermal plant is relatively cheaper than solar PV plant of equivalent capacity

Solar Thermal – Some Areas Under R&D Basic research areas: Advanced power cycles Advanced coatings Improved reflectors Advanced thermal collectors High temperature resistant thermic fluids Applied research areas: Development of organic Rankine cycle system Solar dish engines such as Stirling/steam/micro-turbines for decentralized power Development of suitable receiver systems Solar energy storage devise – Solargas, Fuel Cells, Molten salts with low freezing temperatures and options for low & medium temperature applications Development of heliostats with automatic tracking controls Advanced solar systems for cooling green buildings cooking air heating & drying etc.

Areas of basic research: –Crystalline silicon based solar technology Modeling & simulation of novel structures Reduction in optical losses Reduction in wafer thickness Indigenous development of transparent conducting light trapping oxides (TCLO) Development of silver paste etc –Non-crystalline based solar technology Development of CIGS (Copper indium gallium di-selenide) based solar modules Amorphous silicon based modules Nano-silicon & dye sensitized modules Areas of applied research –Improvement of module life –Module making processes –Low weight modules etc. Solar PhotoVoltaic – Some Areas Under R&D

RESOURCES NEEDED…..cumulatively 2010 – Initiation & lantern project 2011 – Data generation & research project initiation 2012 – Building & lab upgradation + demo projects onstream 2013 Projects fructifications Landmarks * * In case of certification/accreditation lab

LIST OF ACTIVITIES ActivityDedicated Manpower Quantity Lantern project2 Equipment procurement & Building/lab set up 2 Lab upgradation2 Product development (PV + thermal)2 (1+1) Solar fuels (gasification + reforming)2 (1+1) Data generation (PV + thermal + outside R&D) 3 (1+1+1) Demo systems3 Propulsions2 TOTAL