3.1. Dimensioning
● Case 1 calculation
The dimensioning process of a district heating system involves the calculation of three main sections: the generator plant, the distribution system and the substations. Geothermal energy was in this case selected as the energy source to constitute the generator plant. By using the energy demand of the set of buildings integrating the district heating, the geothermal installation was calculated by the software “Earth Energy Designer” (EED). This software, developed by Blocon Software (Lund, Sweden), allows knowing the total drilling depth of the vertical closed-loop system and the heat pump power required in the plant. The calculation process of EED is based on a series of initial data (provided by the user) about the installation and the ground where it will be placed [
26,
27,
28]. These initial data include the selection of the heat exchangers design. For this research, double-U polyethylene pipes of 32 mm in diameter, will allow the thermal exchange with the ground.
Once introduced the particular data of the system in question, EED evaluates the main parameters of the geothermal installation. In this way, the heat pump power and the number and length of boreholes required to cover the specific demand were calculated. During the process of calculation, the software suggests a series of alternatives. For the present assumption, the most optimal option (the first one) was selected so the installation requires a heat pump power of at least 330.62 kW and 49 boreholes of 178 m depth spaced every 20 m. The general distribution of each of the components of the geothermal district heating is presented in
Figure 6.
By the above calculations, the part of the system corresponding to the geothermal installation (generator plant) was completely defined.
In relation to the distribution system, it was designed as a double-pipe system connecting the generator plant with each building. As made in the generator plant, this section was also thoroughly established. The diameters of the pipes were defined according to the mass flow rate. The required mass flow rate was calculated using Equation (1):
where:
= mass flow rate (kg/s),
= Capacity (kW),
= temperature difference (K) and
= specific heat capacity (kJ/kgK).
Considering PEX-a pipes, it was possible to observe at the nomogram of
Figure 7 the recommended pressure loss area (in darker colour) for this kind of pipes. This nomogram allows knowing the diameter of piping required in function of the power installed and the expected thermal increase. On the basis of these data, the pipe diameter (mm), pipe friction resistance (kPa/m) and velocity (m/s) are directly deduced.
Entering in the nomogram the power installed in each section, the diameters of each pipe were directly obtained. The pipe friction resistances and velocities corresponding to those pipes were also established.
Table 3 lists the descriptions of each section of pipe.
It must be clarified that the total power installed (section 1–2) should be 330.62 kW according to the calculations presented above. However, it is not possible to find commercial heat pumps with that exact power. Thus, the most similar commercial power was the 360 kW listed in
Table 3.
Another important aspect to be considered is the heat loss through the pipes previously selected. They were accordingly calculated from the thermal transmittance provided by the manufacturer for each pipe diameter (considering pipes mounted in the air). These calculations can be found in
Table A3 of
Appendix A. Heat losses results are obtained for each section by the product of the thermal transmittance, the piping length and the thermal increase. The thermal increase considered in this
Table A3 (80 K) represents the maximum increase that could be achieved in the system conditions for which the maximum heat losses would be found. Since the total losses are fewer than 3%, they have not been considered for subsequent calculations.
Substations were the last modules to be defined. They must be integrated by a set of heat exchangers, a buffer tank and different regulation and control devices. The buffer tank is responsible for adjusting the temperature and pressure conditions of the fluid coming from the generator plant. Its capacity was defined according to the “Regulation of thermal installations in buildings” (RITE) [
30], which recommends a volume of 15–30 litres per kW of usable nominal power generated. Additionally, heat exchangers connect the generator plant with the primary circuit as well as the primary circuit with the rest of secondary nets. These systems were selected in function of the power installed in the section where they are placed. All of them were designed to work with the following conditions (
Table 4):
● Case 2 calculation
The process of calculation of the geothermal district heating in this second case was equally performed by using the EED software. In the present option, the 70% of the whole demand (demands of buildings presented in
Table 1) is covered by the renewable part of the mixed system (geothermal district heating). Therefore, entering in the software with the pertinent demand and the rest of specific values of the ground and installation, new working conditions were obtained. Thus, a heat pump power of 229.38 kW was needed and 36 boreholes of 193 m depth spaced every 24 m were required.
The same methodology than in the previous assumption was also applied to define the distribution system and substations in case 2. Given that the system of piping is identical, Equation (1) and nomogram presented in
Figure 7 were also used to define the main parameters of each section of piping. These parameters can be found in
Table 5.
Substations are constituted by the same elements described in case one. A buffer tank was also selected in this second option with a lower capacity since the total power was also lower. Relative to heat exchangers, they were designed to operate with the conditions previously collected in
Table 4. The selection of these devices was also made depending on the power installed in each section.
Lastly, the remaining 30% of the global demand was covered by the set of individual natural gas boilers placed in each of the buildings. Thus, additional calculations were not needed given that the mentioned heaters were already installed and operating.
● Case 3 calculation
The generator plant was in this case planned to be constituted by a geothermal system and a sole natural gas heater. The geothermal plant was identical to the one calculated above for case 2 (since it covers the 70% of the demand too). Regarding the natural gas boiler, considering and efficiency of 0.9 (higher than the existing devices), to cover the 30% of the current demand (obtained from the consumptions of
Table 1), a heater device of at least 218.9 kW would be needed. Thus, three commercial natural gas heaters of 80 kW (each one) were chosen providing enough power to supply the requested demand.
In relation to the distribution system and substations, they were designed to transport the whole power produced in the generator plant. Since the total distributed power was the same than in case one, the dimensioning process was identical and therefore parameters were those presented in
Table 3 and
Table 4. Therefore, piping, buffer tank and heat exchangers were the same than in case one.
3.2. Economic Analysis
Along this subsection an economic calculation is presented for each of the assumption considered in this research. This analysis includes the initial investment and operational costs as can be seen below.
3.2.1. Initial Investment
● Case 1
Once the first case was designed, it was possible to calculate the initial investment required.
Table 6 presents the unitary and the total price of each of the components of the generator plant, distribution system and substations that are part of the geothermal district heating. Additionally, the total investment for this assumption is also collected in
Table 6.
● Case 2
As in the first option, the initial investment was calculated as follows: regarding the natural gas installation, and given that it already exists, the initial costs of this part of the mixed system are zero. For this reason, the initial investment corresponding to the second case only includes the elements required in the geothermal district heating. Thus, the same elements of the previous option were also considered in this second assumption.
Table 7 presents the initial investment of the mentioned elements belonging to the geothermal district heating of the second option.
● Case 3
The initial investment for case three includes the costs associated to the general district heating system. On this matter, the investment of the generator plant must consider the implementation of the geothermal module and the natural gas boiler. The costs connected to the distribution system and substations were identical to those calculated in case one.
Table 8 collects the initial investment that case three involves.
3.2.2. Operational Costs
● Case 1
Despite being a completely renewable installation, in addition to the initial investment, several additional costs have to be considered. Such costs mainly correspond to the heat and circulating pump operation and the periodic installation maintenance.
Most of the energy consumption derives from the heat pumps working. The excellent coefficient of operation (COP) of these devices allows them to provide a notable quantity of thermal energy consuming a minor amount of electricity. For the present case, two heat pumps of 180 kW (produced by ENERTRES, Galicia, Spain) connected in series provide a total of 360 kW that thoroughly cover the demand of 330.62 kW previously calculated. According to the manufacturer’s data, the power consumption of each of these devices is 40.92 kW, given the high COP (4.27) they have. This COP was calculated from the mean temperature of the fluid simulated with EED software for a thirty years operational period. From this simulation presented in
Figure 8, the mean temperature of the fluid (3 °C) was estimated in order to obtain the mentioned COP for that period and according to the European Normative UE 813/2013 [
31].
Heat pumps will be operational during 9 months a year for an average of 10 h a day (considering the climatic conditions of the area and the use of the buildings). It means an electrical use of 220.968 kWh/year for the set of geothermal heat pumps. It is important to clarify that the high seasonal COP is possible thanks to a combination of different factors. The heat pumps connection (in series) increases the COP of the second heat pump, this fact joined to the favourable geological and hydrogeological ground conditions result in an improvement of the global COP. Additionally, the ground/heat pump contribution ratio shoots up the COP with a small ground contribution increase. This fact can be observed in
Figure 9.
Since the electrical use of the rest of components that integrate the geothermal district heating was comparatively lower, in this section, only the heat pumps consumption and the maintenance of the whole installation were considered.
Table 9 provides the costs associated to the mentioned items.
● Case 2
The operational costs in this case derive from the heat pumps operation and maintenance of the whole district heating system as well as the fossil installation working. Regarding the geothermal plant, two heat pumps (of 90 kW and 140 kW) connected in series provide 230 kW to supply the previously calculated power of 229.38 kW. The COP of these pumps is also extraordinary (of 4.27 and 4.33 respectively) and hence, the power consumptions of these devices are 20.46 kW and 32.76 kW. These COP values were equally calculated as in the previous case 1. Likewise, heat pumps will be operational during 9 months a year to an average of 10 h a day. Thus, the electricity use of both heat pumps will be of 143.694 kWh/year. As in the previous case, the electricity use of the rest of components of the geothermal district heating was not considered (since it is comparatively lower).
Thanks to the geothermal system, the 70% of the total demand is covered. The remaining demand is provided by the existing fossil installation. For this reason, the operational costs must also include the pertinent natural gas use.
Table 10 collects the operational costs including all the mentioned items.
● Case 3
In this last case, operational costs include the district heating working which, in turn, involves the heat pumps and natural gas heater operation besides the maintenance of the whole general system.
Since the geothermal plant was designed to cover the same demand than in case two (70% of the total demand), heat pumps described in that case are also used here. Thus, a power consumption of 143.694 kWh/year is required to supply two heat pumps of 90 kW and 140 kW. Natural gas use of the heater that integrates the generator plant must be also considered in this section. As in the previous case, operational costs for the natural gas are calculated considering the natural gas use (kW/h) and a local rate of 0.056 €/kWh + 4.54 €/month.
Table 11 shows the operational cost corresponding to case three.