Customer:
Siemens Ltd. (Canteen Facility, Kalwa, Mumbai)
Project Category:
HVAC Products
Customer Requirement:
Application: Hot water for cooking, soaking rice, cleaning utensils, and beverage preparation. Operating Pattern: 9 kL/day of hot-water demand, 312 working days/year. Existing System: Conventional ETC solar + electric coil heating (30% solar contribution). Goal: Replace with a high-efficiency CPC + heat pump hybrid system providing both 80 °C and 60 °C water, reducing PNG and power use.
Project Result:
Successful completion of Solar Water Heating Project
What we did:
The HeatRay hybrid system couples solar CPC concentrators and a 30 kW air-to-water heat pump to provide continuous hot water under varying weather conditions. System Logic CPC field (200 m² collector area) heats water and stores it in a 7 kL insulated tank. The heat pump activates during low insolation or when tank temperature drops below set threshold. The system generates 7 kL of 80 °C water daily. Of this, 3 kL is used directly (rice soaking and beverages), while 4 kL is mixed with 2 kL fresh water to supply 6 kL at 60 °C for utensil cleaning. PLC-based automation controls the entire process, managing sensor data, pump logic, and temperature mixing. ----------------------------------------------------------------------------------------------------------------------------------------------- Major Components -Heat Pump (30 kW): Air-to-water, Emerson Copeland scroll compressor, Siemens PLC control. -Condenser: Co-axial heat exchanger (SS/copper). -Evaporator: DEX aluminum-fin/copper-tube coil. -Pumps: Shakti / Kirloskar SS 304 multistage centrifugal. -Sensors: Dixell temperature sensors (Italy make). -Expansion Valves: Emerson / Danfoss / Sanhua. Flow Meter: Wikka SS 316. --CPC Collectors: 200 m² reflective area, no tracking required, low maintenance. -Automation: PLC-controlled sequencing with 3-way valve mixing for precise 60 °C/80 °C outputs. ------------------------------------------------------------------------------------------------------------------------------------------ Reliable daily supply of 80 °C and 60 °C water without reliance on electric coils. -Reduction in PNG consumption for cooking and washing by more than 40%. -Annual energy saving: ₹ 10.26 lakh/year. -Payback period: 3.5 years after depreciation (4.3 years gross). -“Make in India” hybrid system with low maintenance and long service life. ---------------------------------------------------------------------------------------------------------------------------------------------
Project Description
Siemens Ltd. aimed to modernize its canteen hot-water generation system, replacing an aging solar-electric hybrid setup that was unable to meet increased load and temperature requirements. HeatRay Solar designed and installed a hybrid hot-water system combining a 200 m² Compound Parabolic Concentrator (CPC) array with a 30 kW air-to-water heat pump, fully automated through a PLC-based control logic. The system provides 9,000 litres/day of hot water at dual temperature levels — 3,000 L at 80 °C and 6,000 L at 60 °C — used for cooking, rice soaking, beverage preparation, and utensil cleaning. --------------------------------------------------------------------------------------- Deliver 9 kL/day of hot water — 3 kL at 80 °C and 6 kL at 60 °C. Replace existing solar ETC with CPC concentrators for improved efficiency. Replace electric coils with 3× more efficient heat-pump technology. Reduce PNG consumption in canteen cooking operations. Ensure reliable operation during non-solar days through automatic hybrid control. Achieve 100% automation with minimal manual intervention.
Project Budget:
NA
Completion Date:
2026-04-15T00:00:00
