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"Hey, we don't need you. You haven't got through college yet:'
-HP managers to Apple co-founder Steve Jobs
Chapter 4
Opportunity II
Powering Industry:
Industrial Scale Solar
0 n Monday June 12 2006, the United States soccer team dis
appointed again by losing 3-0 to the Czech Republic at the
FIFA World Cup in Germany. Five million individual soccer fans
worldwide viewed 226 million pages and 425,000 video streams
on the FIFA website hosted by Yahoo, lnc 101 To serve all those
millions of pages the company has built data centers around the
world comprising about half a million computers that search,
store, manipulate, and distribute documents, photos, videos, and
other data. The energy to power those computers and the air-con-
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ditioning to cool them costs Yahoo about $100 million per year.
Energy is Yahoo's second largest expense, after employee payroll.
Google, the largest web company on Earth, does not di-
vulge its energy spending. Using publicly available information,
though, I can deduce that during fiscal year 2008 Google spent
about half a billion dollars to power their massive data centers.
Here's how I arrived at that staggering figure:
It's not that Google hasn't tried to stop itself from suck-
ing up massive quantities of energy. Google works hard to make
its business energy-efficient. It provides accessible, comfortable,
and free buses to transport its employees from San Francisco
to and from its headquarters 40 miles south of the City. It pro-
vides bicycles for commuting on the Google campus in Moun-
tain View. The corn pa ny has a water treatment facility at its data
center in Belgium .
But the web colossus has taken further steps into the
cleantech market. Google's not-for-profit arm, Google.org (now
Google Ventures) has invested in companies whose goal it is to
make solar energy cheaper than fossil fuel energy. Its slogan
"RE<C" (Renewable Energy cheaper than Coal) has shown the
world how corn panies can influence the energy conversation in
a positive way. Google Ventures has invested millions in compa-
nies like eSolar and BrightSource that aim to build gigawatts of
solar power plants. This is a good thing for the planet-and ulti-
mately a great thing for Google's bottom line.
Data centers are the aluminum smelters of the information
age. They consume massive amounts
of energy and need to be located near "Data centers are
plants that produce "cheap" and abun- the aluminum
dant power. The average data center smelters of the
in 2008 was 50,000 square feet and information age:'
needed 5 MW of energy capacity.
Just like Walmarts, Home Depots, and supermarkets, how-
ever, data centers are being supersized . The "average" data center
in 2020 is expected to be ten times larger than its 2008 "small"
siblings: 500,000 square feet. It's also expected to need a capac-
ity of 50 MW. 103 The cost of the power to run data centers in
2005 was $18.5 billion. The following year, 2006, data centers
consumed 61 billion kWh, or about 1.5% of all U.S. electricity
demand 14
By 2020, the energy cost for data centers in the United
States is expected to ri se to a staggering $250 billion. This is about
twice New Zealand's Gross National Product in 2007 ($128 bil-
86 Solar Trillions
Solar Chips
Frito-Lay is one of America's largest snack and "potato"
chip manufacturers. Brands like Doritos, Tostitos, and SunChips
have been satisfying (and growing) America's taste for crunchy
eats for decades. Frito-Lay, a subsidiary of PepsiCo, makes these
chips in seven plants around the United States, including Ari
zona; Piano, Texas; and Modesto, California.
It is ironic that Frito- Lay's SunChips, which are manufac
tured in Modesto, one of the sunniest places in America, lacked
one key ingredient: the sun111 Granted, FossilChips would not
sound right. Nor would GasChips, even though the chip manu
facturing process in these plants has traditionally relied on natu
ra I gas to heat the oi I that fries the ehips. Not any more.
In 2008 Frito-Lay unveiled a 2.4-MW solar thermal plant
(built by Abengoa Solar) to generate steam directly and power its
industrial process heat. This plant consisted of 5,065 m 2 (54,500
square feet) of aluminum parabolic-trough collector mirrors that
heat pressurized water to temperatures of up to 249 C {4 80 F).
SunChips are now truer to their brand name because they're
made using the sun. The solar-heated water is pumped into the
manufacturing plant's boiler system, which routes it to the ce
real (wheat or corn) heater and the cooking oil heater. As usual
in this solar technology, the water is then recirculated in a closed
loop to be heated again.
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sion losses, and when that electricity arrives at its destination and
is used to boil water, still more energy is lost. In the end up to 85%
of the primary energy is dissipated. But solar parabolic trough
technology can heat water or steam directly with the sun, with
out wasteful intermediate steps. To do this, a power plant simply
uses water rather than oil as the heat transfer fluid in the receiver
tubes. This is what Frito-Lay did in its Modesto SunChips plant.
By boiling water directly, companies save on the ineffi
ciency of having to generate electricity to do it. Heat doesn't
travel well, so the solar thermal (parabolic trough) plant needs
to be close to the user of that heat or actually onsite. Frito-Lay
manufactures more than 145,000 bags of SunChips per day us
ing its own onsite 384-collector system, and in the process the
company avoids causing the emission of 1.7 million pounds of
CO 2 , the carbon cost of generating the needed energy in a coal
fired plant.112
Figure 4.2. Energy usage across sectors in the United States, 2004.
(Source: USDOE113)
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Temperature
Industrial sector Process
level [C]
Figure 4.4. Energy loss diagram in a fuel-based process heating system 121.
Egyptian Cotton
Remember Frank Shuman from Chapter 1? Shuman was
a celebrated inventor in an era when inventors were like today's
rock stars: Edison, Bell, Marconi, Tesla. Born in 1862 in Brook
lyn, NY, Shuman had hundreds of patents in his name by the
time he died and was featured in Scientific American twice in a
single year. 122 His invention of shatterproof glass was an imme
diate commercial success that made him famous and wealthy
before he was 30 years old.
Shuman's real passion in life was solar energy. At a time
when Egypt was the largest producer of cotton in the world,
Shuman engineered, raised financing for, and built that solar
power in Maadi. The plant generated 65 horsepower to pump
6,000 gallons of Nile river water per minute and irrigate the
cotton fields. To make his design work, Shuman invented many
corn ponents used in solar plants with only slight changes today.
For instance, he created a low-pressure steam turbine that proc
essed four times more energy than anything then available in the
market.
co,sts an,d z,ero carbon andl merc ury emiss1,ons. Also, you canno,t
1
2030 127 At that ti'me th,e 1,eveliz.ed cost of ener,gy 1pr,oduced b,y
these plants will !be as l ow as 2 c/kWh i'n So1uthern Europe.
1
dow n t0 1 1
3.5 /kWh
loo,k for areas w:ith cheap electricty to by 2020.
p ower their massive data centers, they
1
Un1su1bsidized
coulld do much wors e than 3.,5 <:/kWh 1
sollar will be
in 202,0 and 2, (:/kWh by 2030. ,ch eaper than 1
Aswan Da1m and the Suez CanaL Can this co,untry rise to the
chaUenge of ,making itself an energy, world p,ower'? Two centuries
aft e,r Napoleon's m.ilitary power invadedl Eg1ypt, Cairo can turn
1
the tables by exp,0 rti'ng so,lar power back to Europe. This time,
1
Solar Millennium
Solar Millennium's office Is In an unimposing building in
an unimposing part of Berkeley, California. My first conversa-
tion with Rainer Aringhoff, the President of Solar Millennium
(USA), lasted about two and a half hours-but it occurred to
me that if I had brought good beer or wine instead of coffee, we
could have talked into the wee hours of the morning.
Or rather, I could have listened to him all that time. Mr.
Aringhoff is one of the few executives who have been in the
solar industry since the early 1980s. He is still very much of this
industry, and he's certain that this time, the conditions are ripe
for solar to make a significant leap. Back when President Jimmy
Carter funded the fledgling solar industry to achieve American
"energy independence" from Middle East oil in the late 1970s,
Aringhoff was working to make that vision come true.
After Carter left the White House, the solar industry faced
rapidly diminishing research and development budgets until it
almost disappeared from the map. (One of the first things that
newly inaugurated President Ronald Reagan did in 1980 was
to have the symbolic solar panels installed by his predecessor
ripped from the White House roof.) Partly as a result, today
America is even more dependent on Middle East oil than it was
three decades ago.
In 1972 the United States imported 811 million barrels
of oil, or 19% of our total consumption . In 2008 we imported
3.3 billion barrels or 62% 130 We now consume more oil and are
more dependent on importing it. And it costs more, too. In 1972,
oil cost $1.92 per barrel, while in 2008 it averaged $94.34, ac-
cording to British Petroleum's statistical Review of World Ener-
gy. According to these figures, we went from paying $1 .6 billion
in oil imports in 1972 to more than $350 billion in 2008. So
much for energy independence!
Not only have the prices of oil and other fossil fuel in-
exorably trended up, but just to confuse matters, this upward
trend has been anything but smooth and continual. There's tre-
100 Sola r Trillions
tion until everyone heard the message. Who knew then that it
would be only a couple of years before the idea would enter the
mainstream and Gore would win the Nobel prize, an Academy
Award, and a Grammy? The first time I visited the PSl0 solar
power tower in Seville, they proudly told me Gore had recently
visited the plant. Small world.
When I met with him in Berkeley, Aringhoff and I talked
about Andasol-1 , which was just then starting operations. Solar
Millennium's Andasol-1 plant near Granada, Spain, which offi-
cially went online in July 2009, is a 50-MW plant with 7.5 hours
of thermal energy storage. This plant uses 510,000 m 2 of parabolic
trough collector surface (5.5 million square feet) and two tanks of
molten salt thermal storage to generate a total of 280,000 GWh
per year-about enough power for 170,000 people. Andasol- l 1s
energy storage is the largest in the world and can generate on-
demand electricity in the evening, during rain or cloud cover.
Andasol-2 and Andasol-3 are two identical solar plants
that are being developed as I write this. Each plant has 50 MW
of capacity, 7.5 hours of energy storage, and a total production
of 280,000 GWh per year. More than half million people will
get their electricity from these three plants-plus, their clean
operation will spare the Earth's atmosphere from 450,000 tons
of carbon dioxide per year.
I mentioned earlier in this chapter that the expected size
of a data center in 2020 will be
500,000 square feet. Such a cent- "Gemasola r is a CSP
er is also expected to need a ca- plant with 15 hours of
pacity of 50 MW. 131 Andasol- 1 energy storage. 24/ 7
produces that 50 MW, but only solar power is here."
7.5 hours of storage. Meanwhile
Google, Yahoo, or Microsoft cannot afford to be down even for a
minute. They need a steady flow of power 24/ 7/ 365.
Before you say "lump of coal;1 let me tell you about Ge-
0
masolar. Gemasolar (formerly called "Solar Tres is a solar pow- )
Chapter 5
Opportunity Ill-
Bikini Power: Island and
Village Scale Solar