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5.8 Hybrid systems with solar thermal and boilers

Key idea: In a hybrid system, the cheapest heat source runs first and the heat pump or boiler tops up.

Solar thermal collectors (flat plate or evacuated tube) give free heat on sunny days. A heat pump gives heat at low running cost any time. A boiler (LPG, PNG or diesel) gives high temperature quickly and acts as backup.

The usual order: solar preheats the bottom of the tank, the heat pump lifts water to 50–55 °C, and the boiler or electric heater tops up only for peaks, pasteurisation, or a heat pump failure.

Running cost per kWh of heat delivered (example rates):

Source Example price Efficiency Cost per kWh heat
Solar thermal free — ≈ ₹0 (plus pump power)
Heat pump COP 3.5 ₹9/kWh 350 % ₹2.6
PNG boiler ₹75/scm, ~10.5 kWh/scm (typical) 88 % ₹8.1
LPG boiler ₹100/kg, ~12.8 kWh/kg (typical) 88 % ₹8.9
Diesel boiler ₹100/L, ~10 kWh/L (typical) 85 % ₹11.8
Electric heater ₹9/kWh ~100 % ₹9.0
P&ID 4: hybrid with solar thermal and boiler back-up
P&ID 4: hybrid with solar thermal and boiler back-up
Hybrid control: cheapest heat first
Hybrid control: cheapest heat first

Worked example — annual saving of adding a heat pump to an LPG boiler (Bengaluru hostel)

Load 150 kWh/day heat, 365 days = 54,750 kWh/year. Solar covers 40 % (typical in Bengaluru with good array) = 21,900 kWh. Remaining 32,850 kWh. LPG only: 32,850 × ₹8.9 = ₹2.92 lakh/year. HP covers 90 % of remainder, LPG 10 %: HP 29,565 × ₹2.6 = ₹76,900; LPG 3,285 × ₹8.9 = ₹29,200. Total ₹1.06 lakh. Saving ≈ ₹1.86 lakh/year (example rates).

Remember

  • Solar first, heat pump second, boiler last.
  • Keep each source in its own tank zone to protect stratification.
  • Solar heats the bottom, which lowers HP COP — size HP return accordingly.
  • Use a TMV on outlet when sources can overheat the tank.
Field tip: Interlock so the boiler cannot run while the HP is meeting setpoint; check controller priorities at commissioning.

In a hybrid system, the cheapest heat source runs first and the heat pump or boiler tops up.

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