Granular Flow and Heat Transfer Study in a Near-Blackbody Enclosed Particle Receiver

Concentrating solar power (CSP) is an effective means of converting solar energy into electricity with an energy-storage capability for continuous, dispatchable, renewable power generation. However, challenges with current CSP systems include high initial capital cost and electricity price. The U.S. Department of Energy’s (DOE) SunShot program aims to reduce cost and improve performance of CSP technology. To this end, NREL is developing a solid-particle based CSP system projected to have significant cost and performance advantages over current nitrate-based molten salt systems. The design uses gas/solid, two-phase flow as the heat transfer fluid and separated solid particles as the storage medium. A critical component in the system is a novel near-blackbody (NBB) enclosed particle receiver with high-temperature capability developed with the goal of meeting DOE’s SunShot targets for receiver cost and performance. Development of the NBB enclosed particle receiver necessitates detailed study of the dimensions of the receiver, particle flow conditions, and heat transfer coefficients. The receiver utilizes an array of absorber tubes with a granular medium flowing downward through channels between tubes. The current study focuses on simulation and analysis of granular flow patterns and the resulting convective and conductive heat transfer to the particulate phase. This paper introduces modeling methods for the granular flow through the receiver module and compares the results with an in-situ particle flow test.

Low-Cost Lightweight Thin Film Solar Concentrators

A low-cost rigid foam-based concentrator technology development program was funded by the DOE SunShot Initiative to meet installed cost goals of $75/m2 vs. current costs of $200–250/m2. The cost reduction in this approach focuses primarily on designing a mirror module with a rigid foam center with stainless steel facesheets and reflective film. The low mechanical strength of the foam is compensated by optimizing the densities and dimensions to meet pointing accuracy requirements of 4 milliradians (mrad) in 27mph winds. Two alpha concentrators were built to validate the mirror module manufacturing process and one of them was accurate to 0.15 mrad RMS vs. the design requirement of 1 mrad RMS. To understand the lifetime reliability of the panels, fifteen 4-inch square samples were exposed to various environmental conditions including acid rain, bird droppings, thermal cycling, and the final results indicated no loss in reflectivity of 95%. UV testing will be performed in the next phase. Three mechanical structure options covering the range of large multi-faceted heliostats with diagonal load carrying elements, small single facet heliostats low to the ground and optimized truss-based deep structure designs were analyzed with FEA and analytically; results indicated a significant cost benefit (>2×) for the truss-based design over the other options. Other elements such as the controls, actuators were also considered in th analysis with vendor data. Cost trades were performed for heliostats ranging from 10m2 to 250m2. The results indicated a broad installed cost minimum around $113/m2 for heliostat sizes ranging from 80 m2 to 130 m2. Additional cost saving approaches will be considered in Phase 2 of the project.

Oxidation Rate Analysis of Carbon Nanoparticles for a Small Particle Heat Exchange Receiver

A new experimental set-up has been introduced at San Diego State University’s Combustion and Solar Energy Lab to study the thermal oxidation characteristics of in-situ generated carbon particles in air at high pressure. The study is part of a project developing a Small Particle Heat Exchange Receiver (SPHER) utilizing concentrated solar power to run a Brayton cycle. The oxidation data obtained will further be used in different existing and planned computer models in order to accurately predict reactor temperatures and flow behavior in the SPHER. The carbon black particles were produced by thermal decomposition of natural gas at 1250 °C and a pressure of 5.65 bar (82 psi). Particles were analyzed using a Diesel Particle Scatterometer (DPS) and scanning electron microscopy (SEM) and found to have a 310 nm average diameter. The size distribution and the complex index of refraction were measured and the data were used to calculate the specific extinction cross section γ of the spherical particles. The oxidation rate was determined using 2 extinction tubes and a tube furnace and the values were compared to literature. The activation energy of the carbon particles was determined to be 295.02 kJ/mole which is higher than in comparable studies. However, the oxidation of carbon particles bigger than 100 nm is hardly studied and almost no previous data is available at these conditions.

Development of High Temperature, Corrosion Resistant Sensors for Concentrating Solar Power Systems

Solar power is a sustainable resource which can reduce the power generated by fossil fuels, lowering greenhouse gas emissions and increasing energy independence. The U.S. Department of Energy’s SunShot Initiative has set goals to increase the efficiency of concentrating solar power (CSP) systems. One SunShot effort to help CSP systems exceed 50% efficiency is to make use of high-temperature heat transfer fluids (HTFs) and thermal energy storage (TES) fluids that can increase the temperature of the power cycle up to 1300°C. Sporian has successfully developed high-temperature operable pressure, temperature, thermal flux, strain, and flow sensors for gas path measurements in high-temperature turbine engines. These sensors are based on a combination of polymer derived ceramic (PDC) sensors, advanced high-temperature packaging, and integrated electronics. The overall objective is the beneficial application of these sensors to CSP systems. Through collaboration with CSP industry stakeholders, Sporian has established a full picture of operational, interface, and usage requirements for trough, tower, and dish CSP architectures. In general, sensors should have accurate measurement, good reliability, reasonable cost, and ease of replacement or repair. Sensors in contact with hot salt HTF and TES fluids will experience temperature cycling on a daily basis, and parts of the system may be drained routinely. Some of the major challenges to high-temperature CSP implementation include molten salt corrosion and flow erosion of the sensors. Potential high-temperature sensor types that have been identified as of interest for CSP HTF/TES applications include temperature, pressure, flow, and level sensors. Candidate solar salts include nitrate, carbonate, and chloride, with different application temperatures ranging from 550°C-900°C. Functional ceramics were soaked for 500 hours in molten nitrate, carbonate, and chloride salts, showing excellent corrosion resistance in chloride salts and good resistance in nitrate salts. The demonstration of functional ceramics in relevant HTFs laid the foundation for full prototype sensor and packaging demonstration. Sporian has developed a packaging approach for ceramic-based sensors in various harsh gaseous environments at temperatures up to 1400°C, but several aspects of that packaging are not compatible with corrosive and electrically conductive HTFs. In addition to consulting published literature, a 300 hour soak test in molten chloride salt allowed the authors to identify suitable structural metals and ceramics. Based on discussions with stakeholders, molten salt corrosion testing and room-temperature water flow testing, suitable for CSP sensor/packaging concepts were identified for future development, and initial prototypes have been built and tested.

Preliminary Feasibility Study of Groundwater Source Geothermal Heat Pumps in Mason County and the American Bottoms Area, Illinois

Groundwater source heat pumps exploit the difference between the ground surface temperature and the nearly constant temperature of shallow groundwater. This project characterizes two areas for geothermal heating and cooling potential, Mason County in central Illinois and the American Bottoms area in southwestern Illinois. Both areas are underlain by thick sand and gravel aquifers and groundwater is readily available. Weather data, including monthly high and low temperatures and heating and cooling degree days, were compiled for both study areas. The heating and cooling requirements for a single-family house were estimated using two independent models that use weather data as input. The groundwater flow rates needed to meet these heating and cooling requirements were calculated using typical heat pump coefficient of performance values. The groundwater in both study areas has fairly high hardness and iron concentrations and is close to saturation with calcium and iron carbonates. Using the groundwater for cooling may induce the deposition of scale containing one or both of these minerals.

Volume Sizing for Thermal Storage With Phase Change Material for Concentrated Solar Power Plant

With a large capacity thermal storage system using phase change material (PCM), Concentrated Solar Power (CSP) is a promising technology for high efficiency of solar energy utilization. In a thermal storage system, a dual-media thermal storage tank is typically adopted in industry for the purpose of reducing the use of the heat transfer fluid (HTF). While the dual-media sensible heat storage system has been well studied, a dual-media latent heat storage system (LHSS) still needs more attention and study; particularly, the sizing of volumes of storage tanks considering actual operation conditions is of significance. In this paper, a strategy for LHSS volume sizing is proposed, which is based on computations using an enthalpy-based 1D model. One example of 60MW solar thermal power plant with 35% thermal efficiency is presented. In the study, potassium hydroxide (KOH) is adopted as PCM and Therminol VP-1 is used as HTF. The operational temperatures of the storage system are 390°C and 310°C, respectively for the high and low temperatures. The system is assumed to operate for 100 days with 6 hours charge and 6 hours discharge every day. From the study, the needed height of the thermal storage tank is calculated from using the strategy of tank sizing. The method for tank volume sizing is of significance to engineering application.

Development of High Temperature Liquid Metal Heat Transfer Fluids for CSP Applications

In response to the DOE Sunshot Initiative to develop low-cost, high efficiency CSP systems, UCLA is leading a multi-university research effort to develop new high temperature heat transfer fluids capable of stable operation at 800°C and above. Due to their operating temperature range, desirable heat transfer properties and very low vapor pressure, liquid metals were chosen as the heat transfer fluid. An overview of the ongoing research effort is presented. Development of new liquid metal coolants begins with identification of suitable candidate metals and their alloys. Initial selection of candidate metals was based on such parameters as melting temperature, cost, toxicity, stability/reactivity Combinatorial sputtering of the down selected candidate metals is used to fabricate large compositional spaces (∼ 800), which are then characterized using high-throughput techniques (e.g., X-ray diffraction). Massively parallel optical methods are used to determine melting temperatures. Thermochemical modeling is also performed concurrently to compliment the experimental efforts and identify candidate multicomponent alloy systems that best match the targeted properties. The modeling effort makes use of available thermodynamic databases, the computational thermodynamic CALPHAD framework and molecular-dynamics simulations of molten alloys. Refinement of available thermodynamics models are performed by comparison with available experimental data. Characterizing corrosion in structural materials such as steels, when using liquid metals, and strategies to mitigate them are an integral part of this study. The corrosion mitigation strategy we have adopted is based on the formation of stable oxide layers on the structural metal surface which prevents further corrosion. As such oxygen control is crucial in such liquid metal systems. Liquid metal enhanced creep and embrittlement in commonly used structural materials are also being investigated. Experiments with oxygen control are ongoing to evaluate what structural materials can be used with liquid metals. Characterization of the heat transfer during forced flow is another key component of the study. Both experiments and modeling efforts have been initiated. Key results from experiments and modeling performed over the last year are highlighted and discussed.

Design of a Concentrator With a Rectangular Flat Focus and Operation With a Suspension Reactor for Experiments in the Field of Photocatalytic Water Splitting

Photocatalytic water splitting is a potential route for future carbon-free production of hydrogen. However catalysts still need to be enhanced in order to reach acceptable solar-to-fuel efficiency. In the context of the project HyCats funded by the Federal Ministry of Education and Research of Germany a high performance test facility for the evaluation of the activity of photocatalysts under practical conditions was established. It mainly consists of a solar concentrator and a planar receiver reactor. A modified linear Fresnel concentrator configuration was chosen based on ray tracing simulation results and improved concerning the number of different facets and the tolerance of tracking errors. It meets the major demand of a homogeneous irradiance distribution on the surface of the reactor. The SoCRatus (Solar Concentrator with a Rectangular Flat Focus) is a 2-axis solar concentrator with a geometrical concentration ratio of 20.2 and an aperture area of 8.8 m2. The tracking accuracy is better than 0.1° respecting both the solar azimuth and altitude angle. Its 22 highly UV/Vis-reflective flat aluminum mirror facets reflect the sunlight resulting in a rectangular focus with a nominal width of 100 mm and a nominal length of 2500 mm. The reactor is placed in the focal plane at a distance of 2500 mm from the mounting plane of the facets and allows concentrated solar radiation to penetrate suspensions of water, electrolytes and photocatalyst particles flowing through it. Corresponding to a maximum angle of incidence of 36.6° the Quartz window reflects not more than 5% of the incoming radiation and assures only marginal absorption, particularly in the UV-part of the sun’s spectrum. The material of the receiver body is PTFE (polytetrafluoroethylene) providing reflection coefficients above 90% concerning wavelengths of UV-A and UV-B. The design of the reactor features two parallel reaction chambers, offering the possibility to test two separate suspensions at the same irradiation conditions. A pump transports the tempered suspension to the reactor. The geometry of the reactor inlet and outlet minimizes critical regions with inadequate flow caused by vortices. Any evolved gases are separated from the suspension in a tank together with nitrogen introduced in the piping upstream and are analyzed by micro chromatographs. Numerous devices are installed in order to control and monitor the reaction conditions. First experiments have been carried out using methanol as a sacrificial reagent.

Computational Analysis of Particulate Storage Bin for High Temperature Thermal Energy Storage

The Riyadh Techno Valley Solar Tower, an innovative type of concentrator solar power plant, is being developed by King Saud University (KSU) and Georgia Tech (GT). The facility is being constructed at the Riyadh Techno Valley development near the KSU campus and will store thermal energy collected from the sun in solid particles, which can be heated to higher temperatures than is currently possible using molten salts. The particles must be well insulated to stop energy loss to the environment. Hence, GT and KSU have incorporated an insulated storage bin into the plant design. The bin will be constructed in several layers: an inner layer of firebrick, which can endure direct exposure to the heated particles; a specially prepared refractory insulating concrete, which maintains good insulating value at high temperatures; and a conventional structural concrete shell surrounding the entire bin. This paper presents a thermal analysis of this storage device and discusses structural analyses. Simplified analytical solutions are compared with the finite element results from a 3D ANSYS model of the entire bin. A temperature distribution is obtained, and heat loss through the bin is also evaluated. Modeling of rebar and concrete cracking are described, and methods of reducing stress on the outer concrete shell are considered. Structural support for an access tunnel into the bin is also explored. The current tunnel design involves a material with a relatively high thermal conductivity, necessitating modifications to the bin. Finally, material selection is considered, particularly with regard to the insulating concrete layer. Limitations on the use of Portland cement based insulating concretes are discussed, and alternative base materials are evaluated.

Sintering of Solid Particulates Under Elevated Temperature and Pressure in Large Storage Bins for Thermal Energy Storage

This research is a part of the DOE-funded SunShot project on “High Temperature Falling Particle Receiver.” Storing thermal energy using solid particulates is a way to mitigate the time of day dependency of concentrated solar power. Small particles may be stored easily, and can be used as a heat transfer medium to transfer heat to the power cycle working fluid through a heat exchanger. This study examines the physical characteristics of solid particulates of different materials kept inside large storage containers. Particle behavior at the expected high temperatures of the concentrated solar power cycle combined with the elevated pressure experienced within the storage container must be evaluated to assess the impact on their physical properties and ensure that the particles would not sinter thereby impacting flow through the system components particularly the receiver and heat exchanger. Sintering is a process of fusing two or more particles together to form a larger agglomerate. In the proposed concentrated solar power tower design, particles will experience temperatures from 600°C to 1000°C. The increase in temperature changes the physical characteristics of the particle, along with any impurities that could form particle to particle bonds. In addition, the hydrostatic pressure exerted on particles stored inside a storage unit increases the probability of sintering. Thus, it is important to examine the characteristics of particles under elevated temperatures and pressures. The experimental procedure involves heating particulates of a known mass and size distribution to temperatures between 600°C and 1000°C inside a crucible. As the temperature is held constant, the particulate sample is pressed upon by a piston pushing into the crucible with a known constant pressure. This process is repeated for different temperatures and pressures for varying lengths of time. The resulting particulates are cooled, and their size distribution is measured to determine the extent of sintering, if any, during the experiment. The particulates tested include various types of sand, along with alumina particles. The data from this experiment will allow designers of storage bins for the solid particulates to determine when significant sintering is expected to occur.