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ANU Solar Thermal Energy Research - High Temperature Concentrator Basics

Concentrating Solar Thermal Systems

This material is an extract from “Solar Thermal Power Systems” Keith Lovegrove and Andreas Luzzi, Encyclopedia of Physical Science and Technology, 3rd Edition, Vol 15.

1 Introduction

Various devices for collecting solar radiation thermally have been devised. At the simplest level, a flat metal plate painted black and placed in the sun will heat up until it reaches a temperature where the heat that it looses to the air around it and also by radiating itself, exactly balances the amount of energy it receives from the sun. This “stagnation temperature” occurs at around 80oC for a simple flat plate. If water, for example, is passed through passages in the plate, then it will stabilize at a lower temperature and the water will extract some of the energy in being usefully heated up. This is the essence of solar thermal energy collection.

Greater levels of sophistication are aimed at reducing the amount of “thermal loss” from the collector surface at a given temperature. This allows energy to be collected more efficiently and at higher temperatures.

Starting with the flat plate, a cover layer of glass helps by cutting down the energy lost by the circulation of cold air. If metal tubes and glass cylinders are used instead of plates, then the space can be completely evacuated, so that air convection losses are completely eliminated. Clever use of coating materials to produce an optically selective surface that absorbs as much as possible of visible solar wavelengths whilst emitting as little as possible of thermal radiation from the plate helps to reduce radiation losses. Various combinations of these measures are used in the production of systems for the production of solar hot water that are used around the world for domestic and industrial applications. In principle, solar collectors of this nature could be used for electricity production. However the low temperatures achievable limit the conversion efficiencies possible to low levels.


Further increasing the temperature at which energy can usefully be recovered requires some method of optically concentrating the radiation so that the size of the absorbing surface and hence its thermal loss, is reduced. The conceptually simplest approach is to employ a series of flat mirrors (called heliostats) that are continuously adjusted to direct solar radiation onto the absorbing surface. This is illustrated conceptually in Figure 1. Large plants called “Central Receiver Systems” or “Power Towers” have been built based on this principle and are discussed in detail in section 2. The concept can also be adapted to linear absorbers and long strips of mirror to create a “Linear Fresnel” concentrator.

Alternatively, the mathematical properties of a parabola can be exploited. The equation for a parabola in the x y plane is;

y=x2/4f

simple central receiver diagram

Figure 1. The central receiver concept; a field of plane mirror heliostats all move independently to each keep a beam of solar radiation focussed on a single central receiver (Figure H. Kreetz).

Rays of light parallel to the y axis of a mirrored parabola will all be reflected and focused at the focal point at a distance f from the vertex.

As illustrated in Figure 2, this effect can be used in a linear arrangement, where a mirrored “trough” with a parabolic cross section will focus solar radiation onto a line focus when it is pointed directly at the sun. The largest Solar Thermal Power plants constructed to date employ this principle, they are reviewed in section 3. Alternatively a mirrored dish with a parabolic cross section (a paraboloid) will focus solar radiation to a point focus (see figure 3). Dish systems are reviewed in section 4. Both dishes and troughs require continuous adjustment of position (or at least frequent readjustment) to maintain the focus as the sun moves through the sky.

trough diagram
Figure 2. A parabolic trough concentrator focuses solar radiation onto a linear receiver when faced directly at the sun (figure from H. Kreetz)
dish diagram
Figure 3. A paraboloidal dish concentrator focuses solar radiation onto a point focus receiver (figure from H. Kreetz).

 

Similar focusing effects can obviously be achieved with lenses of various kinds, but this has not been employed on the scales needed for solar thermal power systems.

Another alternative which potentially avoids the need to track the sun is to employ “non imaging” concentration. As illustrated in Figure 4, this involves the construction of a mirrored “light funnel” of some kind. Such a device will be able to collect rays into its aperture over a range of incidence angles and cause them to exit via a smaller aperture via multiple reflections. Non imaging concentrators have not found application as the “primary” means of concentration for Solar Thermal Power systems but they are frequently applied as “secondary concentrators” at the focus of central receivers, dishes or troughs, where they serve to further reduce the size of the focal region.

Figure 4. (right). A non-imaging concentrator concentrates solar radiation without the need to track the sun.

non-imaging concentrator diagram

The rays of light from the sun are not exactly parallel. This means that even a perfect optical system will produce an image of finite size, with an intensity distribution that is a maximum in the center and tapers off to zero at the edges. Imperfections in mirror shape and tracking accuracy have the effect of further spreading out the sun image.

Each of these approaches to concentration has a typical ratio of collected radiation intensity to incident solar radiation intensity, termed the “concentration ratio”. Table 1 summarizes the options discussed and lists typical concentration ratios, the resultant operating temperatures and the consequent thermodynamic limiting efficiency with which electricity could be produced. The limiting conversion efficiency arises from the second law of thermodynamics. The maximum efficiency for conversion of heat from a constant high temperature source given by;

Maximum conversion efficiency = 1- Tcold/Thot

This is the “Carnot limit”. A simple understanding of why there should be such a limit can be developed by realizing that empirically heat will not spontaneously flow from cold objects to hot ones. If all the heat flow from a hot object could be converted to electricity then this could in turn all be used to heat an even hotter object which we know to be impossible. In real Solar Thermal Power systems, conversion efficiencies around one third or less of the ideal maximum are typically achieved.

Clearly higher concentration ratios give higher efficiency, however they also lead to potentially higher complexity and cost. The ultimate challenge with Solar Thermal Power systems is to produce the desired output as economically as possible. This invariably means a trade off between system efficiency and capital investment drives the design process.

Table 1. Typical temperature and concentration range of the various solar thermal collector technologies.

Technology

T [°C]

Concentration ratio

Tracking

Max Conv. Eff. (Carnot)

Flat plate collector

30 – 100

1

-

21%

Evacuated tube collector

90 – 200

1

-

38%

Solar pond

70 – 90

1

-

19%

Solar chimney

20 – 80

1

-

17%

Fresnel reflector technology

260 – 400

8 – 80

One-axis

56%

Parabolic trough

260 – 400

8 – 80

One-axis

56%

Heliostat field + Central receiver

500 – 800

600 – 1000

Two-axis

73%

Dish concentrators

500 - 1200

800 - 8000

Two-axis

80%


2 Central Receiver Systems

The central receiver concept was first proposed by scientists in the USSR in the mid 1950s. The first experiment was established in Sant' Ilario near Genova, Italy, in 1965 by Professor Giovanni Francia. He installed 120 round mirrors each the size of a 'tea-table', focusing on a small steam generator on top of a steel frame. The product was superheated steam (500 oC, 10 Mpa).
Central receivers have the advantage that all the energy conversion takes place at single fixed point. This avoids the need for energy transport networks and allows investment to improve the efficiency and sophistication of the energy conversion process to be made more cost effectively. Associated disadvantages are that they must be built as single large systems, without the modularity benefits of distributed systems like troughs or dishes. The fixed position of the receiver also means that heliostats do not point directly at the sun, so that the amount of collected solar radiation per unit area of mirror is less than with the other technologies.
Major investigations during the past twenty years have focused on four heat transfer fluid systems; water/steam, sodium, molten salt and air.An overview of the major demonstration grid connected power plants built to date is given in Table2.

Table 2. Summary of Central Receiver demonstration power plants.

 

 

Eurelios ( Italy )

Sunshine ( Japan )

IEA-CRS ( Spain )

Solar One ( Usa )

Solar Two ( USA )

CESA 1 ( Spain )

Themis (France)

MSEE ( USA )

SES 5 (CIS-USSR)

Weizman ( Israel )

Net electric power

1MWe

1MWe

0.5MWe

10MWe

10MWe

1.2MWe

2.5MWe

0.75MWe

5MWe

0.5MWe

Total reflector area

6260m2

12912m2

3655m2

71095m2

81344m2

11880m2

10740m2

7845m2

40584m2

3500m2

Heat transfer fuid

Water/ steam

Water/ steam

Sodium

Water/ steam

Molten salt

Water/ steam

Molten salt

Molten Salt

Water/ steam

Beam down

Storage capacity

0.06MWhe

3MWhe

1.0MWhe

28MWhe

107MWhth

3MWhe

15MWhe

2.5MWhe

1.5MWhe

 

Period of service

1980-1984

1981-1984

1981-1985

1982-1988

1996 -1999

1983-1984

1983-1986

1984-1985

1985-

2001-


To date power generation has been via conventional steam Rankine cycles at the base of the tower. In early systems, receivers were built to produce superheated steam directly, however thermal problems associated with the unsteady boundary between liquid water and steam in the tubes motivated a move to secondary heat transfer fluids. Liquid sodium provides good heat transfer behaviour, but carries the disadvantage that all the transport piping must be heated above sodium’s melting point (slightly below 100oC). The possibility of leaks also provides a significant fire risk. Use of molten salt avoids the fire risk and is thus also well suited to storage in tanks to allow power generation when there is no sun. The nitrate salts used has a melting point of 260oC. They do however lead to corrosion problems if leaks occur. Air is also suggested as a heat transfer fluid, a 3MWth system has been demonstrated at the Plataforma Solar test facility in southern Spain.
Heliostat fields can either surround the tower or be spread out on one side. For a surround field externally radiated circular cross-section receivers are employed, for one sided fields cavity receivers can be used. System designers have developed optimization strategies which determine the best arrangement for a given number of heliostats. These take into account the effects of shading between heliostats, the spread of the field and the optical inefficiency that increases as heliostats are further from the tower.
Two general approaches to heliostat design have been used. The most obvious is a plane structure with rigid mirror facets mounted on it. The structure sits on top of a pedestal with a gearbox arrangement that allows for two axis tracking of the sun.
The other alternative is termed the “stretched membrane” approach. As the name implies a membrane is stretched across a circular frame in a similar manner to a drum skin. The membrane is then covered with mirrors. Thin stainless steel membranes with glass mirrors glued to the surface have been tried as have polymer films which are mirrored themselves. The stretched membrane approach allows the mirrored surface to be curved slightly by the application of a small internal vacuum. In this way heliostats can actually focus their own sun image on the tower receiver rather than just directing a plane beam at it. Figure 6 illustrates an example of a stretched membrane heliostat design. Development trends have suggested that larger heliostats are more cost effective, heliostat modules up to 200m2 have been tested. stretched membrane heliostat photo
Figure 6. Stetched membrane heliostat.
The largest central receiver solar thermal power plant demonstrated to date is the “Solar Two” plant in Southern California. This plant is actually an updated version of the previously operated “Solar One” system. Extra heliostats were added and the receiver converted from direct steam generation to molten salt. Figure 7 shows the Solar Two plant in operation and figure 8 is a schematic illustrating the operating principles. When the solar field is operating, the molten nitrate salt moves from a cold (288oC) storage tank via the receiver at the top of the tower, where it is heated, to the hot storage tank (566oC). Independantly of the solar energy collection process, salt from the hot tank is passed through a heat exchanger where heat is transferred to produce superheated steam, with the salt passing back to the cold storage tank. The steam is used in a conventional steam turbine power plant for electricity generation.
solar one power plant photoFigure 7. The Solar One (later Solar Two) central receiver power plant in operation. solar two diagram
Figure 8. Schematic of Solar Two operation (figure from Bechtel Group Intenational).
The Solar Two plant has one thousand and eighteen 39.1m2 heliostats plus a further one hundred and eight 95m2 heliostats. Under nominal conditions, 48MWth is concentrated onto the receiver which sits at the top of a 91m high tower. Steam is produced in the heat exchangers at 10MPa and 538oC and the net electrical output is 10.4MWe.
One of the most recent developments in the Central Receiver area, is the “beam down” concept proposed by the Weizmann Institute in Israel. Rather that converting the energy at the top of the tower, a hyperbolically shaped secondary directs it vertically downwards. At the bottom a further non imaging concentrator concentrates it further before it is captured by a volumetric receiver capable of heating air to very high temperatures needed for a Brayton cycle.

3 Trough Systems

Solar thermal power in the form of mechanical energy for water pumping was established for the first time near Cairo in 1914 (~ 40 kW). It incorporated a water/steam operated parabolic trough array (5 units, 4m x 62m) and a low pressure condensing steam engine. Solar electric trough development was re-activated by the U.S. Department of Energy in the mid 1970's. The first experimental system started operation in 1979. At the same time a private Research and Development company from Jerusalem, Israel, (LUZ) decided to design and implement commercial scale parabolic trough 'Solar Electric Generating Systems' (SEGS). This decision was strongly motivated by favourable power purchase agreements and tax credits offered in the state of California.
The nine SEGS plants built by LUZ between 1984 and 1989, have a combined capacity of 354MWe. They are all continue to operate on a commercial basis and together they represent by far the majority of operating solar thermal power station capacity in the world.
During the early 1980s small demonstration trough based solar thermal power systems were constructed in the USA, Japan, Spain and Australia. Table 3 lists the details of these plants. Specifications for the 9 SEGS plants are given in Table 4.

Table 3. Details of demonstration trough based solar thermal power plants.

 

Coolidge ( USA )

Sunshine ( Japan )

IEA-DCS ( Spain )

STEP-100 ( Australia )

Net electric power

0.15MWe

1MWe

0.5MWe

0.1MWe

Total aperture area

2,140m2

12,856m2

7,622m2

920m2

Heat transfer fluid

Synthetic oil

Water/steam

Synthetic oil

Synthetic oil

Effective Storage capacity

5MWth

3MWe

0.8MWe

117MWth

Duration of service

1980 -1982

1981 - 1984

1981 -1985

1982 -1985

 

Table 4. Details of the Californiam SEGS plants.

 

SEGS I

SEGS II

SEGS III

SEGS IV

SEGS V

SEGS VI

SEGS VII

SEGS VIII

SEGS IX

Net electric power

13.8 MWe

30 MWe

30 MWe

30 MWe

30 MWe

30 MWe

30 MWe

80 MWe

80 MWe

Total aperture area

83,000 m2

19,000m2

230,000 m2

230,000m2

251,000m2

188,000m2

194,00m2

464,000 m2

484,000m2

Duration of service

1984 - present

1985 - present

1986 - present

1986 - present

1987 - present

1988 - present

1988 - present

1989 - present

1989 - present

 

Figure 9 shows one of the SEGS plants and figure 10 illustrates the operating principles schematically. A synthetic heat transfer oil is pumped through the trough array and heated to up to 400oC. This oil is then used to produce steam in heat exchangers before being circulated back to the array. The steam is used in a conventional steam turbine based electricity generating plant. Although some hot oil based energy storage was provided in the first plant, the SEGS systems overall rely on natural gas firing to provide continuous operation when the sun is not available.
segs photo
Figure 9. View of SEGS trough based solar thermal power plant in southern California.
segs diagram
Figure 10. Schematic representation of SEGS plant operation (figure from ABB).
The LUZ troughs are built using a galvanized steel space frame. This frame supports 4mm thick glass mirror segments which are shaped by heating and molding to match the parabolic profile, before silvering. Each mirror facet is supported only at 4 points of attachment. The most recently constructed systems (termed LS-3) are 5.76m wide and 95m long giving a total aperture of 545m2. 224 glass mirror segments are used and a concentration ratio of up to 80:1 is achieved.

The trough units are lined up in north south rows and track the sun from East to West during the day. During the winter when midday sun elevation is lower some radiation is lost from the end of each trough, but because they are long, this is only a small fraction of the total. Each trough has its own positioning and local control system.

The receiver units of the LUZ troughs consist of a stainless steel tube 70mm in diameter, covered by a Pyrex glass envelope which is sealed to the tube via metal belows at the ends. The space between the steel and glass is evacuated to minimize thermal losses. The surface of the stainless steel absorber tubes is coated with a black chrome selective surface which absorbs 94 % of the solar radiation incident whilst minimizing the amount that is radiated at thermal wavelengths. The combination of trough and receiver is capable of operating at temperatures in excess of 400oC. However the heat transfer oil becomes chemically unstable and begins to degrade at temperatures above 300oC. Approximately 350m3 of oil circulates in one of the 30MWe plants. Depending on the operating regime this can need replacing at rates of up to 8% per year as a result of chemical breakdown.
The latest SEGS plants each employ an Asea Brown Boveri steam turbine with reheat cycle and multiple extraction. With steam inlet conditions of 10MPa and 370oC, thermal to electric conversion efficiencies of approximately 37% are achieved, giving overall peak solar to electric efficiencies of 24%.

Regular maintenance is required for all solar thermal power systems. For the SEGS plants, routine cleaning and replacement of broken mirror facets and receiver modules forms a major part of the maintenance program.

Research and Development on trough systems has continued since the LUZ plants were completed. A major area of investigation has targeted the replacement of the heat transfer oil with direct generation of steam in the receivers. Direct steam generation would allow collection of energy at higher temperatures and so improve the efficiency of the steam turbine. It would also avoid the need to replace the costly oil and eliminate the inherent fire risk. The challenge is managing the rapidly changing thermal stresses induced in the receiver tube by the unsteady movement of liquid and vapor water when boiling is taking place.

In a variation of linear focusing technology a group based at the university of Sydney has developed a concept known as the “Compact Linear Fresnel Reflector”. This operates rather like a linear version of a central receiver system. Fixed linear receivers are illuminated by a series of long narrow mirrors which track the sun individually. If several receiver rows are installed side by side, then the individual mirror units can switch from one receiver to another depending on the relative optical efficiencies at different times of the day. A demonstration system based on this technology is under construction as an addition to an existing coal fired power station in northern Queensland (Australia).

4 Paraboloidal Dishes

The first