Publications

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Multiphase computational models and tests of falling water droplets on inclined glass surfaces were developed to investigate the physics of impingement and potential of these droplets to self-clean glass surfaces for photovoltaic modules and heliostats. A multiphase volume-of-fluid model was developed in ANSYS Fluent to simulate the impinging droplets. The simulations considered different droplet sizes (1 mm and 3 mm), tilt angles (0°, 10°, and 45°), droplet velocities (1 m/s and 3 m/s), and wetting characteristics (wetting=47° contact angle and non-wetting = 93° contact angle). Results showed that the spread factor (maximum droplet diameter during impact divided by the initial droplet diameter) decreased with increasing inclination angle due to the reduced normal force on the surface. The hydrophilic surface yielded greater spread factors than the hydrophobic surface in all cases. With regard to impact forces, the greater surface tilt angles yielded lower normal forces, but higher shear forces. Experiments showed that the experimentally observed spread factor (maximum droplet diameter during impact divided by the initial droplet diameter) was significantly larger than the simulated spread factor. Observed spread factors were on the order of 5 - 6 for droplet velocities of ~3 m/s, whereas the simulated spread factors were on the order of 2. Droplets were observed to be mobile following impact only for the cases with 45° tilt angle, which matched the simulations. An interesting phenomenon that was observed was that shortly after being released from the nozzle, the water droplet oscillated (like a trampoline) due to the "snapback" caused by the surface tension of the water droplet being released from the nozzle. This oscillation impacted the velocity immediately after the release. Future work should evaluate the impact of parameters such as tilt angle and surface wettability on the impact of particle/soiling uptake and removal to investigate ways that photovoltaic modules and heliostats can be designed to maximize self-cleaning.

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A 7.2 kW (electric input) solar simulator was designed in order to perform accelerated testing on absorber materials for concentrating solar power (CSP) technologies. COMPUTER-AIDED DESIGN (CAD) software integrating a ray-Tracing tool was used to select appropriate components and optimize their positioning in order to achieve the desired concentration. The simulator comprises four identical units, each made out of an ellipsoidal reflector, a metal halide lamp, and an adjustable holding system. A single unit was characterized and shows an experimental average irradiance of 257 kWm-2 on a 25.4mm (1 in) diameter spot. Shape, spot size, and average irradiance are in good agreement with the model predictions, provided the emitting arc element model is realistic. The innovative four-lamp solar simulator potentially demonstrates peak irradiance of 1140kWm-2 and average irradiance of 878kWm-2 over a 25.4mm diameter area. The electric-To-radiative efficiency is about 0.86. The costs per radiative and electric watt are calculated at $2.31 W-1 and $1.99 W-1, respectively. An upgraded installation including a sturdier structure, computer-controlled lamps, a more reliable lamp holding system, and safety equipment yields a cost per electric watt of about $3.60 W-1 excluding labor costs.

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This paper presents a study of alternative heliostat standby aiming strategies and their impact on avian flux hazards and operational performance of a concentrating solar power plant. A mathematical model was developed that predicts the bird-feather temperature as a function of solar irradiance, thermal emittance, convection, and thermal properties of the feather. The irradiance distribution in the airspace above the Ivanpah Unit 2 heliostat field was simulated using a ray-trace model for two different times of the day, four days of the year, and nine different standby aiming strategies. The impact of the alternative aiming strategies on operational performance was assessed by comparing the heliostat slew times from standby position to the receiver for the different aiming strategies. Increased slew times increased a proxy start-up time that reduced the simulated annual energy production. Results showed that spreading the radial aim points around the receiver to a distance of ∼150 m or greater reduced the hazardous exposure times that the feather temperature exceeded the hazard metric of 160 °C. The hazardous exposure times were reduced by ∼23% and 90% at a radial spread of aim points extending to 150 m and 250 m, respectively, but the simulated annual energy production decreased as a result of increased slew times. Single point-focus aiming strategies were also evaluated, but these strategies increased the exposure hazard relative to other aiming strategies.

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This paper provides a review of current state-of-the-art commercial central receiver systems and emerging technologies intended to increase the outlet temperature to >700 °C. Research on particle-based, gas-based, and liquid-based receiver designs that can achieve these higher temperatures are discussed. Particle-based technologies include directly irradiated designs (free-falling, obstructed, centrifugal) and enclosed designs (gravity fed, fluidized). New gas-based receivers include micro-channel designs and light-trapping configurations that increase the surface area, heat transfer, and solar absorptance to enable higher fluxes and pressures. Liquid-based receivers and materials that are reviewed include high-temperature halide salts (chlorides and fluorides), carbonate salts, and liquid metals (sodium and lead bismuth). Advantages and challenges associated with each of the technologies and receiver designs are presented.

Previous research at Sandia National Laboratories showed the potential advantages of using light-trapping features which are not currently used in direct tubular receivers. A horizontal bladed receiver arrangement showed the best potential for increasing the effective solar absorptance by increasing the ratio of effective surface area to the aperture footprint. Ray-tracing analyses using SolTrace were performed to understand the light-trapping effects of the bladed receivers, which enable re-reflections between the fins that enhance the effective solar absorptance. A parametric optimization study was performed to determine the best possible configuration with a fixed intrinsic absorptivity of 0.9 and exposed surface area of 1 m². The resulting design consisted of three vertical panels 0.584 m long and 0.508 m wide and 3 blades 0.508 m long and 0.229 m wide with a downward tilt of 50 degrees from the horizontal. Each blade consisted of two panels which were placed in front of the three vertical panels. The receiver was tested at the National Solar Thermal Test Facility using pressurized air. However, the receiver was designed to operate using supercritical carbon dioxide (sCO2) at 650 °C and 15 MPa for 100,000 hours following the ASME Boiler and Pressure Vessel Code Section VIII Division 1. The air flowed through the leading panel of the blade first, and then recirculated toward the back panel of the blade before flowing through one of the vertical back panels. The test results of the bladed receiver design showed a receiver efficiency increase over a flat receiver panel of ∼5 - 7% (from ∼80% to ∼86%) over a range of average irradiances, while showing that the receiver tubes can withstand temperatures > 800 °C with no issues. Computational fluid dynamics (CFD) modeling using the Discrete Ordinates (DO) radiation model was used to predict the temperature distribution and the resulting receiver efficiencies. The predicted thermal efficiency and surface temperature values correspond to the measured efficiencies and surface temperatures within one standard deviation. In the near future, an sCO2 flow system will be built to expose the receiver to higher pressure and fluid temperatures which could yield higher efficiencies.

Supercritical carbon dioxide (sCO2) Brayton power cycles have the potential to significantly improve the economic viability of concentrating solar power (CSP) plants by increasing the thermal to electric conversion efficiency from around 35% using high-temperature steam Rankine systems to above 45% depending on the cycle configuration. These systems are the most likely path toward achieving the Department of Energy's (DOE) Office of Energy Efficiency and Renewable Energy (EERE) SunShot targets for CSP tower thermal to electric conversion efficiency above 50% with dry cooling to air at 40 °C and a power block cost of less than 900 $/kWe. Many studies have been conducted to optimize the performance of various sCO2 Brayton cycle configurations in order to achieve high efficiency, and a few have accounted for drivers of cost such as equipment size in the optimization, but complete techno-economic optimization has not been feasible because there are no validated models relating component performance and cost. Reasonably accurate component cost models exist from several sources for conventional equipment including turbines, compressors, and heat exchangers for use in rough order of magnitude cost estimates when assembling a system of conventional equipment. However, cost data from fabricated equipment relevant to sCO2 Brayton cycles is very limited in terms of both supplier variety and performance level with most existing data in the range of 1 MWe power cycles or smaller systems, a single completed system around 7 MWe by Echogen Power Systems, and numerous ROM estimates based on preliminary designs of equipment for 10 MWe systems. This data is highly proprietary as the publication of individual data by any single supplier would damage their market position by potentially allowing other vendors to undercut their stated price rather than competing on reduced manufacturing costs. This paper describes one approach to develop component cost models in order to enable the techno-economic optimization activities needed to guide further research and development while protecting commercially proprietary information from individual vendors. Existing cost models were taken from literature for each major component used in different sCO2 Brayton cycle configurations and adjusted for their magnitude to fit the limited vendor cost data and estimates available. A mean fit curve was developed for each component and used to calculate updated cost comparisons between previously-reviewed sCO2 Brayton cycle configurations for CSP applications including simple recuperated, recompression, cascaded, and mixed-gas combined bifurcation with intercooling cycles. These fitting curves represent an average of the assembled vendor data without revealing any individual vendor cost, and maintain the scaling behavior with performance expected from similar equipment found in literature.

Particle-based concentrating solar power (CSP) plants have been proposed to increase operating temperature for integration with higher efficiency power cycles using supercritical carbon dioxide (sCO2). The majority of research to date has focused on the development of high-efficiency and high-temperature particle solar thermal receivers. However, system realization will require the design of a particle/sCO2 heat exchanger as well for delivering thermal energy to the power-cycle working fluid. Recent work has identified moving packed-bed heat exchangers as low-cost alternatives to fluidized-bed heat exchangers, which require additional pumps to fluidize the particles and recuperators to capture the lost heat. However, the reduced heat transfer between the particles and the walls of moving packed-bed heat exchangers, compared to fluidized beds, causes concern with adequately sizing components to meet the thermal duty. Models of moving packed-bed heat exchangers are not currently capable of exploring the design trade-offs in particle size, operating temperature, and residence time. The present work provides a predictive numerical model based on literature correlations capable of designing moving packed-bed heat exchangers as well as investigating the effects of particle size, operating temperature, and particle velocity (residence time). Furthermore, the development of a reliable design tool for moving packed-bed heat exchangers must be validated by predicting experimental results in the operating regime of interest. An experimental system is designed to provide the data necessary for model validation and/or to identify where deficiencies or new constitutive relations are needed.

Previous research at Sandia National Laboratories showed the potential advantages of using light-trapping features which are not currently used in direct tubular receivers. A horizontal bladed receiver arrangement showed the best potential for increasing the effective solar absorptance by increasing the ratio of effective surface area to the aperture footprint. Ray-tracing analyses using SolTrace were performed to understand the light-trapping effects of the bladed receivers, which enable re-reflections between the fins that enhance the effective solar absorptance. A parametric optimization study was performed to determine the best possible configuration with a fixed intrinsic absorptivity of 0.9 and exposed surface area of 1 m2. The resulting design consisted of three vertical panels 0.584 m long and 0.508 m wide and 3 blades 0.508 m long and 0.229 m wide with a downward tilt of 50 degrees from the horizontal. Each blade consisted of two panels which were placed in front of the three vertical panels. The receiver was tested at the National Solar Thermal Test Facility using pressurized air. However, the receiver was designed to operate using supercritical carbon dioxide (sCO2) at 650 °C and 15 MPa for 100,000 hours following the ASME Boiler and Pressure Vessel Code Section VIII Division 1. The air flowed through the leading panel of the blade first, and then recirculated toward the back panel of the blade before flowing through one of the vertical back panels. The test results of the bladed receiver design showed a receiver efficiency increase over a flat receiver panel of ∼5 - 7% (from ∼80% to ∼86%) over a range of average irradiances, while showing that the receiver tubes can withstand temperatures > 800 °C with no issues. Computational fluid dynamics (CFD) modeling using the Discrete Ordinates (DO) radiation model was used to predict the temperature distribution and the resulting receiver efficiencies. The predicted thermal efficiency and surface temperature values correspond to the measured efficiencies and surface temperatures within one standard deviation. In the near future, an sCO2 flow system will be built to expose the receiver to higher pressure and fluid temperatures which could yield higher efficiencies.

Novel particle release patterns have been proposed as a means to increase the thermal efficiency of high-temperature falling particle receivers. Innovative release patterns offer the ability to utilize light-trapping and volumetric heating effects as a means to increase particle temperatures over a conventional straight-line particle release pattern. The particle release patterns explored in this work include wave-like patterns and a series of parallel curtains normal to the incident irradiation that have shown favorable results in previous numerical studies at lower particle temperatures. A numerical model has recently been developed of an existing falling particle receiver at the National Solar Thermal Test Facility at Sandia National Laboratories to evaluate these patterns at elevated temperatures necessary to evaluate radiative and convective losses. This model has demonstrated that thermal efficiency gains of 2.5-4.6% could be realized using these patterns compared to the conventional planar release depending on the particle mass flow rate. Increasing the number of parallel curtains, increasing the spacing between curtains, and shifting the particle mass flow rate deeper in the receiver cavity was also found to increase the thermal efficiency. These effects became less significant as the particle mass flow rate increased.

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A 10 MWe north-facing falling particle receiver (FPR) is proposed in this document to support performance comparisons of this design when compared with a direct s-CO₂ solar receiver concept. This document describes the modeling and simulation effort for the proposed FPR to evaluate its thermal performance. A description of the modeling strategy is provided in the following section including details on the receiver and heliostat field. Then, this model is used to evaluate the performance of the receiver at various times of throughout the year. Finally, the results of this analysis are summarized. Direct comparisons with a similarly sized s-CO₂ solar receiver concept are not discussed here.

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A supercritical carbon dioxide (sCO2) Brayton cycle is an emerging high energy-density cycle undergoing extensive research due to the appealing thermo-physical properties of sCO2 and single phase operation. Development of a solar receiver capable of delivering sCO2 at 20 MPa and 700 °C is required for implementation of the high efficiency (∼50%) solar powered sCO2 Brayton cycle. In this work, extensive candidate materials are review along with tube size optimization using the ASME Boiler and Pressure Vessel Code. Temperature and pressure distribution obtained from the thermal-fluid modeling (presented in a complementary publication) are used to evaluate the thermal and mechanical stresses along with detailed creep-fatigue analysis of the tubes. The resulting body stresses were used to approximate the lifetime performance of the receiver tubes. A cyclic loading analysis is performed by coupling the Strain-Life approach and the Larson-Miller creep model. The structural integrity of the receiver was examined and it was found that the stresses can be withstood by specific tubes, determined by a parametric geometric analysis. The creep-fatigue analysis displayed the damage accumulation due to cycling and the permanent deformation on the tubes showed that the tubes can operate for the full lifetime of the receiver.

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Novel designs to increase light trapping and thermal efficiency of concentrating solar receivers at multiple length scales have been conceived, designed, and tested. The fractal-like geometries and features are introduced at both macro (meters) and meso (millimeters to centimeters) scales. Advantages include increased solar absorptance, reduced thermal emittance, and increased thermal efficiency. Radial and linear structures at the meso (tube shape and geometry) and macro (total receiver geometry and configuration) scales redirect reflected solar radiation toward the interior of the receiver for increased absorptance. Hotter regions within the interior of the receiver can reduce thermal emittance due to reduced local view factors to the environment, and higher concentration ratios can be employed with similar surface irradiances to reduce the effective optical aperture, footprint, and thermal losses. Coupled optical/fluid/thermal models have been developed to evaluate the performance of these designs relative to conventional designs. Modeling results showed that fractal-like structures and geometries can increase the effective solar absorptance by 5 – 20% and the thermal efficiency by several percentage points at both the meso and macro scales, depending on factors such as intrinsic absorptance. Meso-scale prototypes were fabricated using additive manufacturing techniques, and a macro-scale bladed receiver design was fabricated using Inconel 625 tubes. On-sun tests were performed using the solar furnace and solar tower at the National Solar Thermal Test facility. The test results demonstrated enhanced solar absorptance and thermal efficiency of the fractal-like designs.

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