Publications

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This report summarizes the results of a two-year project funded by the U.S. Department of Energy's Solar Energy Technologies Office (SuNLaMP 1506) to evaluate the performance of high-temperature (>700 °C) particle receivers for concentrating solar power (see Appendix A for project information). In the first year, novel particle release patterns were designed and tested to increase the effective solar absorptance of the particle curtain. Modeling results showed that increasing the magnitude and frequency of different wave-like patterns increased the effective absorptance and thermal efficiency by several percentage points, depending on the mass flow rate. Tests showed that triangular-wave, square-wave, and parallel-curtain particle release patterns could be implemented and maintained at flow rates of ~10 kg/s/m. The second year of the project focused on the development and testing of particle mass-flow control and measurement methods. An automated slide gate controlled by the outlet temperature of the particles was designed and tested. Testing demonstrated that the resolution accuracy of the slide-gate positioning was less than ~1 mm, and the speed of the slide gate enabled rapid adjustments to accommodate changes in the irradiance to maintain a desired outlet temperature range. Different in-situ particle mass-flow measurement techniques were investigated, and two were tested. The in-situ microwave sensor was found to be unreliable and sensitive to variations in particle flow patterns. However, the in-situ weigh hopper using load cells was found to provide reliable and repeatable measurements of real-time in-situ particle mass flow. On-sun tests were performed to determine the thermal efficiency of the receiver as a function of mass flow rate, particle temperature, and irradiance. Models of the tests were also developed and compared to the tests.

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Operation of concentrated solar power receivers at higher temperatures (>700°C) would enable supercritical carbon dioxide (sCO₂) power cycles for improved power cycle efficiencies (>50%) and cost-effective solar thermal power. Unfortunately, radiative losses at higher temperatures in conventional receivers can negatively impact the system efficiency gains. One approach to improve receiver thermal efficiency is to utilize selective coatings that enhance absorption across the visible solar spectrum while minimizing emission in the infrared to reduce radiative losses. Existing coatings, however, tend to degrade rapidly at elevated temperatures. In this report, we report on the initial designs and fabrication of spectrally selective metamaterial-based absorbers for high-temperature, high-thermal flux environments important for solarized sCO₂ power cycles. Metamaterials are structured media whose optical properties are determined by sub-wavelength structural features instead of bulk material properties, providing unique solutions by decoupling the optical absorption spectrum from thermal stability requirements. The key enabling innovative concept proposed is the use of structured surfaces with spectral responses that can be tailored to optimize the absorption and retention of solar energy for a given temperature range. In this initial study through the Academic Alliance partnership with University of Texas at Austin, we use Tungsten for its stability in expected harsh environments, compatibility with microfabrication techniques, and required optical performance. Our goal is to tailor the optical properties for high (near unity) absorptivity across the majority of the solar spectrum and over a broad range of incidence angles, and at the same time achieve negligible absorptivity in the near infrared to optimize the energy absorbed and retained. To this goal, we apply the recently developed concept of plasmonic Brewster angle to suitably designed nanostructured Tungsten surfaces. We predict that this will improve the receiver thermal efficiencies by at least 10% over current solar receivers.

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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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A 1 MWth high-temperature falling particle receiver was constructed and tested at the National Solar Thermal Test Facility at Sandia National Laboratories. The continuously recirculating system included a particle elevator, top and bottom hoppers, and a cavity receiver that comprised a staggered array of porous chevron-shaped mesh structures that slowed the particle flow through the concentrated solar flux. Initial tests were performed with a peak irradiance of ∼300 kW/m2 and a particle mass flow rate of 3.3 kg/s. Peak particle temperatures reached over 700 °C near the center of the receiver, but the particle temperature increase near the sides was lower due to a non-uniform irradiance distribution. At a particle inlet temperature of ∼440 °C, the particle temperature increase was 27 °C per meter of drop length, and the thermal efficiency was ∼60% for an average irradiance of 110 kW/m2. At an average irradiance of 211 kW/m2, the particle temperature increase was 57.1 °C per meter of drop length, and the thermal efficiency was ∼65%. Tests with higher irradiances are being performed and are expected to yield greater particle temperature increases and efficiencies.

Novel designs to increase light trapping and thermal efficiency of concentrating solar receivers at multiple length scales have been conceived 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, and meso-scale tests have been performed. Results show that fractal-like structures and geometries can increase the thermal efficiency by several percentage points at both the meso and macro scales, depending on factors such as intrinsic absorptance. The impact was more pronounced for materials with lower intrinsic solar absorptances (<0.9). The goal of this work is to increase the effective solar absorptance of oxidized substrate materials from ∼0.9 to 0.95 or greater using these fractal-like geometries without the need for coatings.

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Direct solar power receivers consist of tubular arrays, or panels, which are typically tubes arranged side by side and connected to an inlet and outlet manifold. The tubes absorb the heat incident on the surface and transfer it to the fluid contained inside them. To increase the solar absorptance, high temperature black paint or a solar selective coating is applied to the surface of the tubes. However, current solar selective coatings degrade over the lifetime of the receiver and must be reapplied, which reduces the receiver thermal efficiency and increases the maintenance costs. This work presents an evaluation of several novel receiver shapes which have been denominated as fractal like geometries (FLGs). The FLGs are geometries that create a light-trapping effect, thus, increasing the effective solar absorptance and potentially increasing the thermal efficiency of the receiver. Five FLG prototypes were fabricated out of Inconel 718 and tested in Sandia's solar furnace at two irradiance levels of ∼15 and 30 W/cm2 and two fluid flow rates. Photographic methods were used to capture the irradiance distribution on the receiver surfaces and compared to results from ray-tracing models. This methods provided the irradiance distribution and the thermal input on the FLGs. Air at nearly atmospheric pressure was used as heat transfer fluid. The air inlet and outlet temperatures were recorded, using a data acquisition system, until steady state was achieved. Computational fluid dynamics (CFD) models, using the Discrete Ordinates (DO) radiation and the k-? Shear Stress Transport (SST) equations, were developed and calibrated, using the test data, to predict the performance of the five FLGs at different air flow rates and irradiance levels. The results showed that relative to a flat plate (base case), the new FLGs exhibited an increase in the effective solar absorptance from 0.86 to 0.92 for an intrinsic material absorptance of 0.86. Peak surface temperatures of ∼1000°C and maximum air temperature increases of ∼200°C were observed. Compared to the base case, the new FLGs showed a clear air outlet temperature increase. Thermal efficiency increases of ∼15%, with respect to the base case, were observed. Several tests, in different days, were performed to assess the repeatability of the results. The results obtained, so far, are very encouraging and display a very strong potential for incorporation in future solar power receivers.

Direct solar power receivers consist of tubular arrays, or panels, which are typically tubes arranged side by side and connected to an inlet and outlet manifold. The tubes absorb the heat incident on the surface and transfer it to the fluid contained inside them. To increase the solar absorptance, high temperature black paint or a solar selective coating is applied to the surface of the tubes. However, current solar selective coatings degrade over the lifetime of the receiver and must be reapplied, which reduces the receiver thermal efficiency and increases the maintenance costs. This work presents an evaluation of several novel receiver shapes which have been denominated as fractal like geometries (FLGs). The FLGs are geometries that create a light-trapping effect, thus, increasing the effective solar absorptance and potentially increasing the thermal efficiency of the receiver. Five FLG prototypes were fabricated out of Inconel 718 and tested in Sandia's solar furnace at two irradiance levels of ∼15 and 30 W/cm2 and two fluid flow rates. Photographic methods were used to capture the irradiance distribution on the receiver surfaces and compared to results from ray-tracing models. This methods provided the irradiance distribution and the thermal input on the FLGs. Air at nearly atmospheric pressure was used as heat transfer fluid. The air inlet and outlet temperatures were recorded, using a data acquisition system, until steady state was achieved. Computational fluid dynamics (CFD) models, using the Discrete Ordinates (DO) radiation and the k-? Shear Stress Transport (SST) equations, were developed and calibrated, using the test data, to predict the performance of the five FLGs at different air flow rates and irradiance levels. The results showed that relative to a flat plate (base case), the new FLGs exhibited an increase in the effective solar absorptance from 0.86 to 0.92 for an intrinsic material absorptance of 0.86. Peak surface temperatures of ∼1000°C and maximum air temperature increases of ∼200°C were observed. Compared to the base case, the new FLGs showed a clear air outlet temperature increase. Thermal efficiency increases of ∼15%, with respect to the base case, were observed. Several tests, in different days, were performed to assess the repeatability of the results. The results obtained, so far, are very encouraging and display a very strong potential for incorporation in future solar power receivers.

This paper evaluates the on-sun performance of a 1 MW falling particle receiver. Two particle receiver designs were investigated: obstructed flow particle receiver vs.free-falling particle receiver. The intent of the tests was to investigate the impact of particle mass flow rate, irradiance, and particle temperature on the particle temperature rise and thermal efficiency of the receiver for each design. Results indicate that the obstructed flow design increased the residence time of the particles in the concentrated flux, thereby increasing the particle temperature and thermal efficiency for a given mass flow rate. The obstructions, a staggered array of chevronshaped mesh structures, also provided more stability to the falling particles, which were prone to instabilities caused by convective currents in the free-fall design. Challenges encountered during the tests included non-uniform mass flow rates, wind impacts, and oxidation/deterioration of the mesh structures. Alternative materials, designs, and methods are presented to overcome these challenges.

Flux distributions from solar field collectors are typically evaluated using a beam characterization system, which consists of a digital camera with neutral density filters, flux gauge or calorimeter, and water-cooled Lambertian target panel. The pixels in camera image of the flux distribution are scaled by the flux peak value measured with the flux gauge or the total power value measured with the calorimeter. An alternative method, called PHLUX developed at Sandia National Laboratories, can serve the same purpose using a digital camera but without auxiliary instrumentation. The only additional information required besides the digital images recorded from the camera are the direct normal irradiance, an image of the sun using the same camera, and the reflectivity of the receiver or target panel surface. The PHLUX method was evaluated using two digital cameras (Nikon D90 and D3300) at different flux levels on a target panel. The performances of the two cameras were compared to each other and to measurements from a Kendall radiometer. For consistency in comparison of the two cameras, the same focal length lenses and same number of neutral density filters were used. Other camera settings (e.g., shutter speed, f-stop, etc.) were set based on the aperture size and performance of the cameras. The Nikon D3300 has twice the number of pixels as the D90. D3300 provided higher resolution, however, due to the smaller pixel sizes the images were noisier, and the D90 with larger pixels had better response to low light levels. The noise in the D3300, if not corrected, could result in gross overestimation of the irradiance calculations. After corrections to the D3300 flux images, the PHLUX results from the two cameras showed they agreed to within 8% for a peak flux level of 1000 suns on the target, and less than 10% error in the peak flux when compared to the Kendall radiometer.