Publications

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This is a summary of the performance objectives and outcomes for fiscal year 2015, quarter 4.

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Concentrating solar power receivers are comprised of panels of tubes arranged in a cylindrical or cubical shape on top of a tower. The tubes contain heat-transfer fluid that absorbs energy from the concentrated sunlight incident on the tubes. To increase the solar absorptance, black paint or a solar selective coating is applied to the surface of the tubes. However, these coatings degrade over time and must be reapplied, which reduces the system performance and increases costs. This paper presents an evaluation of novel receiver shapes and geometries that create a light-trapping effect, thereby increasing the effective solar absorptance and efficiency of the solar receiver. Several prototype shapes were fabricated from Inconel 718 and tested in Sandiaas solar furnace at an irradiance of ∼30 W/cm2. Photographic methods were used to capture the irradiance distribution on the receiver surfaces. The irradiance profiles were compared to results from raytracing models. The effective solar absorptance was also evaluated using the ray-tracing models. Results showed that relative to a flat plate, the new geometries could increase the effective solar absorptance from 86% to 92% for an intrinsic material absorptance of 86%, and from 60% to 73% for an intrinsic material absorptance of 60%.

The goals of this project are to demonstrate the feasibility of significant thermal storage for dish stirling systems to leverage their existing high performance to greater capacity; demonstrate key components of a latent storage and transport system enabling on-dish storage with low energy losses; and provide a technology path to a 25kW_e system with 6 hours of storage.

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The project goals are: demonstrate the feasibility of significant thermal storage for dish Stirling systems to leverage their existing high performance to greater capacity; demonstrate key components of a latent storage and transport system enabling on-dish storage with low exergy losses; and provide technology path to a 25kW_e system with 6 hours of storage.

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Solar thermal receivers absorb concentrated sunlight and can operate at high temperatures exceeding 600°C for production of heat and electricity. New fractal-like designs employing light-trapping structures and geometries at multiple length scales are proposed to increase the effective solar absorptance and efficiency of these receivers. Radial and linear structures at the micro (surface coatings and depositions), 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 also reduce thermal emittance due to reduced local view factors in the interior regions, and higher concentration ratios can be employed with similar surface irradiances to reduce the effective optical aperture and thermal losses. Coupled optical/fluid/thermal models have been developed to evaluate the performance of these designs relative to conventional designs. Results show that fractal-like structures and geometries can reduce total radiative losses by up to 50% and increase the thermal efficiency by up to 10%. The impact was more pronounced for materials with lower inherent solar absorptances (< 0.9). Meso-scale tests were conducted and confirmed model results that showed increased light-trapping from corrugated surfaces relative to flat surfaces.

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Reflective mirror facets for concentrating solar power (CSP) systems have stringent requirements on the surface slope accuracy in order to provide adequate system performance. This paper presents a tool that can fully characterize facets quickly enough for 100% inspection on a production line. A facet for a CSP system, specifically a dish concentrator has a parabolic design shape. This shape will concentrate near-parallel rays from the sun to a point (or a line for trough systems). Deviations of surface slope from the design shape impact the performance of the system, either losing power that misses the target or increasing peak fluxes to undesirable levels. During development or production, accurate knowledge of facet defects can lead to improvements to lower cost or improve performance. The reported characterization system, SOFAST (Sandia Optical Fringe Analysis Slope Tool), has a computer-connected camera that images the reflective surface, which is positioned so that it reflects an active target, such as an LCD screen, to the camera. A series of fringe patterns are displayed on the screen while images are captured. Using the captured information, the reflected target location of each pixel of mirror viewed can be determined, and thus through a mathematical transformation, a surface normal map can be developed. This is then fitted to the selected model equation, and the errors from design are characterized. While similar approaches have been explored, several key developments are presented here. The combination of the display, capture, and data reduction in one system allows rapid characterization. An “electronic boresight” approach is utilized to accommodate physical equipment positioning deviations, making the system insensitive to setup errors. Up to 1.5×10⁶ points are characterized on each facet. Finally, while prior automotive industry commercial systems resolve the data to shape determination, SOFAST concentrates on slope characterization and reporting, which is tailored to solar applications. SOFAST can be used for facet analysis during development. However, the real payoff is in production, where complete analysis is performed in about 10s. With optimized coding, this could be further reduced.