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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Intense, dynamic radiant heat loads damage and ignite many common materials, but are outside the scope of typical fire studies. Explosive, directed-energy, and nuclear-weapon environments subject materials to this regime of extreme heating. The Solar Furnace at the National Solar Test Facility simulated this environment for an extensive experimental study on the response of many natural and engineered materials. Solar energy was focused onto a spot (∼10 cm2 area) in the center of the tested materials, generating an intense radiant load (∼100 kW m−2 –1000 kW m−2) for approximately 3 seconds. Using video photography, the response of the material to the extreme heat flux was carefully monitored. The initiation time of various events was monitored, including charring, pyrolysis, ignition, and melting. These ignition and damage thresholds are compared to historical ignition results predominantly for black, α-cellulose papers. Reexamination of the historical data indicates ignition behavior is predicted from simplified empirical models based on thermal diffusion. When normalized by the thickness and the thermal properties, ignition and damage thresholds exhibit comparable trends across a wide range of materials. This technique substantially reduces the complexity of the ignition problem, improving ignition models and experimental validation.

Nuclear weapon airbursts can create extreme radiative heat fluxes for a short duration. The radiative heat transfer from the fireball can damage and ignite materials in a region that extends beyond the zone damaged by the blast wave itself. Directed energy weapons also create extreme radiative heat fluxes. These scenarios involve radiative fluxes much greater than the environments typically studied in flammability and ignition tests. Furthermore, the vast majority of controlled experiments designed to obtain material response and flammability data at high radiative fluxes have been performed at relatively small scales (order 10 cm2 area). A recent series of tests performed on the Solar Tower at the National Solar Thermal Test Facility exposed objects and materials to fluxes of 100 – 2,400 kW/m2 at a much larger scale (≈1 m2 area). This paper provides an overview of testing performed at the Solar Tower for a variety of materials including aluminum, fabric, and two types of plastics. Tests with meter-scale objects such as tires and chairs are also reported, highlighting some potential effects of geometry that are difficult to capture in small-scale tests. The aluminum sheet melted at the highest heat flux tested. At the same flux, the tire ignited but the flames were not sustained when the external heat flux was removed; the damage appeared to be limited to the outer portion of the tire, and internal pressure was maintained.

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A 1 MWt continuously recirculating falling particle receiver has been demonstrated at Sandia National Laboratories. Free-fall and obstructed-flow receiver designs were tested with particle mass flow rates of ∼1 - 7 kg/s and average irradiances up to 1,000 suns. Average particle outlet temperatures exceeded 700 °C for the free-fall tests and reached nearly 800 °C for the obstructed-flow tests, with peak particle temperatures exceeding 900 °C. High particle heating rates of ∼50 to 200 °C per meter of illuminated drop length were achieved for the free-fall tests with mass flow rates ranging from 1 - 7 kg/s and for average irradiances up to ∼ 700 kW/m2. Higher temperatures were achieved at the lower particle mass flow rates due to less shading. The obstructed-flow design yielded particle heating rates over 300 °C per meter of illuminated drop length for mass flow rates of 1 - 3 kg/s for irradiances up to ∼1,000 kW/m2. The thermal efficiency was determined to be ∼60 - 70% for the free-falling particle tests and up to ∼80% for the obstructed-flow tests. Challenges encountered during the tests include particle attrition and particle loss through the aperture, reduced particle mass flow rates at high temperatures due to slot aperture narrowing and increased friction, and deterioration of the obstructed-flow structures due to wear and oxidation. Computational models were validated using the test data and will be used in future studies to design receiver configurations that can increase the thermal efficiency.

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When exposed to a strong radiant heat source (>1,000 kW/m2), combustible materials pyrolyze and ignite under certain conditions. Studies of this nature are scarce, yet important for some applications. Pyrolysis models derived at lower flux conditions do not necessarily extrapolate well to high-heat-flux conditions. The material response is determined by a complex interplay of thermal and chemical transport phenomena, which are often difficult to model. To obtain model validation data at high-heat-flux conditions (up to 2500 kW/m2), experiments on a variety of organic and engineered materials were performed at the National Solar Thermal Test Facility at Sandia National Laboratories. Mass loss during the short duration (2-4 sec) heat pulse was determined using the pre- and post-test weight. The mass-loss data were fairly linear in the fluence range of 200-6000 kJ/m2. When divided into subsets based on material types, the mass loss was similar at the peak flux/fluence condition for engineered polymers (≈1 g) and organic materials (≈2.5 g), although some exceptions exist (PMMA, dry pine needles). Statistical correlations were generated and used to evaluate the significance of the observed trends. These results contribute to the validation data for simulating fires and ignition resulting from very high incident heat flux.

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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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