solar tower technology - status and r&d at dlr dr. reiner ...apr 10, 2014 · • cerro...
TRANSCRIPT
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Solar Tower Technology - Status and R&D at DLR Dr. Reiner Buck German Aerospace Center (DLR) April 10, 2014 Stellenbosch University, South Africa
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DLR German Aerospace Center
Research Institution Space Agency Project Management Agency
34 research institutes and facilities, all over Germany 820 Mio € for Research & Operation 7,700 employees
> 3,000 scientists > 500 doctoral students and junior scientists
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Solar Research at DLR
Institute of Solar ResearchProf. Dr. Pitz-Paal
Prof. Dr. Hoffschmidt
Qualification
Dr. P. Heller
Solar Process
TechnologyDr. C. Sattler
Point Focussing SystemsDr. R. Buck
Test Facilities and Solar Materials
Dr. K.-H. Funken
Line Focussing SystemsK. Hennecke
H2O
H2
OO22
H2O
H2
OO22
H2O
H2
OO22
about 140 staff members in • Köln • Stuttgart • Almeria (Spain) • Jülich
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Department „Point Focus Systems“
DepartmentPoint Focus Systems
Dr. Reiner Buck
Receivers
Ralf Uhlig
Simulation and Open Air Receivers
Peter Schwarzbözl
Systems and Concentrators
Stefano Giuliano
11 staff members
ST
5 staff membersKP +JL
6 staff membersST
- institutional funding: R&D with long term perspective - current focus: direct absorption receivers and systems
- third party funding: short- to mid-term perspective - technology transfer and continued development - component development - tool development
- 25 staff members, budget 2013: 3.5 Mio €
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Solar Research Test Facilities (Cologne)
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DLR owns Solar Tower Test Facility Jülich
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owned by CIEMAT; permanent delegation of DLR Solar Research
Plataforma Solar de Almeria, Spain
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- CSP with storage and fossil backup: firm, dispatchable power
- thermal storage lowers LCOE
- high local content possible
2000 h
+2000 h
η >98%
100 h
Firm capacity
Advantages of Concentrating Solar Power Plants
R. Buck > DLR Stuttgart > Stellenbosch University, April 10, 2014 9
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CSP Characteristics
solar tower:
⇒ higher concentration
⇒ higher process temperature
⇒ higher solar-to-electric efficiency
⇒ reduced collector area
(Tabsorber = Tprocess) [K]
η max
Flat Plate Collector
Parabolic Trough
Solar Tower
Parabolic Dish
ηmax= ηth,Carnot* ηabsorber
C ∼ 𝟖𝟖
C ∼ 𝟐𝟖𝟖𝟖
C ∼ 𝟓𝟖𝟖 C = 1
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data from CSPtoday Project Tracker, status: March 2014
CSP Technology Perspective
total: 3957 MW total: 1212 MW total: 2786 MW
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Solar Resource in South Africa
• annual DNI level has strong influence on LCOE
• DNI levels > 2000 kWh/m²a are required
• South Africa has excellent DNI resources in several regions
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Scheme of a Solar Tower Plant
Tower
Receiver
Hotstorage
G
Steam generator
Condenser
Solar field
Steam turbine
Coldstorage
Aux. heater
Heliostats
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Overview
• PS10/20: near Seville (Spain), 10 + 20MW, ∼ 1h storage
• Gemasolar: near Seville (Spain), 20MW, 15h storage
• Ivanpah: near Las Vegas (USA), 377MW, no storage
• Sierra SunTower: Lancaster (USA), 5MW, no storage
Operational Commercial Solar Tower Plants
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Operational Solar Tower Plants: Gemasolar (Torresol)
Power rating 19.9MW Annual production 110 GWh/a Capacity factor 74% Heat transfer fluid molten salt Storage molten salt,
15h Power block steam cycle,
wet cooling
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Operational Solar Tower Plants Ivanpah (Brightsource)
Power rating 377MW Annual production 1‘079 GWh/a Capacity factor 33% Heat transfer fluid Water/steam Storage - Power block steam cycle,
dry cooling
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• Crescent Dunes, USA (SolarReserve) • 110MW, 10h storage • under commissioning
• Khi Solar One, South Africa (Abengoa) • 50MW, 2h storage
• Cerro Dominador, Chile (Abengoa) • 110MW, 17.5h storage
• Ouarzazate, Morocco • 110MW, storage • bidding process underway
Future Solar Tower Plants
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• relevant parameter is LCOE [$/kWh], not specific cost [$/kW]
• additional value from dispatchability and security of supply
Economics of Solar Tower Systems
• CAPEX is dominant cost fraction
⇒ financing conditions important!
• actual LCOE: 0.16 … 0.36 US$/kWh
• 2020 LCOE: 0.08 … 0.16 US$/kWh
• LCOE depends on • solar resource • financing
(all cost in 2010 US$)
solar tower, 100MW with 15h storage
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Solar Tower Technology:
• ascending renewable power technology
• firm capacity with high capacity factors
• significant cost reductions expected • technological development • improved manufacturing • increased maturity (financing)
• high local content achievable
• also suitable for HT process heat
Summary
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R&D Activities at DLR Solar Research Department „Point Focus Systems“
R. Buck > DLR Stuttgart > Stellenbosch University, April 10, 2014 22
Goal: Cost Reduction of CSP Plants (Solar Tower, Dishes) - performance optimization
- heliostat field, receiver, system - cost reduction
- component cost, O&M cost
R&D topics: - receivers - heliostats - system aspects - control - simulation tools
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HelFer Cost Optimized Heliostat Production
Aim Cost reduction of heliostats by complementary development of production concepts and heliostat structures
Status - Heliostat developed - Design of central production
unit almost finished - Basic concept for integration
of qualification methods in production process (photogrammetry and deflectometry) developed
Partners - Kraftanlagen München GmbH - Heidelberger Druckmaschinen AG
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AutoR Autonomous Light Weight Heliostat With Rim-Drives
Aim Cost reduction of heliostats by about 30% through complementary approaches
Partners - Trinamic Motion
Control GmbH - Institute of
Telematik, TU Hamburg Harburg
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Source: G. Kolb et al., Heliostat Cost Reduction Study, 2007
AutoR Autonomous Light Weight Heliostat With Rim-Drives
Cost reduction potential wireless: - Wiring cost for
one 14m² heliostat: 300$
- No lightning protection needed
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AutoR Autonomous Light Weight Heliostat With Rim-Drives Cost reduction potential of drives and steel structure (cost estimations):
14m² BSE (Reference) Rim Drive Elevation drive 80 € 6 €/m² 30 € 2 €/m² Azimuth drive 300 € 21 €/m² 30 € 2 €/m² Central tilting device 65 € 5 €/m² 40 € 3 €/m² Rims, guidance 0 € 0 €/m² 100 € 7 €/m² Locking devices 0 € 0 €/m² 20 € 1 €/m² Mirrors 168 € 12 €/m² 168 € 12 €/m² Mirror support structure 400 € 29 €/m² 300 € 21 €/m² Pylone and foundation 240 € 17 €/m² 240 € 17 €/m² Control, wiring, installation 600 € 43 €/m² 600 € 43 €/m²
total (without impact of optics) 1853 € 132 €/m² 1528 € 109 €/m²
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AutoR Autonomous Light Weight Heliostat With Rim-Drives First prototype almost finished
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R&D on Receiver Technologies
- development / technology transfer - open volumetric air receiver - pressurized volumetric air receiver
- development of receivers with liquid HTF
- molten salt receivers - liquid metal receivers
- innovative concepts: direct absorption - particle receivers
particle receiver: test at 900°C
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Tower Plant with Open Volumetric Air Receiver Solar Tower Demonstration Plant Jülich, Germany
~
Heliostat Field
Hot Air 680 °C
Cold Air 120 °C
Steam
HRSG
T urbine Thermal Storage
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Open Volumetric Air Receiver
- improvement of volumetric absorber structures
- optimization of air receiver system
- dynamic simulation of receiver
- aim point optimization
- support of market introduction - scalable design - design of prototype plants - know-how transfer
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Pressurized Volumetric Air Receiver
- volumetric absorber structures: - metallic wire grid (T < 800°C) - ceramic foam/matrix (T > 800°C)
- transparent quartz window - tested at Plataforma Solar de Almeria:
- temperature up to 1030°C - pressure up to 15bar
- modular design with secondary concentrator
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Tube Receiver Design and Analysis Example: SOLUGAS receiver
SOLUGAS facility Abengoa, Seville
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SOLUGAS Tube Receiver in Solar Gas Turbine System
Abengoa Solar Power Plants, near Seville, Spain
SOLUGAS plant
800°C reached
installation of an additional 1000°C pressurized volumetric receiver module in preparation
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Receiver component development - antireflective coated segmented receiver window
2 cm
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LIMTECH: Systems using Liquid Metal as HTF
• large temperature range in liquid phase
• chemically stable
Fluid Solar Salt Na LBE Sn
Tmelt [°C] 220 98 125 232
Tboil [°C] 565 883 1553 2687
⇒ receiver with higher flux density, i. e. smaller receiver
⇒ higher receiver efficiency ⇒ lower levelised costs of electricity
(at 1bar)
• high heat transfer coefficient
• thermal storage concept? • corrosion? • cost?
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Particle Receiver Power Plant - Solid ceramic particles as absorber, heat
transfer and storage material Advantages: - Direct absorption - No freezing - No decomposition - High temperatures - Inherent Storage
- Low Levelized Electricity Costs
R. Buck > DLR Stuttgart > Stellenbosch University, April 10, 2014 38
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Particle Receiver Concepts
- direct absorption concept ⇒ high efficiency
- different receiver approaches: - falling film receiver - centrifugal receiver - entrained particles
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Falling Particle Receiver in Face-Down Cavity
R. Buck > DLR Stuttgart > Stellenbosch University, April 10, 2014
concentrated solar radiation
20°section
Particle-curtain
particle inlet
particle outlet
particle curtain
40
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Particle Receiver with Smart recirculation - different recirculation strategies studied - MATLAB and CFD model for „smart“
recirculation predict higher efficiency
- further efficiency increase with more recirculations predicted
- gain in efficiency flattens → additional
effort for more recirculations might not be justified
R. Buck > DLR Stuttgart > Stellenbosch University, April 10, 2014 41
800°C particle exit temperature
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The Centrifugal Particle Receiver (CentRec)
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10kW Prototype in Laboratory Scale
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- Measured wall temperatures indicate homogeneously distributed particle film - Increasing temperature from receiver inlet (z/L = 1) to outlet (z/L = 0)
demonstrates gradual heating of particles - Particle outlet temperature of about 900°C is reached - film can be controlled by rotation speed
CentRec: Experimental Results
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Solar-hybrid Microturbine System
Turbec T100 microturbine, Pel=100 kW 4.5 barabs, 950°C Turbine inlet temperature 600°C recuperator outlet temperature η ∼ 31% (standard unit)
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Solar-hybrid Microturbine System with Integrated Solar Particle Loop
direct contact HX 1
direct contact HX 2
“high” temperature storage (1000°C)
solar receiver
“low” temperature storage (600°C)
particle loop
• replaces standard recuperator with particle loop recuperator
• potential for significant cost reduction
• challenge: direct contact HX 1 • pressurized • gate for particles
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SMILE Project - Installation of two solar-hybrid microturbine
systems (100kWel) in Brazil - System test with metallic tube receiver for
800°C outlet temperature at PSA (>100h) - Partners in Brazil: FUSP, SOLINOVA
Absorber tubes Distributor
Collector
Quartz window
Microturbine
Inlet
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SOLUGAS Project - demonstration of a pre-commercial solar-hybrid gas turbine system - power level: 4.6 MWe, solar air preheating to 650°C/800°C - partners: Abengoa, GEA, Turbomach, DLR, NEAL - co-funded by EC under FP7 - site: Sevilla
DLR tasks: - receiver design - field layout
in preparation: - receiver temperature
increase to 950°C
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Solarized Gas Turbine Cycles
- several configurations: - Combined Cycle - recuperated cycles - intercooling
LCOE @SM2 (hybrid operation)
intercooled Brayton cycle
• performance prediction: • intercooled Brayton cycle:
• performance better or equal to MS system
• Combined Cycle similar MS
• solar-hybrid gas turbine cycles • high turbine inlet temperature:
⇒ moderate solar share • low turbine inlet temperature:
⇒ high solar share (950°C) • regenerator storage optional
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Overview of DLR CSP simulation tools • DLR simulation tools cover all levels of CSP simulation
GREENIUS: analysis of performance / economics of renewable energy systems
ebsSolar®: detailed performance analysis of CSP systems
component layout: • concentrators (parabolic trough, Fresnel, heliostats) • receivers
system layout optimization: • solar field, receiver • power block • storage
transient system simulation: • real-time, high resolution performance simulation • coupling of components and control
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Detailed System Performance Simulation using Ebsilon®
- „All in One" solution for detailed power plant modelling
- for development, acquisition und planning of all kinds of power plants and thermodynamic processes
- design and development of single components, subsystems and complete systems
- development of new solar library EbsSolar (steag and DLR): - thermodynamic modelling and yield analysis (e.g. annual yields) - components of solar thermal power plants
(Dialog for time series calc., transient calc. for energy storage, fluid properties for solar applications)
- 2010: library for line focussing systems -Parabolic Trough -Linear Fresnel
- 2011: library for Solar Tower systems - currently more than 70 licences of EbsSolar are used
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System Simulation: Workflow for Solar Towers Annual Yield Calculation Climate data
Power plant process
Solar resource data
Solar field performance Operational strategy
HFLCAL
Field Layout
Jahres -
Power plant - simulation
η gross η net
P el
Q Rec usw .
p amb T amb
η Field
η Rec Q Rec
A Field
etc.
p amb
T amb
ϕ amb
DNI
Interface for annual yields solar tower
receiver
hot tank
G
steam generator
condenser
solar field
steam turbine
cold tank
m PB m R
m B r
R Br
T 1
T 2
PB
m PB m R
Br PB R
T 1
m S T 2
m PB m R
R Br
T 1
PB
T 2
m PB
R Br
T 2
PB
T 1
R : Receiver Br :: Aux. . burner PB : Power block T 1 : hot tank T 2 : cold tank
1 2 3 4 5
m PB
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Solar System Layout Visual HFLCAL: Heliostat Field Layout
• simplified optical model • very fast calculation • optional: use of topography
- fast optimization of heliostat field, receiver and tower
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Component Level: High Precision Ray Tracing (STRAL)
• fast and accurate ray tracing of concentrator systems (tower, trough, ..)
• can use measured heliostat surface data • aim point optimization • tool coupling features
• best simulation environment for specific modeling problems
• exchange data during co-simulation via network • MATLAB® / Simulink®; Dymola©; LABVIEW©; Excel®
client server direct tool coupling
indirect tool coupling
simulation environment XYincluding
communication interface
simulationenvironment XY
STRAL TCP/IP-communication-DLL
for XY
STRAL TCP/IP
TCP/IP
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Tool Coupling Example: Cloud Passage
STRAL
MATLAB
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Aim Point Optimization
- STRAL (Solar Tower Ray-Tracing Laboratory):
- fast ray-tracer for precise flux calculation
- based on heliostat deflectometry data
- assignment of heliostats to aim points is a
combinatorial problem of dimension 𝐷 = 𝑛𝐴𝑛𝐻
⇒ use ant colony optimisation meta-heuristic
- concept proven theoretically by simulation
- 2014: validation at solar tower Jülich
- applications:
- during design phase
- operation assistance system
- integrated in flux/temperature control unit
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Integrated Solar Tower System Layout
- integrated tool under development: combination of
- field layout (heliostat positions)
- aim point distribution
- receiver design (e.g. FEM stress analysis)
FemRay
STRAL: - field layout - aim point optimisation - flux calculation
ANSYS: - FE-modelling - heat transfer calc. - temp. and stress analysis
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Dynamic Modelling of Receivers
• dynamic modelling of an open volumetric air receiver in Dymola/Modelica
for analysis of transient operation
• dynamic modelling of a tubular salt receiver in Dymola/Modelica for
analysis of start-up & shut-down, cloud passage, fill&drain
• dynamic calculation of flux density distribution on receiver surface by
STRAL
• combination of Dymola models with Simulink for modelling of operation &
control structures
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Co-Simulation of total plant behaviour
• philosophy: use best suitable simulation tool for each component
STRAL
heliostat field
Dymola
receiver system
TCP/IP Server Client
flux density distribution
sun position, DNI, clouds
control panel for heliostat field
LabVIEW operation strategy
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High-temperature storage with solid media Regenerator storage, Packed bed
storage with hot gas HTF Particulate storage and heat exchangers
• Thermo-mechanical aspects (thermal ratcheting): particle-discrete models to calculate inter-particle forces ⇒ design of protective measures
• Uniform flow distribution with “low pressure-loss designs”: CFD-based prediction of pressure loss and flow
• CFD-multiphase models for the prediction of flow field and thermal heat exchange in high-temperature granular flows