174 Chen Advanced Trough Designs Using Panelized Reflectors Final

8/3/2019 174 Chen Advanced Trough Designs Using Panelized Reflectors Final

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3M: Daniel Chen, Attila Molnar, Dylan Cosgrove

Gossamer Space Frames: Glenn Reynolds, Robert Vezzuto

SolarPaces 2010, Perpignan France

September 24, 2010

Advanced Trough Designs UsingPanelized Reflectors


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Outline Introduction

Design Elements Solar reflective films

Panelized reflectors

Space Frames

Results

Conclusions and Future Work


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In order to remain competitiveas a renewable energyresource, CSP will require

transformative costimprovement

The solar field and its

assembly is a ripe area forinnovation.

New materials plus structural

design may offer new solutionspace for solar collectors

3

Motivation - CSP Market Situation

Objective: Demonstrate feasibility of film based reflectors

for large aperture parabolic trough collectors


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History Large Aperture Parabolic Trough

Increasing aperture sizeleverages other solar field fixedcosts

Luz designs envisioned up to10m aperture (LS-4). Designhad a capital cost target of


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Large Aperture Collector Design Approach

Elements Reflective film

Panel technology

Space frame

Technology synergies Optics (reflectivity)

Shape accuracy

Stiffness Alignment

Challenges

Materials Optics / Durability Integration

Manufacturability

Optics

AccuracyStiffness

Panel Frame

Film

Integrated solution approach can address both cost reduction

and performance improvement


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3M Solar Reflective Films History

Core Technologies Materials Science / Films Optics Multilayer optical films Weathering

Films Experience Subcontract with NREL, 1982-92 Development of 70 film variants CRADA with NREL 2008

Systems Experience Solar Kinetics T-700 /800 (1980-82) Brayton (1985) IST (1993, 2010)

Reliability Experience Lamination Substrate selection Edge sealing

Partial List of Experim ents

B4-15,153 ECP300 l o t 7 N R E L 2 6 2 m o C12_116B SA85 N R E L 1 6 6 m o C12_15A 305 C2_140A 305 res ins C3_4041A 305 res ins /UV C5_102A,B XO9105 C5_142A 305 C 5 _ 1 4 3 A 3 0 5 C6_36A Cu

C6_41A Cu C7_85A 305 E C P 3 0 5 _ 3 0 5 P L U S HAG_1,2,3 ,4 L968_10A Cu Th i ckness OET_1 305,SS95,SA85 AZ 140 mo, FLA 113

m o , N R E L 1 5 7 m o

OET_3 305+ precursor N R E L 1 5 6 m o O E T _ 5 3 M A l t O E T _ 6 3 M A l t OET_7 305+ precursor AZ 130 mo, FLA 113

m o , N R E L 1 4 5 m o

O E T _ 9 3 0 5 + NREL 144 mo R1003_100A In ter l ayer R1003_101A 305+ precursor R1003_4A SS95/SA85 N R E L 1 6 8 m o

R 1 0 0 3 _6 8 A 1 0 A v s 1 0 B a d h R1003_98A 305 R1212_51A Ag th i ckness R1212_52A A l t R1212_54A A l t R1212_56A A l t R1213_30A A l t R1213_46A A l t

R1213_66A A l t R1213_71A A l t N R E L 1 4 5 m o R1558_115A 305+ NREL 127 mo R1558_36A 305 R 1 5 5 8 _4 7 A 3 0 0 v s 3 0 5 R1558_60A 305+ R 1 5 5 8 _6 0 B 3 0 5 v s 3 0 5 + R1558_95A 305+ , Ag, Cu Sub R1875_10A 300, 305, 305+ N R E L 1 2 4 m o R1875_14A 300, 305, 305+ N R E L 1 2 4 m o R1875_40A 300, 305, 305+ R1875_55A 305+ SS_56 A l t

R1875_14A Northbr i dge R1875_16A Northbr i dge K2141_90A_2 N orthbr idge K2141_91A Northbr i dge K2141_92A Northbr i dge K2141_93A Northbr i dge K2141_94A Northbr i dge

NREL 90 mo

K3718_7A Northbr i dgeW O M 3 m o , N R E L 9 m o

R861_79A Other

3M has a long history in development of reflective films


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3M Solar Mirror Film 1100

Description- Metalized polymer film

- Silver as reflective layer

- Designed for outdoor use

[1] S. Meyen, A. Fernandez, C. Kennedy, E. Lpfert, Standardizationof Solar Mirror Reflectance Measurements - Round Robin Test,16th International SolarPACES Symposium Perpignan, France(2010).

Optical Properties 1

Solar weighted hemisphericalreflectance 94.5% (ASTMG173)

Specular reflectance 95.5%(25 mrad acceptance angle)

Key Features

Design flexibility Lead-free

Scalable manufacturing

Pre-mask protective layer

Reflective films offer optical performance competitive

with traditional glass solutions


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Durability

Long term outdoorexposure at NREL (168months)

Accelerated Aging Testing Thermal cycling

Damp Heat

Humidity Freeze

Neutral Salt Spray

Improvements in progress

Hardcoating

Anti-soiling coating

Improved reflectance

0

10

20

30

40

50

60

70

80

90

100

250 500 750 1000 1250 1500 1750 2000 2250 2500

Wavelength (nm)

Hemispheric

alReflectance(%)

Time Weathered: 168.8 months

Solar weighted hemispherical reflectance 93.05%

Courtesy C. Kennedy, NREL

Durability testing shows the feasibility of long-life reflective films


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Abengoa Solar, Englewood, CO USA1.2 MW thermalUses 3M SMF 1100 Mirror FilmCommissioned June 2010

Photo Courtesy Abengoa Solar


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Panel Technology Development

Design Over 30 design variants studied Key performance factors

Survival to wind Stiffness

Manufacturability Raw materials cost

Methods Mechanical modeling

Loads analysis per Uniform Building

Code CFD using Fluent

Simplified ray tracing approach Used Abaqus backbone Custom Python scripts Calculate normal of each shell element Calculates reflected vector from solar

source and intercept with diameter

Static hydraulic load testing

Mechanical and optical modeling techniques for accelerateddesign and development


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Stress modeling and Testing


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Optical Modeling: 4mm Glass


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Optical Modeling: Panelized Reflector


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Founded in 1999by GlennReynolds, GaryCurtis, and Dean

Hackbarth

Gossamer designphilosophy -lightweight, strong,precise and cost-effective structures

Developed

OrganicConnectorTM andZero clearanceshear pintechnology

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Gossamer Space Frames History

First CSP project in2006

US CSP Plants Nevada Solar One

64 MW

FP&L MartinCounty 75 MW

Spain (50 MW ea.)

La Risca

Palma del Rio I

Palma del Rio II

Majadas

Gossamer a leader in CSP frame design


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Space Frame Technology

Design approach Interlocking delta trusses First self aligning parabolic trough

system Excellent slope error and torsional

stiffness

Fielded Versions 8 and 12 meter Up to 200 kph rated RP-2 and RP3

(1) T. Wendelin, Parabolic Trough VSHOT Characterization, in 2005-2006 NREL 550-40024)

Space frame technology well suited towards larger aperture design


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Integration


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Integration

Results

Built 7+m trough section

Used two mirror panels (4.4 m2 ea)

Initial photogrammetry complete

Intercept factor 98.3% for a 70mmtarget (ATT Metrology)


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LAT Next Generation Performance

Performance/C

ost

LS-25m

LS-3Eurotrough5.7m

Heliotrough6.8m

LAT-17 m

LAT-29 m

Glass Torque Tube Film Space FrameLAT offers a new design and performance space for parabolic trough CSP


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Conclusions and Future Work

Conclusions Reflective films are a viable alternative to traditional reflective

materials Panel constructions have advantages of high stiffness, low

weight and high shape accuracy

Large aperture parabolic trough designs (7m+) are feasible

Future Work Full collector construction and characterization

Qualification of pre-production equipment and processes

Test loop

Cost analysis at solar field and LCOE level


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Acknowledgments

National Renewable Energy Lab C. Kennedy

US Department of Energy DE-FC36-08GO18027

DLR E. Luepfert, S. Meyen

CIEMAT

ATT Metrology


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174 Chen Advanced Trough Designs Using Panelized Reflectors Final

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