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DUKE: Solar Field Development for Direct Steam · PDF fileDUKE: Solar Field Development for...
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DUKE: Solar Field Developmentfor Direct Steam Generation
DUKE and METAS InaugurationJune 6, 2013
Fabian Feldhoff
www.DLR.de/SF • Slide 2 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Concentrating Solar Power (CSP)
Parabolic Trough (PSA) Solar Tower (Sandia)
Linear Fresnel (SPG) Dish-Stirling (SBP)
Up to 1000 °C,Gas Turbines,
MotorsUp to 550 °C,
Steam Turbines
www.DLR.de/SF • Slide 3 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Why Direct Steam Generation?
www.DLR.de/SF • Slide 4 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Parabolic Trough Plants with Oil
+ Commercially applied+ One-phase flow+ Easily scalable
- Heat exchanger batteries- T < 400°C- Efficiency/process limit
reached- Hazardous to environment
www.DLR.de/SF • Slide 5 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Direct Steam Generation (DSG) Plants
+ No heat exchangers+ High temperatures+ High efficiency+ Non-toxic fluid+ Simple overall configuration- Two-phase flow- Higher control effort- Higher temperature gradients- Expensive thermal storage
(so far)
www.DLR.de/SF • Slide 6 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
A brief history of DSG development…
www.DLR.de/SF • Slide 7 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Milestones in DSG developmentThe very beginnings – DSG was first
John Ericsson• New York, USA, 1870 and 1883• 3.25-m2-aperture collector• Driving a small 373-W engine.
Frank Shuman• Meadi, Egypt, 1912-1913• 5 collectors 62x4m• driving a steam engine (~40 kW)
used to pump water for irrigation
Fernández-García, A., Zarza, E., Valenzuela, L., et al., 2010,"Parabolic-trough solar collectors and their applications," Renewable and Sustainable Energy Reviews, 14, pp. 1695 - 1721.
Shuman Collector
www.DLR.de/SF • Slide 8 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Milestones in DSG developmentDISS: EU project at PSA: 500 m/100 bar/400 °C
Zarza, E., Valenzuela, L., León, J., et al., 2004, "Direct steam generation in parabolic troughs:Final results and conclusions of the DISS project," Energy, 29 (5-6), pp. 635-644.1721.
www.DLR.de/SF • Slide 9 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Milestones in DSG developmentPlanning of demonstration plant
INDITEP- Application of design
tools- 5 MWe, 410°C / 70 bar- Recirculation with
decentral separators- Another 200m for DISS
Zarza, E., Rojas, M. E., González, L., et al., 2006, "INDITEP: The first pre-commercial DSG solar power plant," Solar Energy, 80 (10), pp. 1270-1276.
www.DLR.de/SF • Slide 10 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Milestones in DSG developmentDSG Component tests at 500 °C
2010/2011Real-DISS test facility112 bar / 500 °C
PCM storagesystem
www.DLR.de/SF • Slide 11 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Lessons learned
• Solar steam generation in horizontal pipes is possible• Tubes do not need to be tilted, if mass flow is high enough• Most robust and safe operation with recirculation mode• Parallel flow distribution can be handled by
controlling inlet mass flow to every loop• Outlet temperature should be controlled by
additional injection in superheating section
Implemented in commercial plants!
www.DLR.de/SF • Slide 12 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Milestones in DSG developmentLinear Fresnel plants
PE-1: 1 MW, 55 bar, saturated steamPE-2: 30 MW, 55 bar, saturated steamBoth plants with Linear Fresnel technology by Novatec Solar Source: DLR
www.DLR.de/SF • Slide 13 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Milestones in DSG developmentThe first parabolic trough plant with superheating
Source: Solarlite
TSE-1, Thailand5 MWe34 bar, 340 °CTechnology by Solarlite
www.DLR.de/SF • Slide 14 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DSG Status: It‘s commercial!
Topics for industry:• Higher steam parameters (up to 110 bar /500 °C)• Parameter Optimization Pressure and temperature vs. piping cost• Improvements in plant configurations and costs
Topics for R&D:• Solar Field Optimization Optimized recirculation, once-through• Operation Optimization Start-up, Control• Thermal Energy Storage Costs, Performance• Plant integration options Hybrid, TES
www.DLR.de/SF • Slide 15 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
And now? Further solar field development…
www.DLR.de/SF • Slide 16 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
State-of-the-Art Solar Field Concepts for DSG
• With central steam drum
• With decentral steam drums
• With one or two injectionsRecirculation Once-Through
Source: DLR
www.DLR.de/SF • Slide 17 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Concept Comparison > Sub-field Layout
Recirculation (cental) Once-through
Source: DLR
About 70% less piping and less header heat losses
www.DLR.de/SF • Slide 18 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Concept Comparison > Pros and Cons
+ Very robust operation+ Commercially applied
- Higher investment
- Slower start-up
- Higher design effort
+ Easily scalable+ Fast start-up+ Lower investment+ Higher efficiency
- Less robust
- Higher control effort
- End of evaporation not fixed
Recirculation Once-Through
www.DLR.de/SF • Slide 19 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Goal:• Analysis and demonstration of once-through concept
under real irradiation conditionsPartners:
• DLR• (Solarlite)• In cooperation with CIEMAT-PSA
Tasks:• Design and build test facility• Test control strategies and
solar field behaviour• Evaluate results and potential
Once-through mode > DUKE Project
DUKE = Durchlaufkonzept – Entwicklung und Erprobung
www.DLR.de/SF • Slide 20 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Demonstration at DISS Facility at PSA
BOP und Control room
New Solarlite 4600+ collectors (3x 100m)
North
www.DLR.de/SF • Slide 21 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
www.DLR.de/SF • Slide 22 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
Three new Solarlite collectors
www.DLR.de/SF • Slide 23 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
Relocation of inlet valves
www.DLR.de/SF • Slide 24 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
New Receivers for 125 bar / 500°C
www.DLR.de/SF • Slide 25 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
Aligning coll. 9 horizontally
www.DLR.de/SF • Slide 26 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
New ball joints and piping
www.DLR.de/SF • Slide 27 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
New steamattemperator
www.DLR.de/SF • Slide 28 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
New injection instrumentation
www.DLR.de/SF • Slide 29 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
Fast temperature measurements along end zone of evaporation
(57 thermocouples in total)
www.DLR.de/SF • Slide 30 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Upgrade of DISS Test Facility
Adapted receivers with thermocouples in vacuum around circumference
(10 along end zone of evaporation)
www.DLR.de/SF • Slide 31 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Upgraded DISS Facility is ready
• Extension to 1000 meters• New design values
500°C and 112 bar at outlet• New instrumentation for better
once-through mode analysis• Temperature measurements
along end of evaporation• Cross section measurements
at critical locations• …
Photo by DLR/QFly, January 2013
www.DLR.de/SF • Slide 32 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
What will be tested in the project?
www.DLR.de/SF • Slide 33 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
DUKE > Different Types of Tests
1. Qualification of components(Optical efficiency, heat loss…)
2. Validation of dynamic models(step response tests…)
3. Test and validation of derivedcontrol concepts
Derivation of directly applicable control strategies for commercial plants
www.DLR.de/SF • Slide 34 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Main goal > Develop and test control strategies
• Control of outlet temperature• Stabilization of end point of evaporation
• Sensitive to DNI variation
• Non-minimum phasesystem behaviour due toevaporation
• Bad state observability in evaporation section
www.DLR.de/SF • Slide 35 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Why do we need control strategies?
• DNI varies with timeand location!
Inbalance of loop Inbalance of whole field
Aerial view of Andasol Plants
www.DLR.de/SF • Slide 36 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Outlook on control strategies (I)
• Use current control concepts for outlet temperature as reference• Adapt controller parameters according to operation point• Use temperature observation in superheating section for outlet control• Use temperature observation to determine former end of evaporation
Currently applicable, to be implemented in DUKE
www.DLR.de/SF • Slide 37 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Outlook on control strategies (II)
• Use prediction of DNI in evaporation section to determinefuture/current end of evaporation for better control results
Realistic DNI prediction not yet possible METAS
Local DNI Prediction
www.DLR.de/SF • Slide 38 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Conclusions and Outlook
• Direct Steam Generation in recirculation mode is commercial• Next step for research: development of once-through concept
• More efficient and easier to scale• But: not that robust and so far unclear impact of fluctuating end of
evaporation• Projekt DUKE to answer the remaining questions
• Upgrade of DISS test facility• Demonstration/proof of once-through concept• Evaluation of concept‘s potential
www.DLR.de/SF • Slide 39 > DUKE-METAS Inauguration, June 6, 2013 > Solar Field Development > Fabian Feldhoff
Questions and Contact…
Jan Fabian FeldhoffDLR Institute of Solar Research, [email protected]
By Ron Tandberg