Research in Concentrating Solar Thermal: Opportunities in Process heat … · 2019-07-11 ·...

University of Adelaide 1

Research in Concentrating Solar Thermal:

Opportunities in Process heat and Fuels

Professor Gus Nathan

Contributors: Z. Sun, T. Lau, B. Dally, E. Lewis, W.L. Saw, Z.T. Alwahabi, A. Chinnici, M. Jafarian, M.

Arjomandi, J. Pye, W. Lipinski, R. McNaughton, A. Beath

ERICA Conference, 2019


Industrial Heat: A Major Emerging CO2 Challenge

Philibert, “Renewable Energy for Industry” IEA

Report (2017)

Anticipated Trends in Global sources of CO2


High temperature processes with suspended powders

Typical size: 100 < dp < 300m

Typical loading:

10-4 < ሶ𝑚𝑝

ሶ𝑚𝑎< 10-2

Cement Alumina

Alumina


Temperatures and status of Low-CO2 technologies for industrial processes

Process Technology Temperature Low CO2 options Status

Iron-steel Blast Furnace 1300 – 1500 C Hydrogen Pilot1,2

Iron-steel Direct Reduction 800-900 C HydrogenConc. Solar Thermal

Large1,2

Concept2

Lime / Cementcalcination

Pre-calcinerRotary kiln

850 C Oxy + CCSCST + CCS

Pilot1,2

Pilot2

Cement clinkering

Rotary kiln 1450 C Bio/waste fuels commercial1,2

Alumina Precalciner 800 – 1000 C HydrogenCST

Pilot2

Pilot2

Source: 1 de Pee et al, “Decarbonisation of Industrial Sectors: The Next Frontier” McKinsey & Co, (2018)2 Nathan et al (2018) “HiTeMP Outlook” www.adelaide.edu.au/hitemp/

New understanding of particle-laden flows is needed for either solar or hydrogen because flash calciners and direct reduction furnaces both process material as a powder

http://www.adelaide.edu.au/hitemp/


Estimated costs of alternative H2 production options

Finkel Briefing Note to COAG “Hydrogen for Australia’s Future” (2019)


Maximum useful temperature limited by radiation losses

Source: Romero M, Steinfeld A. Energy &

Environmental Science. 2012;5:9234-45.

H

LHidealworktosolar

T

T

IC

T11

4

,

,

rec carnot

For various optical concentration ratios, c


The Sulphur Looping ProcessSuitable receiver temperature

Roeb et al (2011) Int. J. Nuc. Hy. Prod. Applic. 2 (3), 202-226.

SO2 electrolysis:

1/6th electrical

demand of water

H2SO4 Cracking:

demonstrated at 850C

Potential for 650 C using bubbling technology


Emerging options for solar gasification or reformingFor liquid fuels

SNGR: Steam natural gas reformingSCWG: Supercritical water gasificationTC: Thermochemical water splittingSDFB: Solar dual bed gasification

Value drivers for solar gasification:– Conversion to diesel yields higher value than power or methane

– Liquid fuels are readily stored

– Steps toward a circular economy – re-use in the business

– Avoids the need to connect to a pipeline

– Reduces exposure to potential increases in the cost of diesel

– Market advantage from green products


Solar thermal gasification of agriculture residues:


Solar hybridised dual bed gasification - Typical configuration

Treceiver 950C; Tgasifier 850C;


ALCOA, August 2003

Viable technologies for 50% CST in Bayer ProcessBreakthrough technology for solar calcination

Solar DigestionSteam at 180C

(alone or as CHP)

Solar Reforming Nat Gas to syngas Solar Calcination

at 1000C


Commercial technology: Steam turbine at

Tubular receivers

Molten salt as HTF to 580 C

4 – 16 hr of thermal storage

Flux < 1MW/m2

Emerging Particle Technology in Concentrating Solar Thermal Energy

Ivanpah Power Station

Mojave Desert, California

392 MWe from three towersFalling particle receiver

Ho &Iverson, Ren. Sust. Energy, Rev.

29, 835-846 (2014)

Emerging high temp technology: Particle receivers to 1000C

Sensible / chemical storage

Air & CO2 power cycles

Solar fuels production

Solar minerals processing


Emerging Solar Particle Technologies

G3P3 Falling Particle Curtain (Sandia, ASTRI & partners)

Part of US$72m to demonstrate >2000 hours Target temperature > 700C

Centrifugal Receiver (DLR and partners) Demonstrated on-sun at TRL-5 Target temperature 1000C

Fluidised Bed (Niigata & partners; Magaldi) Being developed for solar fuels Target temperature 1300C

Expanding Solar Vortex Receiver (Adelaide & partners) Being developed for alumina calcination Target temperature 1000C


Falling Particle Curtain Technology

Sandia test facility. Images: Dr Cliff Ho, Sandia. National Lab.

Heliostats

TowerFalling Particle

Curtain

a)b)

c)


Uni Adelaide research in Solar Vortex Receiver/Reactors

Alumina calcination (CET / ETH)Davis et al. (Green Chem, submitted)

Program Status

Flow field measurements with PIV Single Phase (Chinnici et al., 2017)

CFD Model development Validated with available data (Chinnici et al., 2017,8)

Analytical heat transfer model Ongoing, e.g. Davis et al (2018)

Residence time measurement Ongoing, e.g. Davis et al (2019)

System modelling Ongoing, e.g. Guo et al (2018)

Hot testing With window (Davis et al, 2017), windowless – in progress

Aerodynamic Curtain In progress

PIV measurementsChinnici et al. (Solar Energy, 2017)


Scientific challenges of solar-irradiated particle-flows

Image: Lau & Nathan (2017), I. J. Multiphase Flow, 88, 191-204.

Turbulent, two-phase flow with dp K

Also poorly understood inflow conditions

Particle clustering“Cloud” aerodynamics

2-way coupled

𝟏𝟎−𝟔 <ሶ𝑽𝒑ሶ𝑽𝒇< 𝟏𝟎−𝟑

Particles Flow

Solar Flux > 1 MW/m2

Strong gradients in and

Strong attenuationCorrections needed for optical measurements

Strong scatteringComplex heat transfer

Optical interference


High Speed Tomographic PIV (at Sandia)

Quantronix Hawk HP dual head laser, 532nm,

Combined repetition rate of 80kHz.

CMOS cameras (Vision Research Phantom v1610) 512×304 pixels. θ=20°, 45°, 135°, and 160°.

Laser sheet thickness 2.8mm (FWHM).

Conditions:

• Re = 10,000

• uj / uco 12

• ሶ𝑚p / ሶ𝑚air = 0.4

• dj = 6.22mm

SkD = 1.4

• dp = 10 1μm

• ρp = 1200 kg/m3

SkD = 0.004

• dp = 0.3 (mean)

• ρp = 3950 kg/m3


Clusters confirmed to be “rope-like” from 3D T-PIV

SkD = 1.4SkD = 0.004

Pseudo-colour

by depth (z)

Lau, Frank & Nathan, Physics of

Fluids Letters (to appear).


SkD = 0.004 SkD = 1.4

Time-series of 3D clusters measured at the exit of a long pipe


Final Comments

• Solar thermal particle technology: leading path for T 1000C

Four complementary technologies under development

• Strong potential for their application in processes heat eg alumina:

Opportunity: relatively low cost renewable, stored heat source

Challenges: integration, upscaling and proving reliability

• New opportunities to lower cost of H2 through novel processes:

Sulphur cycle: moderate temp (800 C) & useful chemicals

Bubbling molten metal reactors: avoid surface damage, high mixing rates

• New opportunities to de-risk upscaling through optical diagnostics:

Laser diagnostics & CFD models: improved model validation


Centre for Energy Technology

Director: Professor Gus Nathan W: http://www.adelaide.edu.au/cet/T: +61 (0)8 831 31448E: [email protected]

Thankyou!

http://www.adelaide.edu.au/cet/


Centre for Energy Technology

Director: Professor Gus Nathan W: http://www.adelaide.edu.au/cet/T: +61 (0)8 831 31448E: [email protected]

Extra slides for discussion

http://www.adelaide.edu.au/cet/


Commercial status of methane pyrolysis

• Solid catalytic process (Hazer) demonstrated at pilot and above

must address coking of catalyst

• Molten metal bubbling reactors demonstrated at pilot scale

avoids coking of catalyst, since Carbon floats

reaction occurs at 800 C (in molten tin)

Abanades et al, I. J. Hydrogen Energy, 41, 8159-67, 2016


Uni Adelaide / Uni Queensland collaboration

Developing advanced materials & reactors together

Novel metals and salts (UQ)

Optimising patent-pending reactors (UA)

Demonstrating improved system at lab scale

Techno-economics

Multi-Phase Metal/Salt

System

Carbon floats


Bubbling molten metal reactor technology

Solar bubbling reactor demonstrated

high rates of heat and mass transport

• Jafarian & Nathan, (2019) Solar Energy (in press)

patent-pending interconnected bubbling reactor

• Jafarian, Abdollahi, Arjomandi, Chinnici, Tian, Nathan (2017) Int. Patent App. No. PCT/AU2018/050034


The role of Stokes number for mono-disperse flows

Conditions:• Re = 20,000

• uj / uco = 12

• dp = 10 5%, 40 5% μm

• ρp = 1200 kg/m3

• ሶ𝑚p / ሶ𝑚air = 0.4

• dj = 12.7mm

𝑺𝑘𝟎 =𝝉𝒑

𝝉𝒇=𝜌𝑢𝑑𝑝

2

18𝜇𝑑𝑗where:

= fluid viscosity


The role of Stokes number in clustering

SkD = 0.004

SkD = 0.69SkD = 0.34

SkD = 0.12

SkD = 1.38 SkD = 5.51

Particle clustersalready present


Gaussian Flux of up to 35 MW/m2

0

5

10

15

20

25

30

35

40

0 2 4 6 8 10 12 14 16 18

Flu

x [M

W/m

2]

Current [A]

d = 10.5mm

d = 20 mm

d = 40 mm

Alwahabi , Nathan, Kueh, Cannon, Optics Express (2016), 24 (2). A1444.


Single shot images of particle temperature heated by radiation

Thermo-phosphoresis

Kueh, Lau, Nathan, Alwahabi (2017), Optics Express, 25 (23), 28764

Fluidised bed

Solid State Solar Thermal Simulator3 kW @ 910nm, to 36.6 MW/m2)

PhosphorescentPlate for

calibration

ZnO:Zn particles

1m < dp < 50 m

𝑇 ∝𝐼1

𝐼2=

σ𝜆=410440 𝐼𝜆

σ𝜆=381399 𝐼𝜆


Calibration of thermo-phosphor against heated plate

Kueh, Lau, Nathan, Alwahabi (2017), I.J. Multiphase Flow, 100, 186-195

൙

𝐼410−440𝐼381−399

(𝐼410−440𝐼381−399

)𝑅𝑒𝑓

ZnO:Zn ThermophosphorT = 35 C

T = 103 C

T = 207 C


Toward in-situ heat transfer measurement


𝐼1𝐼2=σ𝜆=410440 𝐼𝜆

σ𝜆=381399 𝐼𝜆

A

B


Distribution of temperature within particles


Experimental System for 2-line PLF of toluene To assess interference by particles on measurement

Scattering suppression filters:• 275 nm long-pass (Asahi spectra)

Image splitter:• 310 nm dichroic (Semrock FF310-Di01).

Blue filters:• 272 nm long-pass (Semrock FF01-272/LP) • 280 nm band-pass (Semrock FF01-280/20).

Red filters:• 300 nm long-pass (Semrock FF01-300) • 330 nm short-pass (Semrock FF01-330/SP).


Anticipated cost trajectory & markets for commercial renewable H2

CSIRO Roadmap (2018): Bruce, Temminghoff, Haywood, Schmidt, Munnings, Palfreyman, Hartley


Gap between projected H2 costs and current fuels / electricity

2020 2025 2030

80

64

48

32

16

0

AU

D $

/GJ

$10/GJTyp. Current natural gas

$18/GJ

SMR + CCS at 2025 (Finkel)

Gap between projected CO2-free H2 by commercial technology and present natural gas

CSIRO H2 Best case supply costvia electrolysis and PV


Measurement of volume fraction in an optically attenuating flow

• Correcting for attenuation can be done for mono-disperse flow With ray-tracing: solving iteratively against measured total attenuation

• Plausible options for local Vp/Vtot in a poly-disperse flow: measure rp accurately: no planar method is readily available

Count individual particles: limited to Vp/Vtot 10−4

Signal from a pixel

Scattering Coefficient (incorporating collection optics)

Particle radius No of Particles

Incident laser intensity

Kalt et al (2007), Applied Optics, 24, 5823-5834


Research challenges & opportunities for Solar Particle Technology

• Processes opportunities in temperature range 600 – 1000 C Integration

• Technology challenges: Develop and demonstration: reliable and efficient operation

Upscale the technology

• Upscaling challenges: Velocity and number density of both phases

Temperature of both phases

Also need dp (either measured or prescribed, mono-disperse)


System under developmentTo date components have been demonstrated in isolation

Wind tunnel Long pipe supplying particle-laden jet

Coannular tracer flow = co-flow velocity

Mono-disperseparticles


Tomographic PIV & number density – low loadingor PIV & nephelometry - high loading


Particle temperature measurementTwo-line thermo-phosphorescence of TP-particles

Solid state Solar Thermal Simulator3kW and 38 MW/m2 @ 910nm

Thermo-phosphor particles


Gas-phase temperature measurementTwo-line Laser-induced Fluorescence of toluene

Solid state Solar Thermal Simulator3kW and 38 MW/m2 @ 910nm

Toluene seeded into N2 jets


Instantaneous Particle Distributions in Turbulent Jet

SkD = 0.3

SkD = 1.4

Clusters are generated within the pipe and propagate


Mean exit concentration profiles from “long” pipe depend on Sk0

Lau & Nathan, 2014, J. Fluid Mech., 757, 432-457.

Lp/d = 360

No definitive understanding of what

constitutes fully developed two-phase

flow is present available


Automated Planar Detection of Clustering

Lau & Nathan (2017), I. J. Multiphase Flow, 88, 191-204.

Steps in cluster detection:

Explicit mathematical steps

• Rigorous, but not absolute

Dimensions derived from algorithm

• morphological skeletonisationand pruning

Allows conditional statistics


Automated, explicit planar detection of clusters

Lau & Nathan (2017), IJMF, 88, 191-204.

Mean

Mask Isig > Inoise (n)

Instantaneous

Hadmund I/Imean

Smoothed (Gaussian filter)

Binary Mask: I > I (t )

Noise (n)

Threshold (t )


Length scales of clusters in the jet

Cluster width of 0(0.2 d) implies generation by large-scale eddies

Lau & Nathan (2017), IJMF, 88, 191-204.

Research in Concentrating Solar Thermal: Opportunities in Process heat … · 2019-07-11 ·...

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