Shott Receiver Glass to Metal Seal
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Transcript of Shott Receiver Glass to Metal Seal
SCHOTT BUSINESS UNIT SOLAR
1
Solar Thermal Power Plants
SCHOTT BUSINESS UNIT SOLAR
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Kramer Junction (Ca):
- Output 150 MWel
- 900.000 m² aperture area
- 45.000 receiver
SCHOTT BUSINESS UNIT SOLAR
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Parabolic Trough Power Plant- schema
A solar thermal power plant with a
capacity of 50 MWel consist of a mirror
area of approx. 360.000 m² and 15.000
Receivern (total length 60 km)
SCHEMA
SCHOTT BUSINESS UNIT SOLAR
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Collector field and turbine at
Shuman in Meadi close to Cairo (1914)
5 loops à 62 m, steam turbine 120 PS
(technisches Archiv des Deutschen Museums)
Parabolic trough power plants are not new .......
Geschichte
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There are different designs of parabolic troughs...
Parabolrinne mit Blechspiegel, IST
Fix mirror, tracking receiver (General
Dynamics)
2-axis tracking troughs
Ansaldo, Italy
Bauformen
2-axis tracking troughs
MAN, Germany
SCHOTT BUSINESS UNIT SOLAR
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Receiver for Eurotrough
Technical data:length: ca. 100 m
Aperture area: 5,8 m
Concentration factor: approx.. 80 Eurotrough
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Solar Thermal Power Plants – producing electricity over 20 years
Power Plants since 1984
SCHOTT BUSINESS UNIT SOLAR
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Cost development of SEGS plants
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Energy Pricing Policy
•Energy prices and Tax Credits
collapsed
•SO#4 Contract (removed risk
of energy prices for 10 years)
suspended
•Investors return rising from
14% to 17%
•Short construction period
forced causing additional costs
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The receiver is the core component
low thermal losses ( vacuum)
high solar absorption ( high transmission of glass cover )
minimal shading
Übersicht SH
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SCHOTT PTR70 ReceiverReceicer designed according to the existing troughs (LS3, Euro trough, US-trough)
Übersicht SH
Characteristics of PTR 70 Receiver:Glass-to- metall –sealing
selective absorber coating
Antireflective coating ( high transmission)
bellow to compansate thermal expansion
Vacuum between steel and glass tube
diameter 70mm
length 4 m
SCHOTT BUSINESS UNIT SOLAR
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Known Problems
breakage of glass-to metal-seal
(2 - 2.5 %/a)
shading of radiation shields
(> 7% of length)
degradation of coatings
0%
1%
2%
3%
4%
5%
6%
7%
8%
9%
10%
1989 1991 1993 1995 1997 1999 2001 2003
Rec
eive
r G
lass
Fai
lure
s (%
of Fi
eld)
Other
Glass/Metal Seal Failure
Bowing
HR Related Failure
Unknown
Receiver failures at KJC, source: Hank Price, NREL
bellow shields
florescent absorber tubes
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New Receiver DesignBellows are compressed during operation which leads to further reduction of shading
Glass-to-metal-seal is protected against radiation
Active length of Receiver is more than 96%
glass
absorber
vacuum
glass-to-metal-seal glass
absorber
vacuum
glass
absorber
vacuum
glass-to-metal-seal
SCHOTT BUSINESS UNIT SOLAR
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New Glass-to-Metal Seal Improves Strength Properties
Breakage of glass-to-metal sealing (Housekeeper) is main
cause for damages of receivers in existing power plants
New approach with adapted CTE yields a sealing with low stress
Only one glass type necessary
Automated production process
Stainless Steel
CTE=16*10-6/K
Glas
CTE=5.5*10-6/K
Housekeeper - Method SCHOTT Approach
Glas
CTE=3.3*10-6/K
Metal
CTE=5.5*10-6/K
SCHOTT BUSINESS UNIT SOLAR
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Reliability Solar Receiver
silicon oil
glas tube
vacuum
absorption layer
steel tube
permeation barrier
radiation gain
radiation loss
gas convection loss ?
• sufficient H2 getter• optimize hydrogen barrier of steel tube
• Hydrogen permeation from cracked heat transfer fluid (oil) to evacuated tube is limiting factor for lifetime
SCHOTT BUSINESS UNIT SOLAR
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G/M-Seal - Thermal shock test
Intention: A thermal shock produces stress in the glass-to-metal seal
pieces with failures are detected and sorted out easily
Test conditions: sudden thermal shock from 225°C -> 25°C
The thermal shock resistance of the glass itself is about T= 220K.
Result: The glass-to metal seal is nearly as durable as the glass itself
0
50
100
150
200
250 thermal shockresistance GMV
thermal shockresistenceglass only
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Field Test with New Glass-to-Metal-Seal
100 Receivers operating in KJC
since October 03
No breakage
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Performance Test in Eurotrough-Collector(PSA, June 2004)
18 Receivers installed in June 2004
2 % increase in performance compared to UVAC
SCHOTT BUSINESS UNIT SOLAR
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Field Test with Pre-Production Prototyps192 Receivers installed in test loop at KJC in July and October 2004
no breakage
2.4% increase in preformance compared to previously installed tubes of competitor
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Receivers for Molten Salt TechnologySCHOTT tubes installed in 100m test loop at ENEA/Italy
goal: 500-550°C operating temperature
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Pilot Production since 2004
2004:
tubes for field test
1 MW power plant in Arizona
tubes for test loop ENEA (Italy)
2005:
spare parts for KJC/FPLE: 670 tubes
tubes for test loop ENEA
tubes for other customers
Pilot ProductionPilot Production
Evacuation
Welding
Glass-to-metalseal
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New Production Line
Beispiel: Prozess „Hüllrohr“
located in Germany
in operation in summer 2006
highly automated
capacity: 50.000 tubes per year
First supply for 64MW Nevada power plant
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Parabolic technology has a head start in the field of solar power...
Dish-Stirling-Systems - stand-alone system with up to 25 kWe
- marketable
- competing with photovoltaics
Solar Tower Technology - 0,5-12 MWe-systems in R&D
- no commercial operation
Fresnel Line Focus - feasibility study
(SolarMundo) - only 50-70% of „parabolic tube efficiency“
Competing Solar Technologies
SCHOTT BUSINESS UNIT SOLAR
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Receiver – Comparison of costs depending on grid- and local situation
10-45 %
(depending upon
technology)
0,05-0,3 €/kWhBio mass
45-55%ca. 0,03 €/kWhFossil Energy
10-16%
(with 100-180°C)
0,07-0,15 €/kWh (8.000 h/a)Geo Thermal
(Power Plant)
75-93%0,03-0,08 €/kWh (1-5 MW)
0,1-0,2 €/kWh ( 1 MW)
Hydro Power
0,06-0,13 €/kWh (on-shore)
Ca. 0,07 €/kWh (3MW, off-shore)
0,09-0,16 €/kWh
0,4-0,7 €/kWh (on-grid)
Ca. 1,0 €/kWh (solar home system)
Both indication for Central Europe
Costs per kWh
50%Wind Power
15-16%Solar Thermal Power Plants
15%Photovoltaics
EfficiencyTechnology
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Reasons for future power plantsRenewable Energy Portfolio Standards (RPS)
Übersicht SH
SCHOTT BUSINESS UNIT SOLAR
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New Spanish Feed-In Law: RD 436/2004
Grants same tariffs for PV and CSP
from 100kW to 50MW
Cost covering with up to 0.21 €/kWh
Annual adaptation to
electricity price escalation
After implementation of first 200MW
tariff will be revised for subsequent plants
to achieve cost reduction
SCHOTT BUSINESS UNIT SOLAR
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ACS+SMAG2 x 50 MW AndaSol
SMAG 50 MWExtremaSol 1c
HC2 x 50 MW PT
Iberdrola7 x 50 MW PT
EHN+SolarGenix15 MW PT
SENERSolar Tres 15MW
Tower
Abengoa10MW Tower
2x20MW Tower50 MW PT
Spain: Within 12 months after publication of the feed-in law, more than a dozen projects started development
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AndaSol: Key data
Technology: „Solar-only“ Parabolic Trough
Power Plant
Installed Capacity:
49.9 MWel
Storage: Molten salt storage for 7.5 full load
hours
Project Site: Plateau of Guadix, Province
Granada
Net electricity production:
approx. 180 Mio. kWh/a
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First Parabolic Trough Project in Spain (AndaSol1) is moving forward, but one year in delay…
Reasons for delay :
project with cost > 250 Mio €
tedious process for bank financing
new technology
various permit procedures
new players and new partnerships to be established
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Existing SEGS354 MW
SolarGenix50 MW PT
SolarGenix1 MW PT
GEF Mexico25 MW PT
NAFTA: Projects in USA and MexicoDriving Force in USA: Renewable Energy Portfolio (RPS) in south-western states
1000 MW Initiative of Western Governer Association
Mexico: GEF Project
Problems:
Up to now no feasible imple-
mentation strategy for RPS
High risk for IPPs, bankability
15 % of all electricity generated in Nevada be derived from new renewables by the year2013.5% of the RPS must be from solar energy projects.
RPS Nevada
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Nevada ProjectSize: 64 MW solar only
IPP concept, PPA with Nevada Power
Garanty from State of Nevada for PPA in Dec. 04 enabled bankability of project
Start in 2006
Boulder City, NV
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Africa and AsiaAfrica:
Morocco project (GEF) most promising.
Prequalification for bidders completed, award in 2005
GEF project in Egypt in progress, bidding process should start in 2005
Algeria: attractive „Feed in Law“ for solar combined cycle plants
Asia:
GEF project in India with
low probability due to political difficulties
Gas-solar electricity export to Europe
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Reasons for new projectsWorld Bank-Projects: 200 Mio USD
Übersicht SH
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excellent good suitable not suitable
Sou
rce
: S
ola
r M
illenn
ium
AG
, E
rlangen
Sites for CSP are in the Sun Belt
Other factors:
industrialized countries
environmental awareness
and political commitment
incentives
SCHOTT BUSINESS UNIT SOLAR
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Egypt
0
5
10
15
20
25
30
2000 2010 2020 2030 2040 2050
Year
Ele
ctr
icity C
ost o
f N
ew
Pla
nts
[c/k
Wh
]
Photovoltaics
Wind
Wave / Tidal
Biomass
Geothermal
Hydropower
CSP Plants
Oil / Gas
Coal
LEC New Plants c/kWh 2000 2010 2020 2030 2040 2050Wind 6.2 5.2 3.8 3.7 3.7 3.6Photovoltaics 31.9 14.7 7.4 5.8 4.6 4.2Geothermal 19.1 7.4 5.3 4.5 4.4 4.3Biomass 7.6 6.2 5.4 5.3 5.2 5.2CSP Plants 7.9 7.1 5.2 4.5 4.1 4.0Wave / Tidal 0.0 0.0 0.0 0.0 0.0 0.0Hydropower 2.9 3.0 3.1 3.1 3.2 3.3
Oil / Gas 5.4 5.8 6.2 6.7 7.2 7.8Coal 4.0 4.2 4.5 4.8 5.1 5.5
Electricity Cost of Power Technologies (Example)
by courtesy of:MED-CSPMED-CSP
SCHOTT BUSINESS UNIT SOLAR
36 Thank you very much !