With Intelligent Optimisation Strategies and Higher Temperatures to Better Performance and Lower Cost

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1 With Intelligent Optimisation Strategies and Higher Temperatures to Better Performance and Lower Cost SOLAR-ERA.NET - Information and Match Making Event Dr. Mark Schmitz February 24th, 2016 Issued date: Feb 24, 2016 Created by: M. Schmitz

2 Content Introduction Technological success factors for EPC businesses Challenges and Opportunities for the Solar Industry Examples for the opportunity Public Funding Seite 2

3 Introduction to TSK Flagsol Business focus: Full EPC of renewable energy power plants TSK group: turn-over 800 M, 68% in energy, 1100 employees In 2013: Formation of TSK Flagsol Engineering GmbH using team and IP of Flagsol GmbH TSK Flagsol is the group s international: Competence center for CSP technology The group s combined CSP experience (engineering, partial and full EPC): - 9 parabolic trough plants (Spain, Morocco, South Africa) - 1 integrated solar combined cycle plant (Egypt) - 1 linear Fresnel plant - 1 solar tower (100 MW) engineering for binding full EPC offer Seite 3

4 Technological success factors for EPC businesses Typical main award criterion: Lowest EPC price (engineering, components, subcontracts, contingencies, profit) for given annual energy production Examples: reduced collector field size Reduced optical losses Increased PB efficiency Optimal heliostat arragenent How to reach a lower EPC price? Lower specific material costs Higher temperature Lower storage cost Low contingency Low technological risk Demonstration plant Seite 4

5 Challenges and Opportunities for the CSP Industry Challenges Technological competitiveness despite conservative customers Demonstration projects have to be of relevant size High investment at unknown outcome Volatile CSP market Restrictive tendering Payback time on R&D unsecure! Find ideal solar demonstration conditions (avoid German weather!) Opportunities Public funding, to put risks on broader shoulders Joint use of European know-how Access to R&D facilities in the EU Seite 5

6 Examples for the Opportunity Solar-Era.Net: Solar-Era.Net offers TSK Flagsol these opportunities Example 1: Breaking the 400 C barrier Example 2: From the math labs to the desserts reduced collector size Reduced optical losses Increased PB efficiency Reduced heliostat blocking SolFieOpt How to reach a lower bid? Lower specific costs Higher temperature Lower storage cost SITEF Low contingency Low technological risk Demonstration plant Seite 6

7 Examples for the Opportunity Solar-Era.Net: Breaking the 400 C barrier State of the art Heat transfer fluid for parabolic trough: high-temperature hydro-carbon oil Problem chemical decomposition at 400 C Opportunity Silicone oil with T max 425 C Carnot efficiency rises by 3% 25% more energy in same TES* Path forward European R&D team Solar-Era.Net project SITEF demo in relevant scale (200-m loop) DLR, CIEMAT, Wacker, Senior Flexonics, TÜV Nord * TES = thermal energy storage Seite 7

8 Examples for the Opportunity Solar-Era.Net : From the math labs to the desserts State of the art Heliostats are arranged in fixed patterns Problem - non-optimal land use - optical blocking between heliostats Opportunity Use of innovative algorithms to place heliostats individually Path forward Solar-Era.Net project SolFieOpt Analysis of concept viability European R&D team TSK Flagsol, Universidad de Sevilla, RWTH Aachen Seite 8

9 Thank you for your attention! Contact: Seite 9

10 Skal-ET Evolution Basis: Dimensions and experiences of LUZ s LS3 collector Aim: Cost reduction, performance increase, sourceability of components Result: The EuroTrough (ET) 2 nd step: Improvement through scale-up of SCA length 96 to 144 m Result: The Skal-ET Seite 10

11 Skal-ET Lessons Learnt Constant subtle reengineering due to lessons learnt, but: Some lessons learnt required complete redesign: - Bigger is better! Less drives, less foundations - Bearing axles and sliding motion create too much twist loss of performance - Screwing mirrors incurs deformations unnecessary spillage Seite 11

12 Comparison SKAL-ET vs. HelioTrough HT 24 = 24 m SCE length SKAL-ET HelioTrough 2 SCE Width: [m] 5,77 6, % SCE Length: [m] % HCE Diameter: [mm] 70 88,9 + 27% SCEs / SCA [-] % Effective Aperture Area / loop: [m²] % Seite 12

13 Innovations: Continuous Torque Tube HT 19 = 19 m SCE length HelioTrough is designed with a continuous torque tube First Gapless SCA (no mirror gap between individual SCEs) Improved efficiency due to reduced heat losses Better usage of HCEs Less space consumption 100% stiffness at torque transfer Less twist Higher optical efficiency Seite 13

14 Innovations: Mounting of mirrors: Patented 3D-Tolerance Adjustment The mirrors are placed on an accurate jig Mirrors in a perfectly shaped parabola SCE-Frame is lowered on the jig Anchor rods are surrounded by the hollow shape of the pods Pods are filled with glue, while the mirrors stay in the ideal position Improved optical efficiency due to perfectly shaped parabola Seite 14

15 Innovations: New Bearing Concept Support Roller with maintenance free bearing very low friction leads to low torsion and high performance Seite 15

16 Loop in Operation since end of 2009 Seite 16