Cranfield University: Capability in. Concentrating Solar Power. Dr Christopher Sansom FHEA. Associate Professor in. Concentrating Solar Power

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1 Cranfield University: Capability in Concentrating Solar Power Dr Christopher Sansom FHEA Associate Professor in Concentrating Solar Power Manufacturing Department Cranfield University, UK

2 Outline What is Concentrating Solar Power? What expertise do we have in the UK?

3 Outline What is Concentrating Solar Power? What expertise do we have in the UK?

4 Burning Mirrors depicting Archimedes destruction of Roman warships during the siege of Syracuse (212 BC), by Guilio Parigi (1600) Concentrated Solar Power started about 2300 years ago. under a Defense Program Like many other existing technologies

5 Concentrating Solar Power (CSP) Solar Thermal Concentrating systems for: Electricity (energy) generation, Heating and cooling, Desalination, water purification, cooking, and Industrial process heat Line Focusing Point Focusing Trough Fresnel Tower Dish Large-scale technologies that also have the potential to incorporate thermal energy storage. Small-scale technology no storage 5

6 CSP PLANTS IN SPAIN Distribution of CSP plants in Spain (2014) Trough plants with thermal storage (82%) 50 plants 2305 MW in operation in

7 MOLTEN SALTS THERMAL STORAGE Storage Type: 2-tank indirect. Solar field provides energy to power block and storage system; when no solar radiation is available, the storage system is the source of thermal energy Storage Capacity: MW. 1,010 MWh. Thermal Storage Description: 28,500 tons of molten salt. 60% sodium nitrate, 40% potassium nitrate. Tanks size: 14 m high, 36 m diameter. Cold tank temperature: 292 ºC Hot tank temperature: 386 ºC

8 CSP PLANTS IN THE MENA REGION 470 MW Integrated Solar Combined Cycle (ISCC) plant at Ain-Ben- Mathar (Morocco) 100 MW Shams-1 at Abu Dhabi (2500 hectares and 500 M of investment)

9 SOUTH AFRICA TROUGHS PLANTS 50 MW Bokpoort CSP Plant owned by ACWA Power Technology: SENER parabolic trough 9,5 hours of two tanks indirect - molten salts thermal energy storage Plant cost: EUR 300 Million Growing interest of South African goverment to CSP technologies due to the perception of clear benefits over the local economy and employment

10 FRESNEL PLANTS IN AUSTRALIA 44 MW Kogan Creek Fresnel ISCC Plant (Australia) The Kogan Creek Solar Boost project is a 44 megawatt solar addition to the existing 750 megawatt Kogan Creek Power Station Technology: Areva Solar KCP Pty Ltd Location: Kogan, Queensland (Australia) Project cost: USD 14 Million

11 FRESNEL PLANTS IN INDIA 100 MW Dhursar Fresnel Plant Reliance Power 100 MW linear Fresnel plant (Rajasthan, India) Technology: Rajasthan Sun Technique, a subsidiary of Reliance Power EPC contractor: AREVA Electricity price offered: rupees /kwh USD 20 cents/kwh Land area: 340 hectares No storage Project cost: USD 336 Million Plant was commissioned in March

12 ABENGOA PS10 & PS20 PS10 (2007) with 624 heliostats, distributed over 50 hectares was the first ever commercial solar tower plant. PS10 PS20 PS20 (2009) solar field is formed by 1,255 two-axis (Solucar 120) sun tracking heliostats (120m² reflecting surface), totalizing 151,276 m 2 over 80 hectares PS20 and PS10 (Seville, Spain) view

13 19.9 MW GEMASOLAR PLANT Location: Fuentes de Andalucía, Sevilla (Spain). DNI: 2,172 kwh/m2/yr. Owner: TORRESOL ENERGY (60% SENER and 40% MASDAR) Heliostat Solar-Field Aperture Area: 304,750 m² Number of Heliostats: 2,650 (140 m 2 each). Land area: 195 hectares Storage Capacity: 15 hours. Annual equivalent hours = 6,500. Storage type: Two-Tanks direct. From the cold tank (290ºC) salts are pumped to the tower receiver and heated up to 565ºC, to be stored in one hot-salts tank (565ºC). Project cost: EUR 230 Million. Operative since April

14 392 MW IVANPAH SOLAR FACILITY World s largest Solar-Thermal power plant (2013) Primm, San Bernardino, CA DNI: 2,717 kwh/m2/yr Plant cost: USD 2,200 Million. Technology: Brightsource. Operational since MW Gross. 1x116 MWe + 2x133 MWe turbines. No thermal storage (gas back-up) 173,500 heliostats (15 m 2 area). 2.6 million m 2 reflecting area. Solar steam generator (inlet temp.: 250 ºC; outlet temp.: 565 ºC). Dry cooling

15 392 MW IVANPAH SOLAR FACILITY

16 110 MW CRESCENT DUNES, 2013 Location: Tonopah, near Las Vegas (NV) DNI: 2,685 kwh/m2/yr Technology: Solar Reserve (EPC Sener) Storage capacity: 10 hours (2-tank direct) 17,170 heliostats (62.4 m 2 area/unit). Solar steam generator (inlet temp: 288 ºC; outlet temp: 565 ºC). Hybrid cooling PPA (Power Purchasing Agreement) tariff rate: US$ per kwh

17 CURRENT CSP COSTS Typical Characteristics Power Generation Types: parabolic trough, Fresnel, tower, dish Plant size: MW (trough); MW (tower); MW (Fresnel) Capacity factor: 20 40% (no storage); 35 75% (with storage) CONCENTRATED SOLAR POWER (CSP) Capital Cost (USD/kW) Trough with no storage: 4,000 7,300 (OECD); 3,100 4,050 (non-oecd) Trough: 7,100 9,800 (6 hours storage) Tower: 6,300 10,500 (6 15 hours storage) Typical Energy Cost (LCOE - US cents/kwh) Trough and Fresnel: (no storage); (6 h. storage) Tower: (6 7 h. storage); (12 15 h. storage) Renewables Global Status Report (REN21) The acceleration of worldwide CSP development would only be possible through the research intensification with the main goal on cost reduction and performance enhancement EERA JP on CSP (only 1 UK member)

18 Outline What is Concentrating Solar Power? What expertise do we have in the UK?

19 Global CSP Laboratory The UK Centre for CST/CSP, Precision Engineering Institute, Cranfield University Collaborative research: 3 FP7 projects, DECC supplier contract, UK company funding International events CSP short-course 2013,2014,2015 EERA-JP on CSP Only UK representative in EERA-JP (CSP) and in STAGE-STE FP7 project Consultant to Carbon Trust on CSP DECC/DFID advisor on CSP for Sub-Saharan Africa and South America Currently 4 FT staff, 10 PhD students, 10 Masters students, 2 visiting Fellows, 2 visiting academics

20 CSP Research activities; Origins were in 2007 through the Precision Machining capability in large optics ESO European Extremely Large Telescope ( E-ELT ) 39m f/1 primary mirror: Consortium formed: Cranfield University Optropreneurs Ltd Zeeko Ltd QioptiQ Ltd TNO (Delft) This will be the largest telescope in the world Cranfield PEI role : Primary mirror segment grinding, Subsequent smoothing, Optical and mechanical assessment

21 Only UK research team working exclusively on CSP

22 SAM - System Advisor Model Version SAM models system performance using the TRNSYS software developed at the University of Wisconsin. TRNSYS is a validated time-series simulation program that can Simulate the performance of PV, CSP, water heating systems, and other renewable energy Systems using hourly resource data

23 CSP Power Plant: Cranfield University activities MATS FP7 EU project Solar Field schematic Started July 2011 Technology Schematic

24 Capability on collector design Collector characterisation Measurement of form Durability and ageing Receiver tube manufacture Coatings deposition and process control Machine design

25 Photogrammetry form results Concentrating Solar Power (CSP) Characterization of CSP collector surfaces - Ronda mirror segment Removing focal error reveals the smaller variations. These error positions correspond to structural points where the mirror is supported.

26 Concentrating Solar Power (CSP) Photogrammetry form results Flabeg mirror (CIEMAT-PSA) Form surface error map for position 1 Surface error with form removed for position 1

27 Photogrammetry form results Concentrating Solar Power (CSP) Characterization of CSP collector surfaces - Ronda mirror segment (ENEA)

28 Photogrammetry form results Concentrating Solar Power (CSP) Characterization of CSP collector surfaces - Flabeg (CIEMAT-PSA)

29 Concentrating Solar Power (CSP) Characterization of CSP collector surfaces - KAU CEDT) King Abdulaziz University, Jeddah (Parabolic Trough)

30 Concentrating Solar Power (CSP) Characterization of CSP collector surfaces - KSU Point-focus linear Fresnel configuration Mechanical Engineering Department, King Saud University, Riyadh

31 Concentrating Solar Power (CSP) Characterization of CSP collector surfaces - COMSATS (Islamabad) Linear Fresnel configuration solar cooker - Pakistan LF focus on receiver tube, showing misalignment of some collectors strips ~50mm

32 Sand erosion of glass Sand-induced visual damage of glass Glass reflectance after sand erosion Damage occurs at particle speeds of 17m/sec Corresponding reduction in reflectance It has also been shown that sand of μm diameter becomes airborne in gusts of m/sec From our measurements in Egypt we know that the average wind speed during storms is 9.5 m/sec and gusts reached m/sec. particles moving at peak sandstorm speeds will cause surface damage to glass

33 Sand Erosion test apparatus Designed for erosion testing of aero-engine turbine materials Compressor feeds accumulator to maintain pressure Air passed through heater (labyrinth path) Abrasive medium injected in acceleration tube (1.2m from sample) Sample located 50 mm from nozzle exit Exit nozzle diameter 13 mm Sample face 90º to air path

34 Contact Cleaning - simulation FANUC Robot M-710i Rotary head (300 rpm) Brush unit (ASTM 2486 standard) Wash cycles 400, linear speed 285mm/min

35 Non-contact Cleaning simulation Kärcher K2.36 water jet washer Input power 1400W Water flow 360L/hr Washer nozzle 200mm from sample Cleaning in raster pattern

36 Anti-soiling coatings Based on novel copolymers that can adhere strongly to surfaces One block adheres strongly to the surface The second block projects away from the same surface making that surface unattractive for dust and dirt to stick to. The copolymers should form aggregates The aggregates resulting in a very high coverage of the copolymer The aggregates provide an efficient barrier to dust and dirt. The polymers are able to adsorb from a water based formulation and the layer that adheres is only nanometres thick meaning it is essentially invisible RepelSmart solar product

37 CSP FP7 Project design and build of a receiver tube and absorber tube coating system (with 4m capability) Design properties of the innovative receiver: (transmittance >96%, absorptance >95%, emittance 250 C <7%). Low-cost, high throughput Manufacturing of receivers Regional breakdown of solar thermal potential for process heat in industry (UNIDO) This corresponds to kW plants across Africa and kWplants across Latin America in 2050

38 CSP FP7 Project design and build of a receiver tube and absorber tube coating system (with 4m capability) Concept Design Using a capability for design and fabrication of large machines for large optics applications

39 Small-and medium scale - Global CSP

40 Low-cost solar cooker design Cranfield prototype 2 nd Prize2014

41 Seasonal Heat storage Working with Open University Seeking UK and EU funding

42 Thermal storage Material Energy Density (GJ/m 3 ) Charging Temperature ( O C) MgSO 4 7H 2 O MgCl 2 6H 2 O 1.62 NiCl 2 NH CaCl 2 NH Silicagel H 2 O 0.76 Zeolith H 2 O 0.8 FeCO Ca(OH) Fe(OH) CaCO CaSO 4 2H 2 O

43 Summary UK Centre of excellence in Concentrating solar energy (ST and PV) UK Centre of excellence in long-term thermal storage Selected expertise in solar PV and waste heat energy harvesting First choice UK research partner in EU funded CST/CSP programmes First choice for DECC on Concentrating solar and long-term heat storage UK First choice for international PhD students for Concentrating Solar research

44 Contact: Dr Christopher Sansom FHEA Associate Professor in Concentrating Solar Power Precision Engineering Institute, Manufacturing Department School of Aerospace, Transport, and Manufacturing Cranfield University Cranfield, MK43 0AL, England, UK Tel: +44 (0) FRESH NRG