Raising the Lifetime of Functional Materials for Concentrated Solar Power 17 th of May 2017, Madrid F. Sutter (DLR) Slide 1
Agenda Presentations from consortium members and externals (will be uploaded on www.raiselife.eu) Central questions will be discussed by the groups Session leaders summarize outcomes of discussions 9:00 Greetings from José Manuel Pingarrón Carrazón, Vice- Chancellor for Transfer of Knowledge and Entrepreneurs 9:10 RAISELIFE project overview 09:30 Durability of solar reflectors for CSP 10:30 Coffee break 11:00 Absorber coating durability 12:00 Durability issues related to Molten Salt 13:00 Group picture 13:05 Lunch 14:00 Impact of degradation on plant performance and economics 15:00 Coffee Break 15:30 Discussion session: Solar reflectors and Molten Salt 16:30 Discussion session: Absorbers and Impact of degradation 17:30 Final session summary 18:00 End Slide 2
Workshop participants Industry (external) Salzgitter Mannesmann COBRA EBL Valspar Rioglass Suntrace Abengoa Sandvik Sener Consortium members (of which 22% are industry partners) R&D (external) National Institute of Chemistry IK4-Tekniker International University of Rabat IMDEA Energy Institute Tecnalia Protermosolar GTER 71 participants in total Slide 3
Project facts Funded by: EU H2020 program, Call: NMP-16-2016 Nanotechnologies, Advanced Materials and Production Duration: 48 months Start date: 01/04/2016 End date: 31/03/2020 Budget: Total cost: 10.5 M EU contribution: 9.3 M Slide 4 2 nd and final Dissemination Workshop will be held at the end of the project! Main project goals: Durability testing newly developed functional materials for CSP (TRL4-6) Analysis of their failure modes and producing a second generation of life-time optimized materials Deriving performance prediction models of the RAISELIFE materials Computing the economical impact of material degradation Improvement of production process and O&M: automatic coating machine for absorber coatings, sensor development to monitor corrosion in molten salts, definition of a catalogue of best practices to reduce in-service degradation
Reflectors 8 different back coatings 2 anti-soiling coatings 1 ultra-thin glass with composite backing structure Secondary Reflector 2 silver reflectors stable up to 400ºC Absorbers 4 absorber coatings (up to 750ºC) 5 molten salt coatings 1 abrasion resistant AR coating 2 selective absorber coatings (up to 400ºC) System simulation to derive economic impact of RAISELIFE materials Slide 5
RAISELIFE consortium Slide 6
Distribution of tasks Slide 7
Silvered-glass reflectors [Flabeg] Glass Ag Cu Base coat New in RAISELIFE: Cost optimized 2 layer systems (for sites of low corrosivity) Multiple layer system (for sites of extreme corrosivity) Lead free layer system Slide 8
Ultra-thin glass mirrors Ultra-thin glass (100 200 µm) Silver layer Composite (ca. 2cm) Reduced protective layer system Glass thickness [mm] ρ s,h [%] 0.1 95.9 0.2 96.0 2 95.2 4 94.8 5 94.3 Slide 9
Methodology for mirror lifetime testing Testing campaign at 11 sites: Lifetime prediction testing - Spain (2) - France (1) - Israel (1) - Morocco (5) - Chile (2) Slide 10
Methodology for mirror lifetime testing Neutral Salt Spray (NSS) ISO 9227 Copper-accelerated acetic acid salt spray (CASS) ISO 9227 Condensation ISO 6270-2 UV and humidity test ISO 16474-3 Thermal cycling/condensation (AENOR draft) Thermal cycling IEC 62108 (Test 10.6 TCA3) Damp Heat IEC 62108 (Test 10.7b) Sand erosion test Combinations of the tests above Lifetime prediction testing Slide 11
Methodology for mirror lifetime testing Microscopic comparison to determine if accelerated aging test excites the same mechanism as outdoors Lifetime prediction testing Selecting the most appropriate test for each mechanism separately! Slide 12
Methodology for mirror lifetime testing Micropit densitiy of aluminum reflectors Lifetime prediction testing Accelerated aging exposure time [h] Outdoor exposure time [h] Slide 13
Anti-soiling coatings for solar reflectors [Sarver et al] Hydrophobic antisoiling coating Measuring of soiling rates and cleaning every 2 weeks Slide 14
Outdoor testing of anti-soiling coatings PSA, Almeria During the first 3 years of exposure anti-soiling coatings show a clear benefit regarding dust adhesion compared to non-coated samples 2 new anti-soiling coatings will be tested in RAISELIFE Slide 15
Anti-soiling coating characterization Pyrheliometer facing the mirror samples Pyrheliometer facing the sun Rotating sample holder containing coated and noncoated reference TRACS measurement system installed in Almeria and Missour (MA) Slide 16
Secondary reflectors Development of uncooled secondaries (up to 400ºC) Thermal analysis Temperature field Accelerated aging tests Environmental durability (climate chambers) Solar furnace tests under high flux Improved reflectors Accelerated aging tests Solar furnace tests Slide 17
Absorber coatings (up to 750 C) Failure of receiver coating during operation Hot oxidation Corrosion Flaking T22 T91 VM12 Inc617 4 new receiver coatings Inorganic paint coating (Brightsource) Aluminid coating (INTA) + Inorganic paint coating on top (Brightsource) Solar selective PVD coating (Fraunhofer) Multi-metallic diffusion coating applied with the powder pack cementation process (Dechema) Slide 18
Absorber coatings (up to 750 C) Distal II test facility, PSA SAAF test facility, PROMES, Odeillo 100 cycles from 200 650 C (750 C for Inconel 617) Solar flux: 250 kw/m² Max. heating/cooling rate: 8 C/min 2 hours per cycle Testing at 650 C (750 C for Inconel 617) Higher flux (500kW/m²) and quick variation of the flux : 250kW/m²/s high thermal gradients of 25 C/s 4 minutes per cycle Slide 19
Absorber coatings (up to 400 C) Hydrophobic AR coatings (Contact angle >100 ) AR coatings with improved abrasion resistance Taber Abrader Slide 20
Hemispherical reflectance RAISELIFE Dissemination Workshop, Madrid, 17 th of May 2017 Absorber coatings (up to 400 C) Selective absorber coating designed to operate in air Sol-gel coating applied with mobile device Absorptance α s = 95.5% Emittance ε = 13% (250 C) 100 90 80 70 60 50 40 30 20 10 0 250 500 750 1000 1250 1500 1750 2000 2250 2500 Wavelength (nm) Slide 21
Absorber coatings (up to 400 C) New AR and selective absorber coating will be tested under accelerated aging in climate chambers and in-service in a long term test in Soltiguas facilities in Italy Slide 22
Corrosion in molten salt 3 aluminide coatings and 2 metallic diffusion coatings will be tested to potentially reduce receiver cost Testing in the standard molten salt mixture (60wt.% NaNO 3 /40wt.% KNO 3 ) and a cost optimized salt mixture Static and cyclic furnace tests Advanced corrosion tests (Slow strain rate testing to study stress corrosion cracking) Slide 23
The effect of molten salt impurity Preliminary tests P91 500 ºC 60wt.% NaNO 3 /40wt.% KNO 3 1500 ppm Cl - / 1500 ppm SO 4 2- t = 0 h t = 1000 h 133 ppm Cl - / 59.2 ppm SO 4 2- Selected impurity levels - 300 ppm Cl - / 300 ppm SO 4 2- - 500 ppm Cl - / 500 ppm SO 4 2- - 700 ppm Cl - / 700 ppm SO 4 2- Ongoing tests P91 560 ºC 250 h Slide 24
The cost of solar reflector degradation Example: 100 MW power plant, 40% annual capacity factor Annual electricity production: 100 MW 8760 h 0.4 = 350,400 MWh 0.2% mirror degradation per year (linear decay) 350.4 MWh less production per year 49,056 US$ / year loss due to degradation (estimated feed-in tariff 0.14 US$/kWh) ~1 Mio. US$/ 20 years RAISELIFE will focus on: Deriving service performance estimations for RAISELIFE materials Definition of reference plants Take entire system, replacement, recoating, O&M, into account to develop more reliable cost predictions [NREL] Slide 25
Economic impact of degradation Economic benefit of RAISELIFE materials Ray tracing simulation with Raytrace3D (Fraunhofer ISE) Thermal FEM simulation (DLR) System simulation in ColSim CSP (F-ISE) Slide 26
Thank you for your attention! Slide 27