high-temperature falling particle receiver€¦ · csp program summit 2016 energy.gov/sunshot 29...

energy.gov/sunshotenergy.gov/sunshotCSP Program Summit 2016

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CSP Program Summit 2016

HIGH-TEMPERATURE FALLING PARTICLE RECEIVER

Contributors: Sandia National LaboratoriesGeorgia Institute of TechnologyBucknell UniversityKing Saud UniversityGerman Aerospace Center (DLR)

Clifford K. Ho, Sandia National Laboratories

SAND2016-3641 PE

energy.gov/sunshotenergy.gov/sunshotCSP Program Summit 2016 2CSP Program Summit 2016

Overview

• Introduction

• Particle Receiver System

• On-Sun Testing

• Conclusions

2


Motivation

• Higher Efficiency Electricity Production

• Supercritical CO2 Brayton Cycles (>700 °C)

• Air Brayton Combined Cycles (>1000 °C)

• Thermochemical Storage & Fuels

• ELEMENTS redox particles (>1000 °C)

• Solar fuel production (>1000 °C)

3

Particle Receivers


Advantages of Particle Receivers

4

• Direct heating of particles

• Higher temperatures than conventional molten salts• Enable more efficient power cycles

• Higher solar fluxes for increased receiver efficiency

• Direct storage of hot particles

• Reduced costs

CARBO ceramic particles (“proppants”)


High Temperature Falling Particle Receiver(DOE SunShot Award FY13 – FY16)

5

Particle curtain

Aperture

Particle curtain

Aperture

Falling particle receiver

Particle elevator

Particle hot storage

tank

Particle cold storage

tank

Particle-to-working-fluid

heat exchanger

Goal: Achieve higher temperatures, higher efficiencies, and lower costs.


Overview

• Introduction


• On-Sun Testing

• Conclusions

6


ReceiverFree-Fall vs. Obstructed Flow

7

Particle curtain

Aperture

Particle curtain

Aperture


Particle Receiver Designs – Free Falling

8


Particle Receiver Designs – Pachinko

9


Particle Flow over Chevron Meshes

10

Pros: particle velocity reduced for increased residence time and heating

Cons: Mesh structures exposed to concentrated sunlight (~1000 suns)


Particles

11


Particle Radiative Properties and

Rejuvenation

12

Material Name Type

Solar

weighted

absorptivity

Thermal

emissivity*

Selective

Absorber

Efficiency**

Carbo HSP Sintered Bauxite 0.934 0.843 0.864

CarboProp 40/70 Sintered Bauxite 0.929 0.803 0.862

CarboProp 30/60 Sintered Bauxite 0.894 0.752 0.831

Accucast ID50K Sintered Bauxite 0.906 0.754 0.843

Accucast ID70K Sintered Bauxite 0.909 0.789 0.843

Fracking Sand Silica 0.55 0.715 0.490

Pyromark 2500 Commercial Paint 0.97 0.88 0.897

*Spectral directional reflectance values were measured at room temperature. The total hemispherical emissivity was calculated

assuming a surface temperature of 700 C.

**Q is assumed to be 6x105 W/m2 and T is assumed to be 700 C (973 K):4

ssel

Q T

Q

Siegel et al. 2015, The Development of Direct Absorption and Storage Media for Falling Particle Solar Central Receivers, ASME J. Solar Energy Eng., 137(4)


Laboratory tests for surface impact evaluation, attrition, and sintering

Particle Durability

Ambient drop

tests at ~10 m

13

Thousands of

drop cycles at

ambient and

elevated

temperatures

(up to 1000 ˚C)

Knott, R., D.L. Sadowski, S.M. Jeter, S.I. Abdel-Khalik, H.A. Al-Ansary, and A. El-Leathy, 2014, High Temperature Durability of Solid Particles for Use in Particle Heating Concentrator Solar Power Systems, in Proceedings of the ASME 2014 8th International Conference on Energy Sustainability, ES-FuelCell2014-6586, Boston, MA, June 29 - July 2, 2014.


Balance of Plant

14


Experimental evaluation and modeling of prototype thermal energy storage designs

Thermal Storage

El-Leathy et al., “Experimental Study of Heat Loss from a Thermal Energy Storage System

for Use with a High-Temperature Falling Particle Receiver System,” SolarPACES 201315


Experimental evaluation of heat transfer coefficients & particle flow

Particle to Working Fluid Heat Exchanger

Golob et al., 2013, “Serpentine Particle-Flow Heat Exchanger with Working Fluid, for Solar Thermal Power Generation,” SolarPACES 2013

Nguyen, C., D. Sadowski, A. Alrished, H. Al-Ansary, S. Jeter, and S. Abdel-Khalik, 2014, Study on solid particles as a thermal medium, Proceedings of the Solarpaces 2013 International Conference, 49, p. 637-646.

16

Sand Flow

Feed Ramp

Hopper

Serpentine Tube

Heat Exchanger

Water/Air In

Water/Air Out

FunnelConveyor Scale

Olds Elevator

Particle Flow

Assist Vibrator

www.solexthermal.com

http://www.solexthermal.com/


Evaluate commercial particle lift designs• Requirements

• ~10 – 30 kg/s per meter of particle curtain width

• High operating temperature ~ 500 C

• Different lift strategies evaluated

• Screw-type (Olds elevator)

• Bucket

• Mine hoist

Particle Elevators

Repole K, Jeter S, “Design and Analysis of a High Temperature Particulate Hoist for Proposed Particle

Heating Concentrator Solar Power Systems”, Energy Conversion and Management, - Submitted

17


Overview

• Introduction


• On-Sun Testing

• Conclusions

18


Prototype System Design

19

~45 ft

Olds Elevator

Top hopper (two release slots)

Receiver

Bottom hopper

Water-cooled flux target

Work platforms

Caged ladders

Open space for 1 MW particle

heat exchanger

Top of tower module


Free-falling particles

Staggered array of

chevron-shaped

mesh structures

Particle Release Configurations

20


Lifting the system to the top of the tower – June 22, 2015

21


Lifting the system to the top of the tower

22


Lifting the system to the top of the tower

23


Prototype System on Tower

24


On-Sun Tower Testing

25

Over 300 suns on receiver(June 25, 2015)



26

Over 600 suns peak flux on receiver(July 20, 2015)



27

Particle Flow Through Mesh Structures(June 25, 2015)


Overview

• Introduction


• On-Sun Testing

• Conclusions

28


Conclusions

29

• Designed and constructed first continuously recirculating, on-sun, high-temperature particle receiver

• Achieved average particle outlet temperatures >700 °C

• Peak particle outlet temperatures >900 °C

• Particle heating up to ~200 – 300 °C/(m of drop)

• Thermal efficiency ~70% to 80%

0

50

100

150

200

250

0 200 400 600 800

Ave

rage

Par

ticl

e D

T p

er

Un

it D

rop

Le

ngt

h (

°C/m

)

Average Irradiance (kW/m2)

~1 - 3 kg/s/m

~3 - 6 kg/s/m

Avg Particle Temperatures = 200 - 600 C

Master_FPR_tests_CorrectedMassFlow_v7_ckho.xlsx

0

50

100

150

200

250

300

350

400

100 300 500 700 900 1,100

Ave

rage

Pat

icle

DT

pe

r U

nit

Dro

p

Len

gth

(˚C

/m)

Average Irradiance (kW/m2)

Original SS316 mesh insert (AvgParticle T = 460 - 660 C)

New Multi-Material Mesh Insert(Avg Particle T = 500 - 710 C)

Particle mass flow ~1.5 - 2.5 kg/s/m

Master_FPR_tests_CorrectedMassFlow_v7_ckho.xlsx

Free-Fall Obstructed-Flow


Next Steps

30

• Received new DOE awards (FY16 – FY18)

• Particle/sCO2 heat exchanger

• Novel particle curtain designs

• Improve receiver efficiency

• Receiver geometry, shape, size, nod angle

• Aperture coverings

• Reduce particle loss

• Abrasion/wear

• Wind

• System designs for scale-up (≥ 10 MWe)


Sandia National Labs• Josh Christian, Daniel Ray, JJ Kelton, Kye Chisman, Bill Kolb, Ryan Anderson, Ron

Briggs

Georgia Tech• Sheldon Jeter, Said Abdel-Khalik, Matthew Golob, Dennis Sadowski, Jonathan Roop,

Ryan Knott, Clayton Nguyen, Evan Mascianica, Matt Sandlin

Bucknell University• Nate Siegel, Michael Gross

King Saud University• Hany Al-Ansary, Abdelrahman El-Leathy, Eldwin Djajadiwinata, Abdulaziz Alrished

DLR• Birgit Gobereit, Lars Amsbeck, Reiner Buck

Acknowledgments

31

Award # DE-EE0000595-1558


Backup Slides

32


SEM Images of Used and Unused Particles

33

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0.1 0.2 0.3 0.4 0.5

Cu

mu

lati

ve P

rob

abili

ty

Particle Size (mm)

Measured particle diameter(unused)

Measured particle diameter(after 187 hrs of testing)

Particle diameter specs(CARBO ACCUCAST ID50)

Unused

Used


July 24, 2015 – Nearly 700 suns

34


SS316 Mesh Failure Analysis

35

Mesh located far from failed region Mesh located within failed region(ceramic particles sintered on mesh)



36

Top left: cross-sectional view of intact wire mesh

Top right: cross-sectional view of oxidized wire mesh



37

Cross-sectional view of oxidized wire mesh; wire ruptured and “leaked” molten steel out of oxidized shell (white is stainless steel, rough gray area is oxidized mesh)


Irradiance Measurements

38

Measured Simulated using Ray Tracing (SolTrace)


Temperature Measurements

39

400

420

440

460

480

500

520

540

560

0 50 100 150

Tem

pe

ratu

re (

C)

Time (s)

TC-BH-005

TC-BH-006

TC-BH-007

TC-BH-008

TC-BH-009

Top Hopper


Evaluate use of air recirculation along aperture to reduce heat loss and impacts of external wind• Investigate particle size, location, particle

flow rate, air flow rate, external wind

Air Curtain Modeling (SNL)

1 mm particle size

40

100 mm particle size 10 mm particle size

high-temperature falling particle receiver€¦ · csp program summit 2016 energy.gov/sunshot 29...

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