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SOLAR




Innovations @Schott - contributions
to a competitive Parabolic Trough
technology

Luis Alberto Solá Paños
SCHOTT Solar SL

EL PAPEL DE LA QUÍMICA EN EL DESARROLLO DE LA ENERGÍA SOLAR TERMOELÉCTRICA

EXPOQUIMIA, Barcelona, Nov. 18, 2011
SOLAR



The Challenge: Cost reduction




 © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



The Task for SCHOTT Solar:
   •     Economies of scale and cost cutting in production
   •     Increasing the efficiency of the receiver component:
         - improved coatings for higher optical efficiency
         - increased aperture
                        p
         - larger component
         - higher operating temperature for new heat
           transfer fluids
   •     Increasing reliability




© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR


Economies of Scale - SCHOTT Solar Production Sites
More than 600.000 Receivers already delivered to power plants around the globe


                                                                    Mainz (Germany)
                                                                      Headquarter
                                                                    Mitterteich
                                                                      Production i
                                                                      P d ti since August 2006
                                                                                   A    t
                                                                      Capacity: 200 MW p.a.
                                                                      Pilot line for new products



                                                                Seville (Spain)
     Albuquerque (USA)                                            Production since March 2008
         Production since April 2009                              Capacity: 400 MW p.a.
         Capacity: 400 MW p.a.




                 standardized production and release processes across all sites
                 best-practice and know-how transfer

  © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR


Towards higher Operating Temperatures
                   Today : HTF: Synthetic Oil with limited operating temperture (400°C)
                           Average annual efficiency 12-13%



                  New heat transfer fluids
                  to increase operating temperature
                               p      g    p
                  and hence increase efficiency and reduce cooling load




       Direct steam generation:                       Molten salt              Improved Synthetic Oil
       • temperatures > 500°C                         • temperatures > 500°C   • temperatures > 400°C
       • efficiency >15%                              • efficiency >15%        • efficiency >13%
       • cheaper HTF                                  • Storage                • less hydrogen


        Solar Only:                                   New salts required to    Limited efficiency gain
        - with storage more ex-
                    g                                 - reduce freezing risk
                                                                       g
          pensive than oil                              = safe operation and   Cost: open
        - without storage not                         - to reduce parasitic
          competitive against PV                        losses
        → Potential niche market
           for hybrid solutions                       Cost: open


© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



Is Molten Salt a good HTF for Parabolic Troughs?
                 g                          g
Under Investigation in indoor and outdoor test facilities:
 corrosion
 bending of absorber tubes
                                                                    Cooling curve
 freeze and thaw tests with single and
 multiple receivers

 Test of drainage scenarios and recovery
 from freeze event
 qualification of absorber coatings for
 operating tempetatures up to 550°C                            Phase
                                                               change




 © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR


Increasing the Operating Temperature
What is the upper temperature limit for the absorber?
Answer important for operation and accelerated ageing test


                                                                        Minimum             Ageing
                                                                      ageing time [h]   temperature [°C]

                                                                           1050               510
                                                                            643               525
                                                                            295               550
                                                                             93               590
                                                                             16               660
                                                                              6               700
                                                                              2               750

                                                         Limit (?)

    Calculated acceleration factors as a function of                 For a simulated 25 year lifetime and activation
    ageing test temperature for different activation                 energy of 170 kJ/mol calculated minimum ageing
    energies (operative temperature 400 °C)                          testing time (operating temperature 400 °C)




 © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



Test result for 590 °C test temperature
                               p
                                       accelerated aging @ 590°C for operative temperature of 400°C

                                                      Emittance@400°C
                                                                                                            10
                                97,5                  Absorptance


                                                                                                            9
                                97,0
               Absorptanc [%]




                                                                                                                 Emitt
                                                                                                            8
                        ce




                                                                                                                     tance [%]
                                96,5

                                                                                                            7
                                96,0
                                96 0
               A




                                                                                                            6
                                           25 years       25 years                      25 years lifetime
                                95,5       lifetime       lifetime                      500°C will be
                                           400°C          450°C                         reached at 4850h
                                                                                                            5
                                       0      500       1000 1500 2000 2500 3000 3500 4800
                                                               Overall aging time [h]



 © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



Solutions for the Hydrogen Problem

Problem:
      Thermo oil decomposes during operation,
      hydrogen is generated.
      Hydogen permeation through steel absorber tube
      Getter secures vacuum
      After saturation of Getter heat losses are
      increasing rapidly



                                                               Glass
                                                 vacuum


                                                 H2           Getter
                                                                Steel tube
                                           oil




© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR


 Noble Gas Capsule
    • located in the glass annulus of the receiver
         opposite to the mirror side
    • to be opened non-invasive by a laser device
    • unique solution for the ´hot tube
         phenomenon
         phenomenon´




                                                              Enhancing the live time:
                                                              - Th h ld glass t
                                                                Threshold l     temperature i di
                                                                                       t    indi-
                                                                cates increased thermal losses
                                                              - release of noble gas by opening the
                                                                capsule with a single laser pulse
                                                              - thermal losses will be immediately
                                                                reduced



 © SCHOTT Solar CSP GmbH
© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



   Noble gas Capsule – How it works
         g     p
   capsule activation (2) can save more than 4000 W per receiver (1)

                                 initial                  end of getter   Hydrogen filling        Capsule
                                 state
                                   t t                    capacity
                                                                it        the
                                                                          th vacuum               activation
                                                                                                    ti ti




                                                                                        5.7x
                                                                                        5 7x
                                                                                5.7x
                                                                                         H2
                                                                                  H2
                                                                            1

                                                                                                 2Xenon
                                                                                                  X
                        relative
                    relative                                                                     capsule
                      heatheat                                                                  activation
                      lossloss

                                                                                                1.3x
                                                                                                1 3x
                                                              1x                                   1.3x
                                                                                                Xe/H 2
                                                 1x                                                 Xe/H2
                                                          PTR70®
                                              PTR70® (vacuum)
                                             (vacuum)
                                                initial                                                        time time
                                                 state         20-25         several           following
                                                               years         weeks             years




© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR


   Shield Reflectors
   designed to enhance receiver efficiency
                                                              REFLECTOR SHIELDS:
                                                              - Cover and insulate space
                                                                between receivers
                                                              - Reflector to use radiation
                                                                hitting the shielded area
                                                              - gains depend on incident
                                                                angle of irradiation




                                                              Illustration of different
                                                              incidence angles




© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



Reflector Shields to Increase Aperture Area




© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR


                     Shield Reflector benefits
                                     h/L 0,3         h/L 0,8             h/L 1                                             h/L 0,3         h/L 0,8              h/L 1                                         h/L 0,3          h/L 0,8             h/L 1
                     3,0                                                                                   3,0                                                                                     3,0
  3,0                                                                                   3,0                                                                                   3,0
                     2,0                                                                                   2,0                                                                                     2,0

                                                                                                                                                                                                                                                                Seasonal 




                                                                                                                                                                              relative gain in %
               n %




                                                                                                     n %
                     1,0                                                                                   1,0                                                                                     1,0
relative gain in




                                                                                      relative gain in
                     0,0                                                                                   0,0                                                                                     0,0
                                                                                                                                                                                                                                                                influence at 
                                                                                                                                                                                                                                                                  fl
                                                                                                                                                                                                   ‐1,0
                                                                                                                                                                                                                                                                Almeria shown 
                     ‐1,0                                                                                  ‐1,0
                                     December                  21st                                                       March / Sep.                    21st                                                          June 21st                               by reference days
                     ‐2,0                                                                                  ‐2,0                                                                                    ‐2,0


-3,0
   ‐3,0                                                                               -3,0
                                                                                         ‐3,0                                                                                -3,0
                                                                                                                                                                                ‐3,0
                            4    6    8    10   12    14       16   18      20   22                               4   6     8    10   12    14       16    18      20   22           4                    6    8    10    12    14       16   18      20   22
                            4                                                    22                               4                                                     22          4                                                                      22
                                                time in h                                                                             time in h                                                                          time in h




                                                                                                                                                                                                                                     Annual yield calculation of 
                                                                                                                                                                                                                                     shield performance 
                                                                                                                                                                                                                                     considering incident angles 
                                                                                                                                                                                                                                     depending on latitudes 
                                                                                                                                                                                                                                     without local DNI effects. 
                                                                                                                                                                                                                                     (reflectance: 80%) 
                                                                                                                                                                                                                                     (reflectance: 80%)




                                                                                                                                                                             Slide 14 of 5 Slides
                        © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR



PTR 70 New Design

SCHOTT PTR®70 Receiver –
Improved performance


  Absorber
  Ab b coating stable up t
               ti   t bl     to
  operating temperatures of 450°C
  Absorptance                     ≥ 95,5%
  Emittance
  E i                             ≤ 9 5% @400°C
                                    9,5%
  Transmittance                   ≥ 96,5%
  Thermal losses                  < 250 W/m (400°C)
  Aperture length: > 96,7% @ working temperature (300 - 400°C)




 © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
SOLAR




                            Gracias por su atención!!




© Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved

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Luis Alberto Solá Paños - El papel de la química en el desarrollo de la energía solar termoeléctrica

  • 1. SOLAR Innovations @Schott - contributions to a competitive Parabolic Trough technology Luis Alberto Solá Paños SCHOTT Solar SL EL PAPEL DE LA QUÍMICA EN EL DESARROLLO DE LA ENERGÍA SOLAR TERMOELÉCTRICA EXPOQUIMIA, Barcelona, Nov. 18, 2011
  • 2. SOLAR The Challenge: Cost reduction © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 3. SOLAR The Task for SCHOTT Solar: • Economies of scale and cost cutting in production • Increasing the efficiency of the receiver component: - improved coatings for higher optical efficiency - increased aperture p - larger component - higher operating temperature for new heat transfer fluids • Increasing reliability © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 4. SOLAR Economies of Scale - SCHOTT Solar Production Sites More than 600.000 Receivers already delivered to power plants around the globe Mainz (Germany) Headquarter Mitterteich Production i P d ti since August 2006 A t Capacity: 200 MW p.a. Pilot line for new products Seville (Spain) Albuquerque (USA) Production since March 2008 Production since April 2009 Capacity: 400 MW p.a. Capacity: 400 MW p.a. standardized production and release processes across all sites best-practice and know-how transfer © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 5. SOLAR Towards higher Operating Temperatures Today : HTF: Synthetic Oil with limited operating temperture (400°C) Average annual efficiency 12-13% New heat transfer fluids to increase operating temperature p g p and hence increase efficiency and reduce cooling load Direct steam generation: Molten salt Improved Synthetic Oil • temperatures > 500°C • temperatures > 500°C • temperatures > 400°C • efficiency >15% • efficiency >15% • efficiency >13% • cheaper HTF • Storage • less hydrogen Solar Only: New salts required to Limited efficiency gain - with storage more ex- g - reduce freezing risk g pensive than oil = safe operation and Cost: open - without storage not - to reduce parasitic competitive against PV losses → Potential niche market for hybrid solutions Cost: open © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 6. SOLAR Is Molten Salt a good HTF for Parabolic Troughs? g g Under Investigation in indoor and outdoor test facilities: corrosion bending of absorber tubes Cooling curve freeze and thaw tests with single and multiple receivers Test of drainage scenarios and recovery from freeze event qualification of absorber coatings for operating tempetatures up to 550°C Phase change © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 7. SOLAR Increasing the Operating Temperature What is the upper temperature limit for the absorber? Answer important for operation and accelerated ageing test Minimum Ageing ageing time [h] temperature [°C] 1050 510 643 525 295 550 93 590 16 660 6 700 2 750 Limit (?) Calculated acceleration factors as a function of For a simulated 25 year lifetime and activation ageing test temperature for different activation energy of 170 kJ/mol calculated minimum ageing energies (operative temperature 400 °C) testing time (operating temperature 400 °C) © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 8. SOLAR Test result for 590 °C test temperature p accelerated aging @ 590°C for operative temperature of 400°C Emittance@400°C 10 97,5 Absorptance 9 97,0 Absorptanc [%] Emitt 8 ce tance [%] 96,5 7 96,0 96 0 A 6 25 years 25 years 25 years lifetime 95,5 lifetime lifetime 500°C will be 400°C 450°C reached at 4850h 5 0 500 1000 1500 2000 2500 3000 3500 4800 Overall aging time [h] © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 9. SOLAR Solutions for the Hydrogen Problem Problem: Thermo oil decomposes during operation, hydrogen is generated. Hydogen permeation through steel absorber tube Getter secures vacuum After saturation of Getter heat losses are increasing rapidly Glass vacuum H2 Getter Steel tube oil © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 10. SOLAR Noble Gas Capsule • located in the glass annulus of the receiver opposite to the mirror side • to be opened non-invasive by a laser device • unique solution for the ´hot tube phenomenon phenomenon´ Enhancing the live time: - Th h ld glass t Threshold l temperature i di t indi- cates increased thermal losses - release of noble gas by opening the capsule with a single laser pulse - thermal losses will be immediately reduced © SCHOTT Solar CSP GmbH © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 11. SOLAR Noble gas Capsule – How it works g p capsule activation (2) can save more than 4000 W per receiver (1) initial end of getter Hydrogen filling Capsule state t t capacity it the th vacuum activation ti ti 5.7x 5 7x 5.7x H2 H2 1 2Xenon X relative relative capsule heatheat activation lossloss 1.3x 1 3x 1x 1.3x Xe/H 2 1x Xe/H2 PTR70® PTR70® (vacuum) (vacuum) initial time time state 20-25 several following years weeks years © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 12. SOLAR Shield Reflectors designed to enhance receiver efficiency REFLECTOR SHIELDS: - Cover and insulate space between receivers - Reflector to use radiation hitting the shielded area - gains depend on incident angle of irradiation Illustration of different incidence angles © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 13. SOLAR Reflector Shields to Increase Aperture Area © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 14. SOLAR Shield Reflector benefits h/L 0,3 h/L 0,8 h/L 1 h/L 0,3 h/L 0,8 h/L 1 h/L 0,3 h/L 0,8 h/L 1 3,0 3,0 3,0 3,0 3,0 3,0 2,0 2,0 2,0 Seasonal  relative gain in % n % n % 1,0 1,0 1,0 relative gain in relative gain in 0,0 0,0 0,0 influence at  fl ‐1,0 Almeria shown  ‐1,0 ‐1,0 December 21st March / Sep. 21st June 21st by reference days ‐2,0 ‐2,0 ‐2,0 -3,0 ‐3,0 -3,0 ‐3,0 -3,0 ‐3,0 4 6 8 10 12 14 16 18 20 22 4 6 8 10 12 14 16 18 20 22 4 6 8 10 12 14 16 18 20 22 4 22 4 22 4 22 time in h time in h time in h Annual yield calculation of  shield performance  considering incident angles  depending on latitudes  without local DNI effects.  (reflectance: 80%)  (reflectance: 80%) Slide 14 of 5 Slides © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 15. SOLAR PTR 70 New Design SCHOTT PTR®70 Receiver – Improved performance Absorber Ab b coating stable up t ti t bl to operating temperatures of 450°C Absorptance ≥ 95,5% Emittance E i ≤ 9 5% @400°C 9,5% Transmittance ≥ 96,5% Thermal losses < 250 W/m (400°C) Aperture length: > 96,7% @ working temperature (300 - 400°C) © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved
  • 16. SOLAR Gracias por su atención!! © Copyright 2011 SCHOTT Solar CSP GmbH, All Rights Reserved