Dr. Christian Sattler, Dr. Reiner Buck, Dr. Karl-Heinz

R&D on CSP and Solar Chemistry at DLR

Dr. Christian Sattler, Dr. Reiner Buck, Dr. Karl-Heinz Funken, Dr. Peter Heller, Klaus Hennecke, Prof. Dr. Bernhard Hoffschmidt, Prof. Dr. Robert Pitz-Paal

[email protected]

> R&D on CSP and Solar Chemistry > Sattler • Japanese CSP Society > 11/12/2014DLR.de • Chart 1

DLR German Aerospace Center

>8000 employees across 32 institutes and facilities at

16 sites.

Offices in Brussels, Paris, Tokyo and Washington, Almería.


Cologne

Oberpfaffenhofen

Braunschweig

Goettingen

Berlin

Bonn

Neustrelitz

Weilheim

Bremen Trauen

LampoldshausenStuttgart

Stade

Augsburg

Hamburg

Juelich

• Research Institution• Space Agency• Project Management Agency

Energy Program Themes

• Efficient and environmentally compatible fossil-fuel power stations(turbo machines, combustion chambers, heat exchangers)

• Solar thermal power plant technology, solar conversion

• Thermal and chemical energy storage

• Wind energy converters

• High and low temperature fuel cells

• Systems analysis and technology assessment


Institutes and Facilities Involved in Energy

BraunschweigInstitute of Aerodynamics and Flow TechnologyGoettingenInstitute of Aerodynamics and Flow TechnologyCologneInstitute of Propulsion TechnologyInstitute of Solar Research Institute of Materials ResearchJuelichInstitute of Solar ResearchStuttgart / UlmInstitute of Technical Thermodynamics Institute of Combustion Technology OberpfaffenhofenInstitute of Communications and Navigation

Almería (Spain)Permanent team from the Institute of Solar Research at the PlataformaSolar de Almería (PSA)


Koeln

Oberpfaffenhofen

Goettingen

StuttgartUlm

Braunschweig

Juelich

Institute of Solar Research

Evaluation Renewable Energies – 26th January 2009Prof. Dr. Robert Pitz-Paal – p 5


Institute of Solar ResearchDirectors

Prof. Dr. Robert Pitz-Paal/ Prof. Dr. Bernhard Hoffschmidt

QualificationDr. P. Heller (33 P)

Line‐Focus Systems

K. Hennecke (16 P)

Facilities and Solar Materials

Dr. K.‐H. Funken (20 P)

Solar Chemical Engineering

Dr. C. Sattler (26 P)

Point‐FocusSystems

Dr. Reiner Buck (34 P)


Institute Profile

2. Aussagekräftiges Bild für das Business

1. Aussagekräftiges Bild für das Business

Mission• 1/3 fundamental scientific questions to enable next generation

technology for electricity, heat, fuel and water using concentrating solar power

• 2/3 applied development task for/with industry to optimize products and technologies

Key data• Annual turnover >15 Mio€ (in CSP related activities)• More than 160 people (among Top 5 worldwide)• Teams in Germany (Cologne, Stuttgart, Jülich) and Spain (Almería)• Unique Infrastructure• Active coordination of national and international networks in CSP

Track record • Awarded as DLR Centre of Excellence 2006, 2009 and 2013• Several license agreements with industry on DLR Patents (Receivers,

measurement technology)• 2 Spin-off companies founded in the last 6 years• CSP Component Qualification Centre QUARZ™ is market reference


Large scale facilities

Tower Research Facility Jülich

Solar Furnace Solar Simulator

Research Plattform 500 kW

8


Department “Line Focus Systems”

Klaus [email protected]


ANDASOL 1: Start of operation 2008State-of-the-art parabolic trough power plant technology


Plant schematic Andasol (50 MW)

Turbina de vapor

Condensador

Precalentadorde presión baja

Sobrecalentador

Precalentadorsolar

Recalentadorsolar

Generador de vapor

Tanque de expansión

Campo Solar

Caldera

Combustibe

(Opcional)


Integrated Solar Combined Cycle plant

Projects inAlgeriaEgyptMoroccoMexico

Solar share limited by solar steam

parameters turbine ability to

accept additional steam

Transition technologybuild confidence


Egypt, 146 MW ISCCS, 30 MW Solar Field

Developer NREA New & RenewableEnergy AgencyEPC financedbyJBIC and NREA with 50Mio Grant984GWh per year, of which 64.5GWh solarAwarded to Iberdrola (CC) and Orascom/Flagsol (Solar Field)


Direct Steam Generation Research

• Understand thermohydraulic phenomena• Validate numerical models• Develop and test operating concepts and control

algorithms• Test components in real scale• Demonstrate technical feasibility• German/Spanish Collaboration PSA DISS test facility:

1000 m collector loop up to 100 bar / 500°C


Direct Steam Generation commercial applications

• TSE1 Kanchanaburi, Thailand

• Developer: SOLARLITE• Operational 11/2012• 5 MWe• 30 bar / 330°C

• PE2 Puerto Errado, Spain• Developer: NOVATEC• Operational 8/2012• 30 Mwe• 55 bar / 270°C

Foto: Solarlite

DLR support portfolio:concept designconstruction supervisioncommissioningacceptance testing


Conclusions on DSG

• For short to mid-term, technology ready for :

• CSP plants without or with small storage

• Integrated Solar Combined Cycle (ISCC) or fuel saver plants

• Industrial process steamapplications

• For long term DSG perspective, R&D requirements:

• Development of economic PCM storage system

• Development of once through process (DUKE Project at PSA)

Solarlite: TSE‐1


Molten Salt R&D: HPS2 Project10 main concerns regarding safe and efficient operation of molten salt systems to be dispelled by erection, commissioning and operation of a Demonstration Loop with Ultimate Trough collectors at Évora, Portugal:

1. Filling and draining of the plant 2. High thermal effort during anti-freeze operational mode (high parasitic load,

added costs for the required heating through the year)3. Danger of freezing during various operation modes (reliability of impedance

heating, failure current of impedance heating, valve heating, …) 4. Blackout scenarios

5. Material requirements, high corrosion 6. Performance of the SCA (receiver performance, Behavior of receiver with

collector) a. thermal performance, b. optical performance, c. mechanical properties

7. Flexible connection: Proof of functionality and tightness8. Steam Generating System: internal leakage due to defect of heat exchanger

tubes9. Maintenance procedures, Handling of disturbances (complete draining and re-

filling, treating of blockages)10. Stability of salt mixtures (time stability, thermal stability)


Parabolic Trough Power Plant with Molten Salt

Advantages• High efficiency of the solar

collector at high operating temperature=> high overall efficiency of the power station

• Direct storage of the collected heat

• Full-decoupling of the solar field operation and the electricity production

• Commercial plants with capacity factors of over 5500 full load hours

• Potential to save up to 40 % of LCoE in comparison to state-of-the-art solar thermal power stations (at highly irradiated locations)

• 100 % renewable and fullystorable energy

Schematic figure of Molten Salt based STPP

LCoE evaluation over technologies


Overview of DLR CSP simulation tools• DLR simulation tools cover all levels of CSP simulation

GREENIUS: analysis of performance / economics of renewable energy systems

ebsSolar®: detailed performance analysis of CSP systems

component layout:• concentrators (parabolic trough, Fresnel, heliostats)• receivers

system layout optimization:• solar field, receiver• power block• storage

transient system simulation:• real-time, high resolution performance simulation• coupling of components and control


GreeniusOverview

• software tool developed at DLR for fast and simple annual performancecalculations of renewable energy plants

• based on datasets for individual subsystems like collector, solar field, powerblock, etc.

• uses steady-state simulations in hourlytime steps

• offers tools for economical analysis andillustration of result

• a free version is available at www.FreeGreenius.dlr.de

QSF

PPB

QSF

PPB

QStor

DNI


1. GreeniusImplemented technologies

• most renewable energy systems• CSP:

• parabolic trough• linear Fresnel• solar tower• Dish Stirling• optional: thermal storage

• process heat generation• solar cooling with absoption chillers• PV and concentrating PV• wind turbines• fuel cells


Detailed System Performance Simulationusing Ebsilon®

• „All in One" solution for detailed power plant modelling

• for development, acquisition und planningof all kinds of power plants and thermodynamic processes

• design and development of single components, subsystems and complete systems

• development of new solar library EbsSolar (steag and DLR):• thermodynamic modelling and yield analysis (e.g. annual yields)• components of solar thermal power plants

(Dialog for time series calc., transient calc. for energy storage,fluid properties for solar applications)

• 2010: library for line focussing systems•Parabolic Trough•Linear Fresnel

• 2011: library for Solar Tower systems• currently more than 70 licences of EbsSolar are used


DLR simulation competence• covers all levels of detail• cover all CSP technologies• coupling of different tools• collaboration experience with

industry and R&D institutions

Summary / Conclusion

Options for collaboration• technology-independent consulting• subcontracted work • joint development of tools• adaptation of tools specific tasks and conditions• licensing of tools, incl. training and support

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300 3600Zeit [s]

Stra

ngm

asse

nstr

om [k

g/s]

m_dot_1 m_dot_2 m_dot_3 m_dot_4 m_dot_5 m_dot_6 m_dot_7


Department “Point Focus Systems” Thematic Orientation

Goal: Cost Reduction of CSP Plants (Solar Tower, Dishes)• performance optimization

• heliostat field, receiver, system• cost reduction

• component cost, O&M cost

R&D topics:• receivers• heliostats• system aspects• control• simulation tools


Contact:Dr. Reiner [email protected]

Receiver Technology R&D

• development / technology transfer• open volumetric air receivers• pressurized air receivers

• extension to liquid heat transfer media• e. g. molten salt

• innovative concepts: direct absorption receivers

particle receiver test to 900°C


Open Volumetric Air Receivers

• development of volumetric absorber structures

• optimization of air receiver system

• support of commercial realization• development of scalable designs• layout of prototype plants• know-how transfer to industry


SOLUGAS: Solar-hybrid Plant Demonstration

650°C / 800°C

4.6 MWe

1150°C350°C

solar airreceiver

650°C

2 MWe

69 heliostats à 121m²

fuel

modified Mercury 50

co-funded by the EC under FP7

project lead: Abengoa


SOLUGAS Project: Solar-hybrid Gas Turbine System

Abengoa Solar Power Plants,near Seville, SpainSOLUGAS plant


Solar Tower with Molten Salt

Improvement of molten salt solar tower systems• next generation technology:

• increased HTF temperature• higher power block efficiency• reduced LCoE

• industry participation• tests planned at

Solar Tower Jülich


Folie 30 SF-PN 2011

• heliostat and field simulation

• structural analysis

• load analysis

• qualification

• control

• operation strategy

Heliostat R&D


System Analysis and Optimization

• pre-feasibility studies• detailed annual performance simulation• cost estimates• LCoE calculation

G

eta gross= 33.83%

Filter

Compressor

Turbine Generator

RekuperatorFilterCombustor

Leakage

Pipe Pipe

Inlet

Outlet

Elevation 0 m --> correction factor 1.00000

0.298 MW 0.392 MW

4.053 bar 926.710 °C

1031.485 kJ/kg 2.082 kg/s

4.135 581.677

613.354 2.065

4.156 191.382

194.699 2.140

1.055 636.677

688.063 2.082

1.023 248.272

257.893 2.082

1.055 636.677

688.063 2.082

0.309 MW

4.135 581.677

613.354 2.065

4.135 581.677

613.354 2.140

4.135 581.677

613.354 2.065

4.635 15.000

32.681 0.018

0.010 bar

1.003 15.000

15.155 2.140

1.013 248.272

257.893 2.082

0.083 bar

0.010 bar

bar °C

kJ/kg kg/s

1.013 15.000

15.155 2.140

ETAIN 0.810 ETAIN 0.860

3.500 %


Simulation Tool Developmentfor Solar Tower Systems

• heliostat field layout

• performance simulation• flux distribution• aim point strategy• efficiency


Simulation Tool Developmentfor Solar Tower Systems

• heliostat field analysis

• real-time optimization of operationstrategy

• dynamic field simulation• dynamic receiver simulation

measured heliostat surfacesolar heat flux

measurement

simulation

aim point strategy


- Solar field has a high share of the total investment- It is a long-term investment- It is of big extent (corrections are expensive)

- Yearly plant output strongly depends on optical quality of collector field

- Measurements showed that without proper quality assurance 3-10% and in some cases even more of the field performance can be lost

- Quality assurance and final acceptance tests of collector fields are necessary for control of subcontractors and warranty claims

Quality assurance of collector field assembly is indispensable and makes economic sense

Department of “Qualification”Motivation: Qualification for Improved Performance


Contact:Dr. Peter [email protected]

Example ANDASOL:1% less optical quality means for investors: 0.5 million € less revenues per year 10 million € less revenues per lifetime

MotivationEfficiency Chain, Example: Parabolic Trough


• Strong impact on the performance and cost efficiency:• CSP component quality and durability• their interaction in the overall system• and the meteorological conditions each

• Development of measurement techniques and devices• Evolution of guidelines and standards

• testing methods• quality criteria

• Customer oriented services Fundamental information for industry to

• Improve quality, performance competiveness• Proof of product quality successful market entry / bankability

Consulting and training

QUARZ® – CenterTest and Qualification Center for CSP Technologies


Solar Resource Assessment

DLR.de • Chart 37 > R&D on CSP and Solar Chemistry > Sattler • Japanese CSP Society > 11/12/2014

Measurements:‐ Solar Radiation‐ Soiling of components‐ Aerosols‐ Beam attenuation, Extinction ‐ Sunshape‐ Nowcasting (prediction of DNI for next 30 min.)

Services:‐ Calibration of sensors‐ Analysis of effects onPlant design, Operation, System performance

SAM Sun Photometer

Rotating ShadowbandIrradiometer (RSI)

Mirror / Collector Shape Accuracy

Evaluation of quality and performance parameters:‐ Methods: deflectometry, photogrammetry(in laboratory, in the collector, in the solar field)

‐ Analysis of reflector deformation(sag, interaction with support structure)


Mirror Reflectance

Hemispherical Reflectance

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0,7

0,8

0,9

1,0

250 500 750 1000 1250 1500 1750 2000 2250 2500wavelength [nm]

Rhe

m,λ

0

0,001

0,002

0,003

0,004

0,005

0,006

0,007

0,008

0,009

0,01

rela

tive

sola

r irr

adia

nce

glass-mirror ρSWH=0.94polymerfoil ρSWH=0.92aluminum ρSWH=0.87Solar Norm G173

Evaluation of quality and performance parameters:‐ Spectral hemispherical reflectance‐ Specular reflectance


Mirror Durability

Accelerated ageing tests‐ Laboratory: humidity, salt spray, UV, temp. cycling, aggressive corrosion

‐ Outdoor ageing tests in different climatic regions


Receiver Performance

Receiver performance parameters:- Optical efficiency ηopt,rec(T)- Thermal loss power Pth,loss(T) (non‐destructive measurements)


Receiver Durability

Durability tests:- Overheating and Thermal Cycling- Bellow fatigue tests‐ Operability tests under real solar conditions (Kontas at PSA, Spain)


Performance testing – collector module

Collector quality features:‐ Peak efficiency, thermal losses‐ Incident angle modifier‐ Behavior under different load conditions(tracking quality, deformation, torsion)

Temperaturecontrol unit

23 m

Eurotrough 12m


Performance testing – collector loopMobile Field Laboratory:‐ Clamp‐on ultrasonic flow meter‐ Clamp‐on temperature sensors‐ Irradiance measurement station‐ Camera equipped quadcopter

Benefits‐ Detecting optimization potential of solar field‐ Accurate performance parameters lead toreliable results of system simulations


PhasesObjects

R&D Phase Production Phase O&M PhasePrototypes Mass Product Commissioned Plant

Con

cent

rato

rR

ecei

ver

Mat

eria

ls

Parabolic Trough Coll.

Central Receiver

Parabolic Trough Receiver

Severalmanufacturing specific quality

control measures


control measures


control measures

Heliostats

Qualification in Different Phases


• Detecting optimization potential helps to improve products• Accurate performance parameters reliable results of system simulations • Source of data for a plant’s cost-benefit analysis

• Customer oriented services Fundamental information for industry to

• Improve quality, performance competiveness• Proof of product quality successful market entry / bankability

• Trainings and Seminarsin all CSP Relevant Topics

SummaryQUARZ – Benefits for our customers


Summary (II)Possible Cooperations

Meteorology / Solar Resource Assessment‐ DNI, Sunshape, Soiling Rate, Beam Attenuation in Solar Towers

Solar Towers‐ Receivers and Heliostats R&D, System Optimization

Qualification of Systems and Components‐ Receivers, Heliostats, Collectors, Mirrors, etc.‐ Production Inline Quality Control

Durability Issues of Mirrors and Receivers‐ Ageing by UV Radiation and Corrosive Environments (Salts)

Capacity Building‐ Consulting and training in all CSP Relevant Topics


Department of Solar Chemical EngineeringHead

OrganisationStrategy

Representation in boards

GroupHigh temperature CE

Solar tower >500°C

Solar FuelsSolar Materials

GroupLow temperature CE

Reactors up toParabolic troughs

< 500°C

Heat transfer fluidsSolar fuels

Water treatmentSOWΛRLΛ GmbH

25 Co‐workers + 10 Students, 65% external funding


Competences

Development ofcomponents andprocesses

and

scientific, technologic andeconomic evaluation

850 mm

530 mm 1000 mm

1373

1500000

06

314

1500000

25

CO2TOT

1073

1500000

25

CO-O2

973

1500000

20

CO

1073

1500000

5O2

500

1500000

20

1

298

1500000

4

N2TOT

1473

1500000

9

REGOUT

1373

1500000

9

5

413

100000

9

7

298

1500000

13

CO2

298

100000

12CO2-OUT

298

1500000

193

DEA 298

1500000

193DEATOT

309

1500000

9

CO-OUT

353

1500000

205

8

371

200000

16

10

422

200000

189

9

298

100000

4WATER

398

100000

193

DEAREC

298

100000

193

RECDEA

413

100000

5

O2,CO2

413

100000

4N2REC

298

1500000

4

N2

RECSPLT

Q=100000000

LOSS1

Q=-2484963

COOL1

Q=-10978344

RECREG

Q=8127743

LOSS2

Q=-1077572

COOL3

Q=-9381091

MIX1

MIX2

ABSORBER

QC=0QR=0

STRIPPER

QC=-21373997QR=87412428

FLASH

Q=-11238142

MIX3COOL4

Q=-58429041

SEP

Q=-1

MIX4Temp erature (K)

Pressure (N/sq m)

Mass Flow Rate (kg/sec)

Q Duty (Watt)

DEA

O2, CO 2

CO


Three examples to achieve the goals

• High Potential Product• Jet-Fuel

• Business Case• Integration of concentrated solar

radiation to enhance existingprocesses

• Continuity• Developments to a certain scale

needs time (unfortunately there isno Manhattan Project for solar fuels yet)


Solar Production of Jet Fuel EU-FP7 Project SOLAR-JET (2011-2015)

SOLAR-JET aims to ascertain the potential for producing jet fuel fromconcentrated sunlight, CO2, and water.

SOLAR-JET will optimize a two-step solar thermochemical cycle based on ceria redox reactions to produce synthesis gas (syngas) from CO2and water, achieving higher solar-to-fuel energy conversion efficiency over current bio and solar fuel processes.

First jet fuel produced in Fischer-Tropsch (FT) unit from solar-produced syngas!

H2O/CO2-Splitting Thermochemical Cycles

Partners: Bauhaus Luftfahrt (D), ETH (CH), DLR (D), SHELL (NL), ARTTIC (F)Funding: EC

Int. J. Heat & Fluid Flow 29, 315-326, 2008.Materials 5, 192-209, 2012.


SOL2HY2 – Solar To Hydrogen Hybrid Cycles

• FCH JU project on the solar driven Utilization of waste SO2 from fossil sources for co-production of hydrogen and sulphuric acid

• Hybridization by usage of renewable energy for electrolysis

• Partners: EngineSoft (IT), Aalto University (FI), DLR (DE), ENEA (IT), Outotec (FI), Erbicol (CH), Oy Woikoski (FI)

• 100 kW demonstration plant on the solar tower in Jülich, Germany in 2015

OutotecTM Open Cycle (OOC)

https://sol2hy2.eurocoord.com

• Utilization of waste SO2 from fossil sources• Co-production of hydrogen and sulphuric acid• Hybridization by renewable energy for electrolysis


Investments vs. revenues

• Reduction of initial investments• Financing of HyS development by payback of OOC• Increase of total revenues


HYDROSOL, HYDROSLOL 2, HYDROSOL-3D, HYDROSOL Plant

• 2002 Start HYDROSOL, EU FP5• 2004 First solar hydrogen, DLR• 2005 Quasi-continuous solar

hydrogen, DLR• 2008 HYDROSOL 2, EU FP6, 100

kW demonstration CRS Tower PSA, Spain

• 2013 HYDROSOL-3D, FCH JU, Design of a 1,5 MW demonstration plant ready

• 2014 HYDROSOL PLANT, FCH JU• 2015 750 kW Demonstration plant,

CRS Tower, PSA, SpainAPTL (GR), DLR (DE), CIEMAT (SP), StobbeTech (DK), Johnson Matthey (UK), HyGear (NL), HELPE (GR)


Next Step:Specific Solar Fuel Demonstration Tower needed!

CRS Tower PSA, Spain Solar Fuels Tower


• High concentration > 1000• Heliostats fit to receiver size• Field control adapted to fuel production processes

Thank you very much for your attention!


Documents

Dr. Christian Sattler, Dr. Reiner Buck, Dr. Karl-Heinz