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DOE OSTI2016

Application of Microscale Devices for Megawatt Scale Concentrating Solar Power Plants

Concentrated solar power (CSP) plants have the potential to reduce the consumption of non-renewable resources and greenhouse gas emissions in electricity production. In CSP systems, a field of heliostats focuses solar radiation on a central receiver, which is ultimately transferred to thermal electrical power plant at high temperature. However, the maximum receiver surface fluxes are low (30–100 W cm−2) with high thermal losses, which has limited the market penetration of CSP systems. Recently, small (∼ 4 cm2), laminated micro-channel devices have shown potential to achieve concentrated surface fluxes over 100 W cm−2 using supercritical CO2 as the working fluid. The present study explores the feasibility of using these microscale devices as building blocks for a megawatt scale (250 MW thermal) open solar receiver. This allows for a modular design of the central receiver with non-standard shapes customized to the heliostat field. The results show that the microscale unit-cells have the potential to be scaled to megawatt applications while providing high heat flux and thermal efficiency. At the design incident flux and surface emissivity, a global receiver thermal efficiency of > 90% can be achieved.

14 SOLAR ENERGY↗

DOE OSTI2016

Numbering-Up of Microscale Devices for Megawatt-Scale Supercritical Carbon Dioxide Concentrating Solar Power Receivers

Concentrated solar power (CSP) plants have the potential to reduce the consumption of nonrenewable resources and greenhouse gas emissions in electricity production. In CSP systems, a field of heliostats focuses solar radiation on a central receiver, and energy is then transferred to a thermal power plant at high temperature. However, maximum receiver surface fluxes are low (30–100 W cm -2 ) with high thermal losses, which has contributed to the limited market penetration of CSP systems. Recently, small (~4 cm 2 ), laminated micro pin-fin devices have shown potential to achieve concentrated surface fluxes over 100 W cm -2 using supercritical CO 2 as the working fluid. The present study explores the feasibility of using these microscale unit cells as building blocks for a megawatt-scale (250 MW thermal) open solar receiver through a numbering-up approach, where multiple microscale unit cell devices are connected in parallel. A multiscale model of the full-scale central receiver is developed. The model consists of interconnected unit cell and module level (i.e., multiple unit cells in parallel) submodels which predict local performance of the central receiver. Each full-scale receiver consists of 3000 micro pin-fin unit cells divided into 250 modules. The performance of three different full-scale receivers is simulated under representative operating conditions. The results show that the microscale unit cells have the potential to be numbered up to megawatt applications while providing high heat flux and thermal efficiency. At the design incident flux and surface emissivity, a global receiver efficiency of approximately 90% when heating sCO 2 from 550 °C to 650 °C at an average incident flux of 110 W cm -2 can be achieved.

14 SOLAR ENERGY↗

DOE OSTI2015

System Advisor Model (SAM) Enhancements for CSP

Previous work led by NREL has produced a suite of hourly CSP performance and annual financial models that are currently implemented in SAM. These analysis tools are used within the DOE national laboratory system and worldwide by researchers, industry members, academics, and policymakers to determine the potential performance and financial impact of renewable energy technologies. SAM includes models for the following CSP solar-field technologies: parabolic troughs, both molten-salt and direct-steam central receivers, dish/Stirling, and direct-steam linear Fresnel systems. SAM also includes a generic solar system model that represents the solar field using a set of optical efficiency values for different sun angles and can be used for any solar technology that uses solar energy to generate steam for electric power generation. Each technology model requires information about the receiver and collector, power block, thermal storage, and operating conditions to predict component and overall system performance. The CSP models also include an optional auxiliary fossil backup system, as appropriate. This project aims to maintain SAM’s unique ability to efficiently model pertinent CSP technologies by improving the functionality of SAM and improving current or creating new technology models.

14 SOLAR ENERGY↗

DOE OSTI2019

Design and Field Testing of Manufacturable Advanced Low-Cost Receiver for Parabolic Trough Solar Power

This project addresses the 30-yr service life, ease of manufacturability for low cost, and low Operations and Maintenance (O&M) costs for our novel parabolic trough receiver, SunTrap. Current trough-based commercial power plants operate at 400°C or below, in part due to poor performance and lifetime of existing receivers at higher temperatures. Thermal losses from such receivers are dominated by radiation; by the Stefan- Boltzmann law, radiative losses have a component that scales as T 4, challenging high-temperature efficiency. Our novel SunTrap receiver offers increased reliability by eliminating the need to operate in a vacuum, while improving performance at higher temperatures by using high-performance insulation on exposed sections of the receiver that absorb negligible solar flux. As a result, SunTrap offers comparable optical efficiency to currently available technology while reducing thermal losses at higher temperatures. In this project, our novel receiver and all subcomponents have been designed to be compatible with molten salts to enable operation at next generation trough-based exit temperatures between 500 and 550°C. Norwich Technologies, with collaborators from Creare, Thermodyne, Solar Dynamics (previously Abengoa Solar), and the University of Louisiana – Lafayette successfully iterated the design of the SunTrap receiver through a series of modelling efforts, cost analyses, prototype builds, and performance and lifetime tests to minimize the levelized cost of energy (LCOE). The final design (1) realized predicted receiver performance in a series of field optical efficiency, laboratory thermal efficiency and freeze/thaw recovery tests, (2) optimized the receiver with respect to integration with standard collector systems, receiver-to-receiver connections, and receiver-to-mirror connections, (3) demonstrated 30-yr service life of receiver and all components of the receiver, (4) developed commercialization and manufacturing plans to enable rapid deployment, and (5) demonstrated durability of an air-stable solar-selective coating. NT’s disruptive technology marshals diverse advances in design, materials and coatings to revolutionize key aspects of the CSP trough solar field. By enabling significant operational and cost advances, this technology offers potential decreases in LCOE of over 20% compared to traditional parabolic trough systems.

14 SOLAR ENERGY↗

NASA NTRS1987

Optical emission from coupled surface plasmons

Surface plasmons on opposite sides of a thin metal film surrounded by identical dielectrics interact to form coupled surface plasmons (CSP's). Corrugation of the metal film permits interaction of the CSP's with the radiation field. This paper reports the observation of optical emission from CSP's excited by the near-field coupling of molecules adjacent to a corrugated thin metal film embedded in photoresist.

Gruhlke, R. W.↗

DOE OSTI2023

OpenCSP v.1.0

SAND2024-08987O OpenCSP analyzes and improves the performance of optical mirrors that reflect sunlight and concentrate it onto a receiver. The algorithms in this library analyze the flow of light from an original source—such as the sun—reflecting off one or more mirrors, and onto a receiver, optical screen, or camera. OpenCSP also analyzes optical systems using other techniques, such as shape or slope comparison. The software calculates aggregate properties of the optical system, such as its efficiency, manufacturing error, pointing control error, expected performance, and other useful parameters. OpenCSP also includes high-level tools, such as Open SOFAST, a program that obtains high-resolution measurement of CSP mirrors, full heliostats, and other CSP collectors. OpenCSP supports producing meaningful output data to help CSP designers and field operators improve the performance of their systems. OpenCSP also includes classes and functions that support these calculations, including input utilities, analysis output libraries, geometric constraint analysis for drone flight planning, and more. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Brost, Randolph↗

NASA NTRS1987

Observations and consequences of nonuniform aluminum concentrations in the channel regions of AlGaAs channeled-substrate-planar lasers

Compositional changes in the n-clad layer within the channel region of channel substrate planar (CSP) type semiconductor lasers have been observed. As a consequece, a large optical cavity (LOC) or an enhanced substrate loss (ESL) version of the CSP geometry may result, both of which may have significantly different characteristics from those of a conventional CSP laser. The CSP-LOC generally has a larger near-field spot size, while the ESL-CSP is characterized by an off-axis, asymmetric far-field pattern.

Evans, Gary A.↗

DOE OSTI2023

In Situ Wind and Turbulence Measurements in a Field of Full-Size Parabolic Trough Collectors

Concentrated Solar Power (CSP) is a promising method for using Solar power for electricity generation with thermal energy storage. One of the primary drivers of structural design costs of CSP collector structures is wind loading. To date, the design of these structures has relied on data from wind tunnels that do not adequately capture the dynamic effects observed at scale. NREL initiated a field measurement campaign at the operational Nevada Solar One (NSO) powerplant that uses parabolic troughs as solar collectors. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs, providing insights on structural dynamic response, and generating a first-of-a-kind, comprehensive, high-resolution wind-loading dataset available for validating simulations of wind loading on collector structures. The measurements at NSO consist of Sonic anemometers on masts at different heights to characterize the incoming flow and conditions within and above the trough field, in combination with a Doppler Lidar scanning the horizontal plane above the troughs. The wind measurements at NSO have been continuously operating since October 2021 and provide a year-long dataset characterizing wind and turbulence conditions. The structural load measurements start in November 2022 and will complement the wind measurements. In this poster, we present first results of the wind measurement campaign by highlighting days with different atmospheric flow conditions. We identified three main factors altering the flow over the parabolic troughs: Wind speed, wind direction, and the angle of the parabolic troughs. The highest loads are expected when the wind blows perpendicular to the trough rows. In this case, the first rows experience the highest loads and block the subsequent rows, creating conditions with decreased wind speed and enhanced turbulence within the trough field. Also, turbulent length scales change. These affected conditions produce unique load cases on the structures that will be captured by the load measurements. If the wind blows along the trough rows, wind and turbulence conditions are less influenced by the troughs.

concentrated solar power↗

DOE OSTI2023

OPTOM: Optimization of Parabolic Trough - Operations & Maintenance

The US Department of Energy’s SunShot goals look to reduce the cost of Concentrating Solar Power (CSP) technology to 5¢/kWh for baseload plants. This is about a 50% reduction from current costs. To achieve this cost target, a significant reduction in operation and maintenance (O&M) costs of 40 to 50% is likely needed. Advances are needed in the O&M practices of CSP plants if the technology is to achieve the SunShot cost goals. Digitization of plant performance and O&M data has become a new best practice in the world of renewable energy asset management. Owners and operators of large photovoltaic and wind power plants are working to digitize performance and O&M data at their existing assets, to improve their management of the facilities, to increase performance, reduce O&M costs, and lower the overall life cycle cost of ownership. CSP power plants are behind the curve of other technologies on the digitization of plant information to aid in the plant asset management. This project directly addresses the objective of digitizing the O&M data of the solar field, focusing on three areas: 1) creating a framework for sharing data and information, 2) creating a system for monitoring and managing the maintenance of the solar field collectors, and 3) developing analytic tools to identify issues in the solar field. According to the NREL CSP Best Practices Study, the current practice at many CSP plants is to rely on paper lists, spreadsheets, and email for monitoring and managing problems and maintenance in the solar field. The key element to digitize solar field O&M is the creation of a centralized data archive that all users and systems can interface with. This project developed a centralized relational database framework that allows users and applications to access and share data. Conventional power plants utilize Computerized Maintenance Management Systems (CMMSs) to track the corrective, preventive (scheduled), and predictive maintenance of equipment and subsystems in the power plant. CSP plants use these systems in the power block, but while these systems specialize at tracking maintenance on up to thousands of pieces of equipment, they are not well suited for tracking the tens or hundreds of thousands of components in large commercial CSP or photovoltaic solar fields. In this project we developed a new software application referred to as FieldStatus (TM). This is a specialized database program that is used to track the status of each collector and its components. This application is designed to complement the existing CMMS to enable improved tracking and management of maintenance activities in the solar field. One of the major maintenance tasks for solar fields is maintaining the cleanliness of the mirrors. Although seemingly a relatively straight forward task, it has often proven challenging to maintain high levels of cleanliness in an efficient and cost-effective manner. This project developed new tools and metrics for monitoring and optimizing solar field cleaning resources and overall solar field cleanliness.

14 SOLAR ENERGY↗

DOE OSTI2020

AATTENUATION—The Atmospheric Attenuation Model for CSP Tower Plants: A Look-Up Table for Operational Implementation

Attenuation of solar radiation between the receiver and the heliostat field in concentrated solar power (CSP) tower plants can reduce the overall system performance significantly. The attenuation varies strongly with time and the average attenuation at different sites might also vary strongly from each other. If no site specific attenuation data is available, the optimal plant design cannot be determined and rough estimations of the attenuation effect are required leading to high uncertainties of yield analysis calculations. The attenuation is caused mainly by water vapor content and aerosol particles in the lower atmospheric layer above ground. Although several on-site measurement systems have been developed during recent years, attenuation data sets are usually not available to be included during the plant project development. An Atmospheric Attenuation (AATTENUATION) model to derive the atmospheric transmittance between a heliostat and receiver on the basis of common direct normal irradiance (DNI), temperature, relative humidity, and barometric pressure measurements was developed and validated by the authors earlier. The model allows the accurate estimation of attenuation for sites with low attenuation and gives an estimation of the attenuation for less clear sites. However, the site-dependent coefficients of the AATTENUATION model had to be developed individually for each site of interest, which required time-consuming radiative transfer simulations, considering the exact location and altitude, as well as the pre-dominant aerosol type at the location. This strongly limited the application of the model despite its typically available input data. In this manuscript, a look-up table (LUT) is presented which enables the application of the AATTENUATION model at the site of interest without the necessity to perform the according complex radiative transfer calculations for each site individually. This enables the application of the AATTENUATION model for virtually all resource assessments for tower plants and in an operational mode in real time within plant monitoring systems around the world. The LUT also facilitates the generation of solar attenuation maps on the basis of long-term meteorological data sets which can be considered during resource assessment for CSP tower plant projects. The LUTs are provided together with this manuscript as supplementary files. The LUT for the AATTENUATION model was developed for a solar zenith angle (SZA) grid of 1°, an altitude grid of 100 m, 7 different standard aerosol types and the standard AFGL atmospheres for mid-latitudes and the tropics. The LUT was tested against the original version of the AATTENUATION model at 4 sites in Morocco and Spain, and it was found that the additional uncertainty introduced by the application of the LUT is negligible. With the information of latitude, longitude, altitude above mean sea level, DNI, relative humidity (RH), ambient temperature (Tair), and barometric pressure (bp), the attenuation can be now derived easily for each site of interest.

14 SOLAR ENERGY↗

DOE OSTI2023

CSP Design Study for Sandia National Laboratories and Kirtland Air Force Base

This report provides a design study to produce 100% carbon-free electricity for Sandia NM and Kirtland Air Force Base (KAFB) using concentrating solar power (CSP). CSP plant designs of 50 MW and 100 MW are assessed to meet the electricity needs of Sandia NM and/or KAFB. Probabilistic modeling is performed to evaluate inherent uncertainties in performance and cost parameters on total construction costs and the levelized cost of electricity. Estimated annual electricity production was ~200 – 300 GWh for the 50 MW plant and ~400 – 700 GWh for the 100 MW plant. The overnight construction costs ranged between ~$300M - $400M for the 50 MW CSP plant and between ~$500M - $800M for the 100 MW CSP plant. The heliostat field was the most significant subsystem cost, followed by the thermal energy storage, power cycle, and fixed operation and maintenance costs. Other considerations such as land availability and permitting, funding options, and interconnections are discussed.

Ho, Clifford K.↗

DOE OSTI2024

Studying Wind Loading on CSP Collectors to Improve Performance and Reliability

Electricity generation through Concentrating Solar-thermal Power (CSP) adds the advantage of thermal energy storage and heat production. CSP collector costs constitute nearly one-third of total plant costs. Managing wind loading, especially dynamic wind loading caused by the turbulent wind flow, is a significant design challenge. Traditional collector designs rely on wind tunnel experiments and numerical simulations, which do not fully capture dynamic effects. Here, we provide an overview of NREL's activities on wind loading on CSP collectors, aiming to improve their reliability and cost-efficiency. We present insights from field measurements at operational parabolic trough and power-tower CSP plants. Over two years, we measured turbulent wind fields and resulting structural loads in a parabolic trough plant, revealing wind, turbulence, and collector field interactions. Similar measurements are ongoing at the Crescent Dunes heliostat field. These campaigns show how atmospheric turbulence, wind direction, and collector orientation affect dynamic wind loading. Upwind collector structures can generate turbulent structures, causing fluctuating loads at downstream collectors, impacting fatigue lifetime and optical efficiency. Preliminary results indicate that interior collectors experience higher turning moments than those at the edges, suggesting higher drive wear. At Crescent Dunes, we use instrumented heliostats at the field's edge and interior to study the translation of turbulent wind to dynamic structural loads. The campaign is still ongoing, and we will present first findings. Another focus of our work is tying the experimental wind loading findings to optical performance of the collectors, using simulation tools. For example, we derive torsional errors of the parabolic troughs - the angular offset from the sun position along a collector row. This error is impacted by wind-induced mirror deformations. Future work will focus on continuing the measurement efforts and combining them with computational fluid dynamic simulations. By providing detailed field measurements and validated models, our efforts aim to enhance understanding of wind loading on CSP collectors, improving their structural integrity and optical performance.

CSP↗

DOE OSTI2021

Solar Field Layout and Aimpoint Strategy Optimization

The existing methods that determine heliostat aiming strategies for concentrating solar power (CSP) central receiver plants typically use heuristics and/or are computationally expensive, and they lack flexibility for different desired flux profiles and receiver geometries. Because of the interaction between layout and aimpoint strategy, considering the former without accounting for the latter may yield solutions with superfluous heliostats that cannot be used efficiently without compromising receiver flux constraints. To that end, we develop a software decision tool that uses innovative optimization methods to both optimize aimpoint strategies and improve candidate layouts for the solar collection field of a CSP central receiver plant. A CSP plant’s effectiveness relies on the optical efficiency of the solar field, which may be limited by losses due to (i) the cosine effect, (ii) atmospheric attenuation, (iii) interference (i.e., shading and blocking) between heliostats, (iv) spillage as a result of heliostat positioning and geometry, and (iv) some heliostats’ inability to direct irradiance to the receiver without damage due to excessive thermal flux. The goal of this work is to obtain optimized aiming strategies and improved solar field layouts that reduce capital cost and increase field optical efficiency and utilization, while meeting the power requirements of a given CSP receiver design. We formulate the aimpoint optimization problem as a mixed-integer linear programming model, which we then decompose into submodels that we solve in parallel. The decomposition subdivides the solar field into sections, and aimpoint strategies for each section are obtained independently of the others. To improve existing layouts, we develop a utilization-weighted efficiency metric that we use to relocate heliostats to sections of the solar field with similar efficiency and higher utilization. Finally, to connect our software to high-fidelity flux models, we develop a Python application programming interface for SolarPILOT, a mature software package that characterizes solar field performance and generates the heliostat layouts and flux maps that serve as input to our models.

14 SOLAR ENERGY↗

DOE OSTI2017

Solar Field Optical Characterization at Stillwater Geothermal/Solar Hybrid Plant

Concentrating solar power (CSP) can provide additional thermal energy to boost geothermal plant power generation. For a newly constructed solar field at a geothermal power plant site, it is critical to properly characterize its performance so that the prediction of thermal power generation can be derived to develop an optimum operating strategy for a hybrid system. In the past, laboratory characterization of a solar collector has often extended into the solar field performance model and has been used to predict the actual solar field performance, disregarding realistic impacting factors. In this work, an extensive measurement on mirror slope error and receiver position error has been performed in the field by using the optical characterization tool called Distant Observer (DO). Combining a solar reflectance sampling procedure, a newly developed solar characterization program called FirstOPTIC and public software for annual performance modeling called System Advisor Model (SAM), a comprehensive solar field optical characterization has been conducted, thus allowing for an informed prediction of solar field annual performance. The paper illustrates this detailed solar field optical characterization procedure and demonstrates how the results help to quantify an appropriate tracking-correction strategy to improve solar field performance. In particular, it is found that an appropriate tracking-offset algorithm can improve the solar field performance by about 15%. The work here provides a valuable reference for the growing CSP industry.

14 SOLAR ENERGY↗

DOE OSTI2025

Recyclable Design for Retaining High Solar Absorptivity of the Media in CSP

Efficient thermal energy storage is pivotal to lowering the levelized cost of electricity (LCOE) for Concentrating Solar Power (CSP) plants. In solid-particle systems, however, prolonged high-temperature service degrades particle solar absorptivity, eroding overall efficiency. This project demonstrates a hydrogen-assisted recovery process that reliably restores absorptivity to >90 %, offering a practical route to sustain long-term CSP performance. Bench-scale investigations mapped the reduction kinetics of optically faded particles across hydrogen concentrations, temperatures, and residence times. Coupling mass-spectrometric monitoring with machine-learning optimization minimized energy demand while maximizing absorptivity gain. The resulting process window—moderate hydrogen partial pressures, 15–30 min dwell times, and temperatures well below initial calcination levels—cuts energy consumption well below that of incumbent re-blackening methods. A prototype recovery reactor processed multiple 2 kg batches with repeatable outcomes, confirming scalability and operational robustness. Integrated techno-economic analysis indicates material and operating cost reductions exceeding 15 % relative to conventional particle replacement or chemical re-coating, translating directly into lower LCOE for next-generation CSP facilities. By uniting fundamental reaction-kinetics insight with pragmatic engineering, this work advances the solid-particle pathway, delivering a cost-effective, field-deployable solution to one of CSP’s key durability challenges and strengthening the commercial outlook for high-temperature renewable power.

14 SOLAR ENERGY↗

DOE OSTI2018

Tools to Address Glare and Avian Flux Hazards from Solar Energy Systems

This report describes software tools that can be used to evaluate and mitigate potential glare and avian-flux hazards from photovoltaic and concentrating solar power (CSP) plants. Enhancements to the Solar Glare Hazard Analysis Tool (SGHAT) include new block-space receptor models, integration of PVWatts for energy prediction, and a 3D daily glare visualization feature. Tools and methods to evaluate avian-flux hazards at CSP plants with large heliostat fields are also discussed. Alternative heliostat standby aiming strategies were investigated to reduce the avian-flux hazard and minimize impacts to operational performance. Finally, helicopter flyovers were conducted at the National Solar Thermal Test Facility and at the Ivanpah Solar Electric Generating System to evaluate the alternative heliostat aiming strategies and to provide a basis for model validation. Results showed that the models generally overpredicted the measured results, but they were able to simulate the trends in irradiance values with distance. A heliostat up-aiming strategy is recommended to alleviate both glare and avian-flux hazards, but operational schemes are required to reduce the impact on heliostat slew times and plant performance. Future studies should consider the trade-offs and collective impacts on these three factors of glare, avian-flux hazards, and plant operations and performance.

14 SOLAR ENERGY↗

DOE OSTI2026

Characterizing the Impact of Heliostat Size, Focus Method, and Optical Error on Concentrating Solar Tower Systems

Concentrating Solar Power (CSP) tower systems use heliostat fields to direct solar energy to a central receiver. The efficiency of the heliostat field is crucial for achieving thermal generation targets and is also the largest cost component, making up 30-40% of total project costs. Developers face a tradeoff: reducing heliostat costs may decrease optical performance and increase land use, while improving performance could raise manufacturing costs (through higher precision). The optimal design depends on land, labor, and manufacturing costs. Additionally, inherent performance limitations exist - optical errors result in larger solar images as heliostats move farther from the receiver, increasing spillage and attenuation losses. Ultimately, there exists a point where receiver design power can no longer be achieved at design conditions for a given solar field area. This point depends on key heliostat field design parameters including field layout, heliostats size, focus method, and heliostat optical error. In this work, we explore and characterize the performance trade-offs between heliostat size, focus method, and optical error using Monte Carlo ray-tracing simulations using NREL's high performance computing resources. The goal of this fundamental investigation is to understand practical heliostat design performance impacts that can be used to produce more cost-effective heliostat fields while still achieving plant thermal generation targets.

14 SOLAR ENERGY↗

DOE OSTI2023

Particle Receiver Models for Systems Analysis

Particle receivers are gaining importance in the field of Concentrating Solar Power (CSP) due to the high temperature that particles can achieve without degradation. Several researchers are studying the potential of this technology by means of system analyses, which need simple and light models of the system. This study presents two simple models for the particle receiver. The simplest model is a correlation obtained by fitting the results calculated with a more complex receiver model simulated in CFD. The other model is a 1D model, which is benchmarked against the same CFD results. Although both models achieve high coefficient of determination, R2, when compared to CFD results, the 1D model seems to provide more accurate results (especially during sunsets and sunrises). Both models are integrated into a tecno-economic model developed in previous work. The LCOE obtained with the 1D model is between 7% and 10% greater than the one obtained with the correlation.

González-Portillo, Luis F. (ORCID:0000000348643825↗