Variation in Reflected Beam Shape and Pointing Accuracy Over Time and Heliostat Field Position
Submitted to SolarPACES 2023 Proceedings.
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Submitted to SolarPACES 2023 Proceedings.
This work has been carried out as part of the HelioCon Field Deployment subtask, with the aim to distill published literature in papers and standards on heliostat and solar panel wind loads to develop a reduced order model for heliostat wind loads. It is intended to be understood and applied by structural engineers and heliostat designers as inputs to determine wind loads on heliostats due to the underlying derivations and factors that influence the complex structural dynamics and wind-induced behavior of heliostats.
Our motivation is to develop more efficient heliostats that can provide commercially viable solar thermal power at temperatures > 800°C. Such high temperatures will enable high-temperature industrial processes, as well as electrical generation after sunset with high efficiency. The importance of this research is that such heliostats have the potential to substantially expand the global use of solar energy, by adding solar thermal power as a major component. Thermal solar currently accounts for only 1% of all solar power (with PV being the rest), with heliostat fields providing just 0.25%. Our goals have been 1) to demonstrate a technical improvement for heliostats that can enable fields of them to more efficiently power receivers and reactors, and 2) to show a path to low-cost mass production. Our solution uses new opto-mechanical technology to correct a fundamental deficiency of present heliostats that limits their concentration, namely that they have fixed shape. Most of today’s heliostat research does not address this, but is directed simply toward cost reduction in an effort to make heliostats commercially viable. We are motivated to explore also improving heliostat efficiency, which can be done by continually changing their shape to maximize the concentration of sunlight throughout the day. This is not a new concept, but it has never been implemented in a practical, cost-effective way that approaches the theoretical limit to concentration while also improving mechanical performance; this is our goal. Our major accomplishments have been: 1) We have realized the planned design, construction, and test of a prototype heliostat that achieves the required shape changes in an 8 m2 single-piece glass mirror. The mirror is attached to a steel support frame that is automatically mechanically twisted by the heliostat drives that orient the mirror to direct sunlight to the tower-mounted receiver. Closed-loop tracking is done using a new beamsplitter camera that exploits the target-oriented mount configuration. Field tests of the heliostat show that the light is reflected through the day to always form a disc image of the sun, as needed to obtain the highest concentration. 2) We have developed the design for a field of 431 heliostats to deliver annual average of 1 MW of thermal power at 3,000 sun concentration, matched to a high-temperature ≥ 1000°C chemical reactor. 3) We have also developed, beyond the original stated goals of the project, a new concept for closed-loop tracking and shape-sensing for all the heliostats in the above field, using just 6 cameras around the concentrated reactor focus. Our research adds to the understanding of solar thermal energy by its demonstration of the technical effectiveness of a higher performing heliostat, and by its concept for a new powerful method for real-time tracking and shape sensing in the field, as described above. We have studied the economic feasibility of fields of our twisting heliostats to provide high- temperature heat at a price competitive with that of burning gas, to satisfy the DOE’s studied zero-emissions scenario, where the gas price has to include the cost of carbon capture. The project has the potential to greatly benefit the public if it helps limit global warming by 1) reducing carbon emission from industrial heating, which is currently a major contributor to the 40-billion-ton annual increase in atmospheric CO 2 . 2) Ultimately, the technology could prove to be the least expensive method to power direct air capture of CO 2 on the very large scale needed to remove the 1 trillion-ton excess of CO 2 already in the atmosphere.
This project analyzed a two-stage heliostat concept consisting of a tracking stage and a concentrating stage. The tracking stage uses mirrors mounted on a common drive that move to track the sun. The concentrating stage consists of stationary mirrors that each have a unique angle to direct rays towards a small-area, high-flux, point-focused receiver. By splitting the collection and concentrating process into two stages, multiple small, inexpensive mirrors can share a structure and be controlled by a single drive in the tracking stage. The project effort developed modeling techniques that were specifically relevant to this two-stage heliostat concept. Both field-level and unit-level models were developed. The field-level model does not explicitly consider unit-level losses which are predicted by the unit-level model and then integrated into the field-level model through a correlation referred to as an efficiency modifier. This approach is referred to as the two-model approach; the development and demonstration of this two-model approach for a multi-stage heliostat technology is a key outcome of this work. The field-level model is used to design a field that hits a specific design day power given a set of heliostat design parameters. An oversized field is simulated and then heliostat units are removed based on their annual energy production in order to generate the highest performing field. The field reduction procedure fits a smooth curve fit to annual energy production as a function of position in the field which has the effect of reducing the noise that is otherwise caused by the Monte Carlo ray tracing technique. This approach is referred to as the annual energy fit method and substantially reduces computational run time for a given field level modeling accuracy. The annual energy fit approach enables the selection of a properly sized, high-performing field using orders of magnitude fewer rays than would otherwise be possible and the development of this approach is a second key outcome of this work. These models are used within a genetic optimization algorithm in order to optimize the geometric parameters associated with a heliostat in order to achieve the lowest cost per unit of collected design day power. The cost modeling that underlies the optimization is a simple, scaling type analysis backed up by a much more detailed Design for Manufacture and Assembly (DFMA) analysis. Although the figure of merit used for optimization was not cost per mirror area, this metric is reasonable to use as a means of comparison. The optimally designed 500 kW design has a tracking mirror specific cost of $181.85/m 2 , which is significantly larger than the target value and also larger than the current state of the art. The cost of the torque-tube type linkages contributed substantially to the overall cost. Based on this observation, potentially attractive alternative design configuration utilizing a capstan type actuation system should be investigated. Finally, NREL compared the performance of the two-stage heliostat to the performance of a focused and different sized flat conventional heliostats and showed that, as expected, additional losses versus the convention heliostat caused by a worse cosine efficiency, two stages of reflection, and interstage interactions. The two-stage heliostat requires around 75% more reflective area than a flat 1x1 meter conventional heliostat (similar to a focused heliostat) and 40% more than a flat 2x2 meter conventional heliostat.
Heliostat designs have undergone a widespread and eclectic development process, with many unique designs demonstrated. However, recent developments do not show the overall cohort converging toward a globally accepted universal design. Here, this study characterizes heliostats by breaking down and evaluating design traits based on emergent patterns from a comprehensive compilation of known heliostat designs spanning several decades. Four main categories for evaluation emerged: heliostat base, heliostat primary axis, heliostat drive, and facet support. Each of these four categories is further defined by four subtypes so that all heliostats fall into a single subtype within each category. The classified heliostats are ranked, yielding several view slices into the heliostat compilation or a breakdown of heliostats by type. An analysis of the breakdown shows several trends: a scale-up of established designs, new approaches at small to medium scales, and a movement toward greater adoption of linear drives. These trends reflect the most meaningful contributing factors to a proposed trajectory for a new era of heliostat designs striving to meet widely considered cost targets of $\$$50/m 2 or $\$$75/m 2 .
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.
This work was carried out as part of the Heliostat Consortium (HelioCon) Field Deployment subtask with the aim to develop a reduced order model framework for correlating wind speed and pointing deviation of a heliostat facet. There are only sparse field measurements of heliostat pointing deviations and accompanying wind conditions published in the literature. Heliostat test standards, such as IEC 62862-4-3, propose a suite of tests including laser pointing repeatability at wind speeds below 4 m/s, and provide technical requirements for heliostat slope and tracking deviations in coarse average wind speed bins of 4 m/s, 6 m/s, and 8 m/s. In addressing the gap of the variation of heliostat pointing deviation with wind speed, field measurements of laser pointing on a grid target and wind conditions were analyzed in this study at the Third-Party Metrology Platform at the National Laboratory of the Rockies (NLR) Flatirons Campus. Horizontal pointing deviations were found to follow a logarithmic relationship with peak wind speed, whereas vertical pointing deviations follow an exponential relationship with peak wind speed. Both horizontal and vertical pointing deviations also follow a second order polynomial relationship, as expected from the proportionality of elastic loads and deformations with the square of wind speed. The results indicate that heliostat facet pointing deviations in the vertical direction increase at a faster rate than in the horizontal direction with increasing wind speed over the tested range, however these are dependent on the heliostat structural design. Next steps are recommended for additional field measurements to confirm a linear relationship of pointing deviation with applied moment on a heliostat facet, and to distinguish between gravity-induced and wind-induced pointing deviations at different elevation angles. The derived correlations in the preliminary analysis in this report serve as a case study for heliostat developers and plant operators to estimate the wind-induced pointing deviations and their variation with peak gust wind speed. Next steps in future work would recommend higher resolution and longer duration datasets for different elevation angles and wind directions to reduce uncertainties and variance of collected laser beam spot data and their correlations with bin-averaged wind speed.
This study presents a method to obtain a heliostat size that minimizes the levelized cost of heat (LCOH) of a heliostat-based concentrating solar thermal system for applications of solar heating for industrial processes at operating temperatures from 565 to 1550°C. The method extends prior work by embedding a routine for system design that obtains near-optimal subsystem sizes, increasing the fidelity of drive cost functions, and adding an optical performance model to supplement the previously developed cost models, which we update to reflect current pricing trends. An illustrative business case is developed for Daggett, California, targeting specified annual thermal energy outputs of 50 to 400 GWh th . Optical performance is modeled using verified estimates from the literature. A surrogate heliostat cost model, derived from commercial heliostat designs and scaled for production volume, installation, and operations and maintenance costs, is used to develop cost functions. Results show that heliostat size strongly affects the LCOH, producing a characteristic U-shaped trend with a robust near-optimal window of 7-20 m 2 ; the heliostat size producing the lowest project cost in our study grows slightly as the project size increases, and is reduced as the operating temperature increases. The findings in this study are consistent with the general trend of smaller heliostats being deployed at existing projects for high-temperature industrial process heat and reflect the significant reduction in power electronics and other per-heliostat costs. The methodology we propose is general and can be tailored to revised cost curves as the technology continues to evolve.
Optics plays a major role in the effectiveness of concentrating solar power (CSP) technologies. The nonintrusive optical (NIO) approach developed by the National Renewable Energy Laboratory uses uncrewed aircraft system (UAS)-based imaging to survey heliostats in a commercial-scale power tower CSP plant and characterize their optical errors. The image processing algorithm uses photogrammetry to calculate the camera position for each image frame, and the accuracy of the estimated optical errors is highly sensitive to the calculated camera position accuracy. In this study, we simulate a series of case studies in python to examine the impact of different parameters of the sensitivity of the camera calculation, including the number of facet corners used as control points for the photogrammetric calculation, precision error in the detected pixel locations of the facet corners in the image, and precision error of the canting and mounting positions of the facets of the heliostat. The case studies consider heliostat geometry based on three commercial designs to serve as representative examples of different possible sizes of heliostats that the NIO method could be applied to. The results show that increasing the number of control points can improve accuracy for heliostats with many facets, pixel precision has a significantly larger impact on camera calculation accuracy than facet canting and mounting errors, and the camera distance and focal length must be chosen to ensure adequate pixel accuracy on the heliostat surface depending on the size of heliostat. In conclusion, based on the results, recommendations for the allowable values of each parameter are provided to achieve the required NIO optical error estimation accuracy depending on the size of heliostat.
This study presents a method to obtain a heliostat size that minimizes the levelized cost of a heliostat-based concentrating solar thermal system for industrial process heat (IPH) applications at operating temperatures from 565 to 1550 degrees Celsius. The method extends prior work by embedding a routine for system design that obtains near-optimal subsystem sizes, increasing the fidelity of drive cost functions, and adding an optical performance model. An illustrative business case is developed for Daggett, California, targeting specified annual thermal energy outputs of 50 to 400 GWhth. Optical performance is modeled using verified estimates from the literature. A surrogate heliostat cost model, derived from commercial heliostat designs and scaled for production volume, installation, and operations and maintenance costs, is used to develop cost functions. Results show that heliostat size strongly affects the levelized cost of heat (LCOH), producing a characteristic U-shaped trend with a robust near-optimal window of 8 - 12 m2; the heliostat size producing the lowest project cost in our study grows slightly as the project size increases, and is reduced as the operating temperature increases. The findings in this study are consistent with the general trend of smaller heliostats under deployment at existing projects for high-temperature industrial process heat and reflect the significant reduction in power electronics and other per-heliostat costs. The methodology we propose is general and can be tailored to revised cost curves as the technology continues to evolve.
The idea is to combine the solar energy reflected from a field of many heliostats to obtain a single focus of high concentration and high power. We exploit a new type of “twisting” heliostat” in which as the mount is moved to track the sun through the day, the reflector shape is twisted to maintain a focused image of the sun’s disc on the target, through the day over a wide range of angles of incidence. By combining the light reflected by many twisting heliostats into a single focus, we are not only able to accomplish but also maintain very high concentration and temperature through the day, with higher efficiency than has previously been possible with conventional heliostats having a fixed shape. A circular field of twisting heliostats is used to power a single intense focus atop a central tower. The light from all the heliostats is relayed to an upward facing receiver at the focus via a central Cassegrain secondary reflector located above the receiver. In a specific design targeting 1 MW of power, a 100 m diameter field arrays 431 twisting heliostats, each with a 7 m2 reflector. The secondary reflector ,7.2 m in diameter, is located 24 m above the heliostat field, bringing sunlight with annual average power of 1 MW to a circular focus 0.8 m in diameter, at a concentration averaging 3,000 suns.
On a Concentrated Solar Power (CSP) field, optical errors have significant impacts on the collection efficiency of heliostats. Fast, cost-effective, labor-efficient, and non-intrusive autonomous field inspection remains a challenge. Approaches using imaging drone, i.e., Unmanned Aerial Vehicle (UAV) system integrated with high resolution visible imaging sensors, have been developed to address these challenges; however, these approaches are often limited by insufficient imaging contrast. Here, in this study, we report a polarimetry-based method with a polarization imaging system integrated on UAV to enhance imaging contrast for in-situ detection of heliostat mirrors without interrupting field operation. We developed an optical model for skylight polarization pattern to simulate the polarization images of heliostat mirrors and obtained optimized waypoints for polarimetric imaging drone flight path to capture images with enhanced contrast. The polarimetric imaging-based method improved the success rate of edge detections in scenarios which were challenging for mirror edge detection with conventional imaging sensors. We have performed field tests to achieve significantly enhanced heliostat edge detection success rate and investigate the feasibility of integrating polarimetric imaging method with existing imaging-based heliostat inspection methods, i.e., Polarimetric Imaging Heliostat Inspection Method (PIHIM). Our preliminary field test results suggest that the PIHIM hold the promise to enable sufficient imaging contrast for real-time autonomous imaging and detection of heliostat field, thus suitable for non-interruptive fast CSP field inspection during its operation.
The objective of this project was to design and implement a comprehensive educational and applied research program in Concentrated Solar Thermal Power (CSTP) and heliostat technologies at Northeastern University. In alignment with the U.S. Department of Energy's Heliostat Consortium (HelioCon) goals, the project aimed to expand student and public understanding of CSTP systems while simultaneously contributing to workforce development and the broader decarbonization strategy. A particular emphasis was placed on integrating hands-on student design projects and publicly disseminating educational content relevant to CSTP systems. The project addressed a critical gap in renewable energy education: CSTP and heliostats, despite their importance in utility-scale solar energy, are rarely included in standard mechanical engineering programs. This project established new pathways for students to engage with the topic through the creation of a 4-credit graduate/senior elective course, development of five industry-facing short courses, and the inclusion of CSTP-based capstone design projects. Over two academic years, 36 students across six senior design teams developed and tested technologies such as deformable heliostats, beacon-based tracking systems, and solar-powered pyrolizers for biomass-to-biochar conversion. Concurrently, 30 undergraduate and graduate students were enrolled in the new academic course centered around CSTP principles. To ensure the relevance and accessibility of the short course content, the project team engaged with industry professionals, technical policy stakeholders, and potential course participants through structured surveys and informal consultations. Feedback from 28 respondents guided the structure, length, and delivery format of the courses - resulting in a modular design broken into five workshops. The feedback emphasized the need for flexible, asynchronous delivery and practical case studies, particularly in areas such as heliostat control, thermal storage, and solar fuel production. This engagement helped align the courses with the evolving knowledge demands of the renewable energy workforce and ensured that participants from both technical and policy backgrounds could meaningfully benefit from the material. The research and educational activities advanced the understanding of heliostat control systems, optical performance under misalignment, and thermal system integration in solar-driven pyrolysis applications. Methods and designs explored in this project proved to be both technically effective and economically feasible at the lab scale. Prototypes were constructed using commercially available components and custom-fabricated elements, demonstrating that meaningful performance improvements can be achieved with modest material and fabrication costs, supporting the feasibility of student-led research in this field. The public benefit of this project is twofold. First, it cultivates a pipeline of engineers trained to be familiar with CSTP principles, an essential workforce need identified by the Department of Energy for achieving its 2030 cost and deployment targets. Second, it contributes openly accessible educational materials, course content, and experimental frameworks to the broader community, enabling other institutions to adopt or adapt similar programming. Through outreach activities, curriculum integration, and technical exposure, this project contributes to a more informed and capable renewable energy workforce while supporting innovation in heliostat and CSTP system design. A new technical report is being prepared to document the development of the course and its outcomes, with plans to publish it in the ASME Open Access Journal of Engineering to ensure global accessibility, free of cost.
Since its establishment, the Heliostat Consortium (HelioCon) has made substantial progress toward closing many of the gaps in concentrating solar power (CSP) research. Numerous techno-economic studies have been performed, investigating topics ranging from the trade-off between size and temperature for industrial process heat applications to optimization of the heliostat design itself for various applications. Significant improvements have been made in optical metrology techniques, with first steps toward in situ measurement of heliostat fields. Several standards have been, and continue to be, developed with the coordination of an international group of CSP industry participants. Training programs have been developed, with universities including CSP in their engineering curricula, and many public webinars have been held to provide broad access to the latest CSP research. Improved CSP components such as mirror facets and wireless communication systems have been developed, and the solar tower at Sandia National Laboratories has been upgraded with a testbed for closed-loop controls research and development. Field deployment challenges involving heliostat foundations and sensitive wildlife habitats have been explored, with progress made toward methods for streamlining project development and permitting. Additional knowledge has been added to the body of work on wind behavior of heliostats and arrays of heliostats, with progress made toward a holistic understanding of wind design methods. Finally, techniques have been developed and demonstrated for assessing soiling conditions at a proposed project site, with predictive models for the soiling rate showing good results. Taking these results together, HelioCon has contributed greatly to the global CSP research and development effort over the past several years.
Under HelioCon, NLR began developing a new optical measurement system, called Reflected Target Non-Intrusive Assessment (ReTNA). ReTNA has shown promise towards addressing metrology gaps for heliostat used in concentrated solar thermal (CST) plant. This project is focused on advancing this measurement system from the laboratory into industry, where it can provide valuable information for heliostat developers during research, development, and qualification of a heliostat design, and be used for quality assurance during heliostat manufacture. Over the course of this project, ReTNA was deployed at several commercial heliostat facilities. The system developed and deployed with the primary project partner, Solar Dynamics LLC, is described in detail. The report discusses each project Milestone, the ending status, the achieved value, and how these Milestones improve and qualify the ReTNA measurement tool. Finally, the final report covers the market advancements, path forward, commercial successes, and lessons learned. Final Technical report for TCF Base Technology-Specific project TCF-23-20118, Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) tool, for indoor optical analysis of Heliostats.
Accurate optical surfaces are a primary driver of concentrated solar power plant performance. Errors in pointing and tracking mirrors, the canting of individual mirror facets, and the surface slope of the mirror itself can be caused by errors during assembly, transportation, wind loading, gravity, and many other sources. The tools that exist to measure these error sources today largely rely on fringe deflectometry (SOFAST, QDec, others), or photogrammetry with targets attached to the mirror surface. Since 2022, NREL has been developing a measurement method called the Reflected Target Non-intrusive Assessment (ReTNA) system. This system differs from most established methods in that we perform deflectometry with a pattern of coded targets, identified in space with photogrammetry. Reflected target systems have several advantages over traditional fringe deflectometry systems. Firstly, they can be operated in bright or ambient lighting, a challenge for fringe systems that use a projector and screen. Reflected target systems also can use a much lighter and less expensive target than projector-based systems. Lastly, 2D slope measurement can be solved from a single image, which leads to several advantages for accommodating faster measurements and smaller sized targets. These advantages make ReTNA particularly well-suited for applications where there are space or lighting constraints, like performing heliostat quality assurance on an assembly line. It's also useful when a lightweight, flexible system is needed, like for heliostat developers to quickly measure a new heliostat design at different orientations, to observe gravitational effects on the mirror surface shape. In the last year, significant improvements were made to this tool to make it more useful for these applications. These improvements were focused around validation of the ReTNA measurement system, and automation of the setup and measurement process. First, we present an improved ReTNA layout, for use on the heliostat assembly line. Next, we detail the various changes to the ReTNA software and computer vision methods to automate data collection in this new setup, and lessons learned from this process. The goal with this new setup is to perform a full heliostat surface characterization without removing the mirror from the assembly line. Lastly, we share results from several ReTNA validation studies undertaken over the last year. These include repeated ReTNA measurement on demonstration mirror facets, comparisons with other optical measurement tools, and some studies aimed at quantifying the uncertainty of ReTNA measurement under various constraints (mirror-target spacing, camera resolution, etc.). These results are compared with 2024 HelioCon performance targets, and our planned next steps for the ReTNA measurement system are presented.
We experimentally and computationally investigate a proposed frequency-domain method for detecting and tracking cislunar spacecraft and near-earth asteroids using heliostat fields at night. Unlike imaging, which detects spacecraft and asteroids by their streak in sidereally-fixed long-exposure photographs, our proposed detection method oscillates the orientation of heliostats concentrating light from the stellar field and measures the light’s photocurrent power spectrum at sub-milliHertz resolution. If heliostat oscillation traces out an ellipse fixed in the galactic coordinate system, spacecraft or asteroids produce a peak in photocurrent power spectrum at a frequency slightly shifted from the starlight peak. The frequency shift is on the scale of milliHertz and proportional to apparent angular rate relative to sidereal. Relative phase corresponds to relative angular position, enabling tracking. A potential advantage of this frequency-domain method over imaging is that detectivity improves with apparent angular rate and number of heliostats. Since heliostats are inexpensive compared to an astronomical observatory and otherwise unused at night, the proposed method may cost-effectively augment observatory systems such as NASA’s Asteroid Terrestrial-impact Last Alert System (ATLAS).
Heliostat designs intended to reduce costs and the effect of adverse wind loads on the devices were developed. Included was the low-profile heliostat consisting of a stiff frame with sectional focusing reflectors coupled together to turn as a unit. The entire frame is arranged to turn angularly about a center point. The ability of the heliostat to rotate about both the vertical and horizontal axes permits a central computer control system to continuously aim the sun's reflection onto a selected target. An engineering model of the basic device was built and is being tested. Control and mirror parameters, such as roughness and need for fine aiming, are being studied. The fabrication of these prototypes is in process. The model was also designed to test mirror focusing techniques, heliostat geometry, mechanical functioning, and tracking control. The model can be easily relocated to test mirror imaging on a tower from various directions. In addition to steering and aiming studies, the tests include the effects of temperature changes, wind gusting and weathering. The results of economic studies on this heliostat are also presented.