Energy Systems Integration Partnerships, NREL + Abengoa; Energy Systems Integration (ESI), NREL (National Renewable Energy Laboratory)
This fact sheet details work done at the ESIF in partnership with Abengoa.
24 POWER TRANSMISSION AND DISTRIBUTION↗
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Solar Technology Test, Evaluation, and Data Collection: Cooperative Research and Development Final Report, CRADA Number CRD-08-279
Under this Agreement, NREL will work with Abengoa Solar Inc. on the testing, evaluation, and collection of data related to Abengoa Solar Inc. solar technologies and systems. This work includes, but is not limited to, testing and evaluation of solar component and system technologies, data collection and monitoring, performance evaluation, reliability testing, thermal energy storage integration, solar resource measurement and forecasting, grid impact testing, and analysis. This work will be conducted at NREL, SolarTAC (Aurora), and other field test locations.
14 SOLAR ENERGY↗
Coatings for Tower Receivers
SNL and Abengoa were to cooperatively engage in work to determine an optimal solar selective coating to meet the SunShot initiative performance demands at temperature and longevity and to reduce the Levelized Cost of Coating (LCOC) of these materials. Materials were to be identified, tested for durability and optical properties, optimized, and if successful, were to be tested on-sun for a period of up to a year at Abengoa’s test facilities in Spain.
36 MATERIALS SCIENCE↗
Conversion Tower for Dispatchable Solar Power: High-Efficiency Solar-Electric Conversion Power Tower
HEATS Project: Abengoa Solar is developing a high-efficiency solar-electric conversion tower to enable low-cost, fully dispatchable solar energy generation. Abengoa’s conversion tower utilizes new system architecture and a two-phase thermal energy storage media with an efficient supercritical carbon dioxide (CO2) power cycle. The company is using a high-temperature heat-transfer fluid with a phase change in between its hot and cold operating temperature. The fluid serves as a heat storage material and is cheaper and more efficient than conventional heat-storage materials, like molten salt. It also allows the use of a high heat flux solar receiver, advanced high thermal energy density storage, and more efficient power cycles.
ARPA-E↗
10 MW Supercritical CO 2 Turbine Test
The Supercritical CO 2 Turbine Test project was to demonstrate the inherent efficiencies of a supercritical carbon dioxide (s-CO 2 ) power turbine and associated turbomachinery under conditions and at a scale relevant to commercial concentrating solar power (CSP) projects, thereby accelerating the commercial deployment of this new power generation technology. The project involved eight partnering organizations: NREL, Sandia National Laboratories, Echogen Power Systems, Abengoa Solar, University of Wisconsin at Madison, Electric Power Research Institute, Barber-Nichols, and the CSP Program of the U.S. Department of Energy.
14 SOLAR ENERGY↗
Baseload Nitrate Salt Central Receiver Power Plant Design (Final Report)
The objectives of the work were to demonstrate that a 100 MWe central receiver plant, using nitrate salt as the receiver coolant, thermal storage medium, and heat transport fluid in the steam generator, can 1) operate, at full load, for 6,400 hours each year using only solar energy, and 2) satisfy the DOE levelized energy cost goal of $0.09/kWhe (real 2009 $). To achieve these objectives the work incorporated a large range of tasks relating to many different aspects of a molten salt tower plant. The first Phase of the project focused on developing a baseline design for a Molten Salt Tower and validating areas for improvement. Tasks included a market study, receiver design, heat exchanger design, preliminary heliostat design, solar field optimization, baseline system design including PFDs and P&IDs and detailed cost estimate. The baseline plant met the initial goal of less than $0.14/kWhe, and reinforced the need to reduce costs in several key areas to reach the overall $0.09/kWhe goal. The major improvements identified from Phase I were: 1) higher temperature salt to improve cycle efficiency and reduce storage requirements, 2) an improved receiver coating to increase the efficiency of the receiver, 3) a large receiver design to maximize storage and meet the baseload hours objective, and 4) lower cost heliostat field. The second Phase of the project looked at advancing the baseline tower with the identified improvements and included key prototypes. To validate increasing the standard solar salt temperature to 600 °C a dynamic test was conducted at Sandia. The results ultimately proved the hypothesis incorrect and showed high oxide production and corrosion rates. The results lead to further testing of systems to mitigate the oxide production to be able to increase the salt temperature for a commercial plant. Foster Wheeler worked on the receiver design in both Phase I and Phase II looking at both design and lowering costs utilizing commercial fossil boiler manufacturing. The cost and design goals for the project were met with this task, but the most interesting results had to do with defining the failure modes and looking at a “shakedown analysis” of the combined creep-fatigue failure. A separate task also looked at improving the absorber coatings on the receiver tubes that would improve the efficiency of the receiver. Significant progress was made on developing a novel paint with a high absorptivity that was on par with the current Pyromark, but shows additional potential to be optimized further. Although the coating did not meet the emissivity goals, preliminary testing the new paint shows potential to be much more durable, and potential to improve the receiver efficiency through a higher average absorptivity over the lifetime. Additional coatings were also designed and modeled results meet the project goals, but were not tested. Testing for low cycle fatigue of the full length receiver tubes was designed and constructed, but is still currently undergoing testing. A novel small heliostat was developed through an extensive brainstorming and down select. The concept was then detailed further with inputs from component testing and eventually a full prototype was built and tested. This task met or exceeded the accuracy and structure goals and also beat the cost goal. This provides a significant solar field costs savings for Abengoa that will be developed further to be used in future commercial plants. Ultimately the $0.09/kWhe (real 2009 $) and 6,400 hours goals of the project were met.
14 SOLAR ENERGY↗
Improved Large Aperture Collector Manufacturing
The parabolic trough is the most established CSP technology and carries a long history of design experimentation dating back to the 1970’s. This has led to relatively standardized collector architectures, a maturing global supply chain, and a fairly uniform cost reduction strategy. Abengoa has deployed more than 1,500MWe of CSP troughs across several countries and has built and tested full-scale prototypes of many R&D concepts. The latest trough R&D efforts involved efforts to internalize non-CSP industry experience including a preliminary DFMA principles review done with Boothroyd Dewhurst, a construction literature review by the Arizona State University School of Construction Management, and two more focused manufacturing engineering subcontracts done by Ricardo Inc. and the nonprofit Edison Welding Institute. The first two studies highlighted strong opportunities in lowering part count, standardizing components and fasteners, developing modular designs to support prefabrication and automation, and devising simple, error-proof manual assembly methods. These principles have delivered major new cost savings in otherwise “mature” products in analogous industries like automotive, truck trailer manufacture, metal building fabrication, and shipbuilding. For this reason, they were core in the design development of the SpaceTube® collector, and arguably key to its early successes. The latter two studies were applied specifically to the first-generation SpaceTube® design and were important in setting the direction of the present SolarMat project. These studies developed a methodology to analyze the costs of manufacture and assembly, and identify new tooling concepts for more efficient manufacture. Among the main opportunities identified in these studies were the automated mirror arm manufacturing concept and the need for a less infrastructure-intensive assembly line, both of which now form central pillars of the SolarMat project strategy. These new designs will be supported by new technology in the area of quality control inspection, in which state of the art photogrammetry and laser CMM inspection methods will be used to qualify parts and assemblies, and in which the recently-developed Absorber Reflection Method will enable in-line quality control inspection of modules produced by the new high-rate production line.
14 SOLAR ENERGY↗
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↗
Abengoa/Acciona Power Plant Hydrogen Mitigation Project (Cooperative Research and Development Final Report, CRADA Number CRD-15-583)
Several Gigawatts (GW) of solar concentrating parabolic trough generating capacity have been installed in the U.S. and internationally in the past five years. Many of these power plants include thermal energy storage, which allows the plants to generate electricity during off-sun hours. The U.S. now has about 1 GW of solar-to-electric generating capacity using concentrating parabolic trough technology. Parabolic trough power plants have a long-standing performance issue relating to the build-up of trace quantities of hydrogen gas in the receiver tubes. Hydrogen is a byproduct of the very slow breakdown of the heat transfer fluid. Accumulation of hydrogen in the receivers causes a loss in the thermal efficiency of the receivers and an overall decrease in the power plant annual electricity output. Since a typical plant contains 50,000 receivers, addressing this issue by individual receiver is not practical. The National Renewable Energy Laboratory (NREL) conceived and developed a method to remove or purge hydrogen from the power plant receivers by removing hydrogen from a single location within the plant. Hydrogen gas is purged from the heat transfer fluid that resides in the power plant expansion tanks. Modeling shows that quantitative removal of hydrogen from the expansion tanks will reverse build-up of hydrogen in the receiver tubes and restore the power plant to its full performance and annual energy output. This method is documented in U.S. Patent 8,568,582, which issued in October 2013. Two companies, Abengoa Solar and Acciona Solar Power, Inc. contacted NREL to discuss solutions to the eventual build-up of hydrogen in their commercial parabolic trough power plants. NREL proposed to implement its method at Acciona's Nevada Solar One (NSO) parabolic trough power plant in Boulder City, Nevada. The first year will consist of laboratory testing at the NREL Energy Systems Integration Facility (ESIF) along with process specification, design, and costing. The second year will be the full-scale implementation of the hydrogen mitigation process at the NSO power plant in Nevada.
14 SOLAR ENERGY↗
Drop C: The Drop-In, Ring-of-Power Heliostat (Final Report)
This report summarizes the work performed within the Drop-C: The Drop-In, Ring-of-Power Heliostat project. The Drop-C project aimed to develop a novel heliostat with an installed cost of $\$50$/m 2 ($\$2015$) which is a drastic cost reduction compared to the state-of-the-art. The resulting 27m 2 SunRing TM heliostat’s relative small size necessitates the parallel development of a wireless solar field network and a rapid calibration system. The SunRing heliostat is an evolution of the Ring-of-Power (ROP) design from Abengoa Solar LLC which had a reported installed cost of $114/m 2 . Cost savings relative to the ROP were sought by increasing the mirror area, improving the structural efficiency, a more accurate assessment of wind loads, and an improved assembly and installation procedure. The project spanned three Budget Periods (BP) where a digital heliostat was developed in BP1 using wind tunnel testing to define load conditions.
14 SOLAR ENERGY↗
Cleanable and Hardcoat Coatings for Increased Durability of Silvered Polymeric Mirrors
We have successfully developed coating formulations which significantly increasethe abrasion resistance of mirror films. We have demonstrated manufacturing scale-up of these films to full width andproduction volumes. Implementation of these films in commercial test sites is planned for Q2 2013(Abengoa, Gossamer Space Frames). This slide show outlines the background and objectives of the project, technical approach and results, and key lessons. It also presents the need and opportunity for reduction of costs for CSP and collectors. It also presents an approach for a large aperture parabolic trough collector with reflective film and a high concentration factor, including demonstration and results.
14 SOLAR ENERGY↗
Supercritical CO2 Power Cycles: Design Considerations for Concentrating Solar Power
A comparison of three supercritical CO2 Brayton cycles: the simple cycle, recompression cycle and partial-cooling cycle indicates the partial-cooling cycle is favored for use in concentrating solar power (CSP) systems. Although it displays slightly lower cycle efficiency versus the recompression cycle, the partial-cooling cycle is estimated to have lower total recuperator size, as well as a lower maximum s-CO2 temperature in the high-temperature recuperator. Both of these effects reduce recuperator cost. Furthermore, the partial-cooling cycle provides a larger temperature differential across the turbine, which translates into a smaller, more cost-effective thermal energy storage system. The temperature drop across the turbine (and by extension, across a thermal storage system) for the partial-cooling cycle is estimated to be 23% to 35% larger compared to the recompression cycle of equal recuperator conductance between 5 and 15 MW/K. This reduces the size and cost of the thermal storage system. Simulations by NREL and Abengoa Solar indicate the partial-cooling cycle results in a lower LCOE compared with the recompression cycle, despite the former's slightly lower cycle efficiency. Advantages of the recompression cycle include higher thermal efficiency and potential for a smaller precooler. The overall impact favors the use of a partial-cooling cycle for CSP compared to the more commonly analyzed recompression cycle.
14 SOLAR ENERGY↗
Self-Cleaning CSP Collectors, Concentrating Solar Power (Fact Sheet)
Boston University is one of the 2012 SunShot CSP R&D awardees for their advanced collectors. This fact sheet explains the motivation, description, and impact of the project.
14 SOLAR ENERGY↗
10-MW Supercritical-CO2 Turbine (Fact Sheet)
National Renewable Energy Laboratory is one of the 2012 SunShot CSP R&D awardees for their advanced power cycles. This fact sheet explains the motivation, description, and impact of the project.
14 SOLAR ENERGY↗
NREL Proves Cellulosic Ethanol Can Be Cost Competitive [Fact Sheet]
Ethanol from non-food sources - known as "cellulosic ethanol" - is a near-perfect transportation fuel: it is clean, domestic, abundant, and renewable, and it can potentially replace 30% of the petroleum consumed in the United States, but its relatively high cost has limited its market. That changed in 2012, when the National Renewable Energy Laboratory (NREL) demonstrated the technical advances needed to produce cellulosic ethanol at a minimum ethanol selling price of $\$$2.15/gallon (in 2007 dollars). Through a multi-year research project involving private industry, NREL has proven that cellulosic ethanol can be cost competitive with other transportation fuels.
09 BIOMASS FUELS↗
Flexible Rotary Pipe Interconnection: Final Technical Report
Explore the source record for details and available documents.
14 SOLAR ENERGY↗