Peter Heller Presentation

Parabolic Dishes Peter Heller, DLR
Folie 1 > <Curso Ciemat, Madrid 25.10.2012 > P.Hellerr
History
1816 Robert Stirling obtains the patent Air Motor 1872 John Ericsson constructs first Stirling Motor driven by solar energy
1984 The system Dish/Stirling Vanguard of 25-kWel achieves 29,4% efficiency (solar to electric energy)
Folie 2 > Curso Ciemat Madrid > P.Heller

Dokumentname > Discos Heller Madrid Part 1 25.10.2010
Types of Concentrators
Parabolic trough
Solar tower
Paraboloid
50-100 300-400 C
Concentration factor 500-1000 Operation temperature 550-1000 C
3000-5000 700-1200 C
STIRLING Cycle
3 TL
Pr essu r e
1-2 Compression
2 1
2-3 Displacement (V = const.)
Volume
TH
3-4 Expansion
Tem p er atur e
TH
TK 2 1
4-1 Displacement
Entropie
Volume Change in Real Stirling Process

(4) 0 (1) 90 (2) (3) (4)
180 270 360
VE
Expansion ExpansionsCylinder raum Recuperator Regenerator Continuous Kontinuierliche piston Kolbenbewegung
VS
movement
KompressionsCompression raum Cylinder VK

PHI
Diskontinuierliche Discontinuous Kolbenbewegung

piston movement

The real Stirling process

Why does the real and theoretical process not coincidate?
1. Realizacin de movimiento discontinuo de pistn casi imposible Real Stirling process 2. Etapa isotrmica casi imposible por la alta velocidad del gas 3. Rendimiento del regenerador < 100% 3 4. Efecto Dead Volume p perdida de carga gas real rozamiento
2 4
2
QErhitzer 5. Perdida interna por disipacin por
QErhitzer
4
Qmaterial 6. Perdidas de calor atravez del Khler V
QKhler V

The real Stirling process
Conditions for control of discontinuous movements of piston : - stop of compression piston during expansion - stop of expansion piston during compression => (theor.) acceleration of piston infinite => Inertia extremely high (piston punch, noise, durability)
SOLO STIRLING 161 SOLAR
Absorber Recuperator Expansion Cylinder Gas cooler
Compresion Cylinder Crankcase Gas buffer

Motor STIRLING
Receiver Recuperator Gas Cooler
Expansion Cylinder
Compresion Cylinder
th,St = 1 - T1
T3

Efficiency Calculations
Efficiency total gross: Efficiency net: Concentrator: Receiver:
conv , gross = conc rec eng alt
conv,net = conv , gross
Pparasitics I b ,n Aapp
conc = E cos i
4 4 U (Trec Tamb ) + F Trec Tamb = conc CRg I b ,n
rec

Historical Evolution
Stirling motors United Stirling AB 4-95 Stirling Thermal Motors USAB / SOLO V160 (Stirling 161) Cummins (free piston) Infinia (free piston)

Components: Heat exchanger (receiver)

- Properties of materials limit upper cycle temperature - heat transfer coefficient should be high requieres high gas velocities, reduced dimensions Pressure drop increased - Temperature difference exterior/interior should be small requieres large surfaces dead volumen increased

Components : Recuperator
Objective:
recuperate heat from isochorous cycle
Materials
Requirements:
hight heat capacity small dead volume large internal surface low friction and pressure losses low axial heat conduction

Components : Cylinder
- Unlubricated pistons - Pistons seals problematical due to radial forces, pressure and lack of lubrification => Fundamental difficulty !!! - Expansion Cylinder: thin walled, long (conduction) filled with insulation (convection/radiation) material: hight strenght, small - Protection against deformation: Internal pressure Orifices for pressure compensation Internal reinforcements
Expansion Cylinder
Concentrator Designs
Membrane Facets Shell

Kinematic Motor of 4 cylinders

Kinematic Motor 4 cylinders 4x95cm displacement Double action Power 25kWel Hydrogen 720C, 20MPa 41% efficiency

Free Piston Stirling

Gas Cooler Recuperator Receiver
CPG:
Free piston 6 (9) kWel
Linerar Generator
Compresion Cylinder
Expansion Cylinder
Helium 630C 4MPa Efficiency 33%

Schematic of EURODISH-System
Concentrator Konzentrator Shell Schale
StirlingMotor Einheit Stirling
Elevations Lager Elevation Bearing
Stirling Support Tragwerk Stirling Ringtrger Ring Truss
Elevation Rail Antriebsschiene

Elevation Schaltschrank Control S Cabinet
Turn Table Drehstand
Antriebsschiene Rail Azimuth Azimut Azimuthantrieb
Azimuth Drive
Fundament Foundation

Concentrator Shell

Temporary Rips
FEM Calculation

SOLO STIRLING 161 SOLAR

Cooling System Cavity Aperture Receiver
Blower (peak) Generator
Stirling

Diseo y Construccin de Cavidad Ceramica

Motors (tracking and emergency)

Control Cabinet

Typical Power Output

EURODISH Efficiency
Concentrator
Sun
Cavity
Stirling Engine
Generator
Electr.
Shading, Reflectivity
Blocking
Reflection
IR-Emission
Convection Conduction
Thermal Output
Thermal Losses
Dissipation
74,4 %
84,5 %
39,4 %
92,5 %
Syxstem efficiency solar to electric: 22,5 %

Solar Flux
Aperture
Flux Density [kW/m ]
9500 -- 10000 9000 -- 9500 8500 -- 9000 8000 -- 8500 7500 -- 8000 7000 -- 7500 6500 -- 7000 6000 -- 6500 5500 -- 6000 5000 -- 5500 4500 -- 5000 4000 -- 4500 3500 -- 4000 3000 -- 3500 2500 -- 3000 2000 -- 2500 1500 -- 2000 1000 -- 1500 500 -- 1000 0 -- 500
2
Absorber
Flux Density [kW/m ] 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0 -----------------1700 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100
2
y-Axis [mm]
y-Axis [mm]
7500 5000 2500 0 0 x-Axis [mm]
1500 1000 500 0 x-Axis [mm] 0
Flux Density x-Cut 2 [kW/m ]
Flux Density x-Cut 2 [kW/m ]

Flux Density y-Cut 2 [kW/m ]
10000 Flux Density y-Cut 2 [kW/m ]
2000 500 0 1000 1500 2000
10000
2500
5000
7500
Motivation
Distributed Systems: Why?
- Potential for mass production => Cost reduction - Distributed market of high value - Low economic risk - Quick implementation - Potential for hybridization 3 kW Infinia 60 units, USA 30 units, Espaa 10 kW EURODISH 6 units, Europe 25 kW SES 66 units, USA
Systems in the market :

Comparision Sistemas Disco/Stirling (2005)

- Comparitive Study realized in 2005 (Mancini, Heller et al)
10 kW EURODISH 25 kW SES/Boing
10 kW ADDS
22 kW SunDish

Comparison Dish/Stirling Systems (2005)

Comparison Sistemas Disco/Stirling (2005)

EURODISH Country Reference Units

CRU in Milano/Italy CRU in Seville/Spain
CRU in Wrzburg/Germany
CRU in Odeillo/France

Location Country Reference Units
CRU Wrzburg
CRU Milan
CRU Odeillo
CRU Sevilla
Test bed Almeria

Performance chart sunny winter day

250 1000 900 Pressure [bar], Power [kW], Effic. [%] 200 800 700 150 600 500 100 Engine Pressure Bottle Pressure Gross Power * 10 Gross Efficiency * 10 Max. Receiver Temperatur Direct Beam Insolation 09:00 11:00 13:00 Time 15:00 17:00 400 300 200 100 Irradiance [W/m], Temperature [C]
50
0 07:00
19:00
Folie 34 > Sollab Summerschool Almeria > P.Heller

Input / Output characteristic sunny winter day

12 250 1000 900 Pressure [bar], Power [kW], Effic. [%] Gross Power [kW] 10 200 8 150 6 100 4 50 2 Engine Pressure 800 700 600 500 400 Irradiance [W/m], Temperature [C]
Shut down in the eveningBottle Pressure
300 200 100
Start up in the morning Gross Power * 10 Gross Efficiency * 10 Max. Receiver Temperatur Direct Beam Insolation
300 13:00 400 500 15:00 600 700 17:00 800 TimeInsolation [W{m] Direct Beam
0 09:00 0
100
11:00 200
19:00 1000 900

Expected System Cost

Without any component improvement or other technical advances
140.000 120.000 Euro per 10 kW Unit 100.000 80.000 60.000 40.000 20.000 0 1 10 100 1000 Systems per year
Overhead Transportation Site assembling Project handling Component cost
Expected Component Cost

100.000 90.000 80.000
Stirling Electrics Concentrator Machined parts Steel parts
Euro per unit
70.000 60.000 50.000 40.000 30.000 20.000 10.000
10
100
1000
Units per year

Expected Levelized Energy Cost

0,90 0,80 0,70 Euro / kWh 0,60 0,50 0,40 0,30 0,20 0,10 0,00 1 10 100 Units per year
Sites in South Europe Sites with excellent solar insolation
Dish-Stirling PVtoday 6,5 T/kW PVtoday 5,5 T/kW PV with cost reduction Diesel gen set: 0,40 /l Diesel gen set: 0,60 /l Diesel gen set: 0,80 /l Diesel gen set:1,00 /l
Interest rate: 6% Depreciation period: Dish-Stirling: 12 years Diesel: 15 years PV: 20 years O&M Cost: D-S and Diesel: 2% PV: 1%
1000
10 kW Prototype at KIER, Korea

Prototype 2007 SOLO 161 120 reflectors, 5 curvatures, 1mm mirror clued onto aluminium structure 40,3 m projected reflector area 2 motors for tracking Efficiency : 20,2% peak

Infinia Corporation, EEUU

Investment: $100 million venture capital Data: 3 kWe, 24% efficiency Free Piston Mirrors: SolFocus, Mountain View
Prototype Plants: 6 kW, Kennewick, Wa, EEUU 6 kW, Sandia National Labs, Albuquerque, NM, EEUU 9 kW, Belen, NM, EEUU 15 kW, Kennewick Toyota Center, EEUU 40 kW, Richland, EEUU Development: Storage (molten salt) (R&D proyect, $3m, DOE)

Renovalia (Spain)
Second generation Infinia system 6 months of implementaion (24 months for other technologies) Efficiency 24% (peak) Reflectors: Rioglass Materials: auxiliar sector automotive 1 MW Planta Casa del ngel, Casas de los Pinos, Cuenca, Espaa 71 MW pre-assigned

TM SES SunCatcherTM

SES
50.000 hours of solar operation (motor), 120.000 hours dish efficiency: 30% Significant improvements in design of motor 6 dishes at SANDIA, NM, EEUU

TM SES SunCatcherTM
Tessera Solar International Power company (BOO) May 2008: $100 million for system optimisation (NTR, Irlandia) Improved design of facets Capital cost: 3.000 $/kW Target LEC: $ 0,2 per kWh 55.000 - 60.000 kWh/yr Imperial Valley Solar and Calico Solar (70.000 SunCathersTM, 1.550 MW), CA, EEUU 1.5 MW demo plant (60 SunCathersTM, ) en Maricopa County, Phoenix, AZ, EEUU
STATUS: Insolvency
Proposal of Demo Plant EURODISH

Power: 500kW 1 MW (50 100 units) Investment cost: approx. 4 millons Location: Spain
Expected Results: Cost reduction Improved O&M Serial production proven technology

Conclusion EURODISH
Results:
Functional tests Implementation improvements (cavity etc,) Remote control Demonstration of high availability (>90%) Verification of high performance (>21%)

Next steps:
Demonstration plant de 500kW 1 MW Serial production Technology transfer Development of hybrid system Development of remote system SBP y Cleanergy (SOLO) develop parallel systems based on Eurodish
Conclusin SES
Results:
Incorporated improvements Demonstration of high availability Verification of high performance 6 prototipos in Albuquerque Power Purchase Agreements 1 MW constructed en Arizona

Next steps:
Establishment of serial production Construction of first bulk power plants (500 MW) Situation unclear after insolvency of SES

Summary
High efficiency Learning curve => high cost Competition with cheap PV Storage/dispatchability missing No specific feed-in tariff Most players are disappearing due to market situation

Thank you for your attention !


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Parabolic Dishes Peter Heller, DLR

Folie 1 > <Curso Ciemat, Madrid 25.10.2012 > P.Hellerr

Folie 2 > Curso Ciemat Madrid > P.Heller

Concentration factor 500-1000 Operation temperature 550-1000 C

2-3 Displacement (V = const.)

Volume Change in Real Stirling Process

180 270 360

KompressionsCompression raum Cylinder VK

Diskontinuierliche Discontinuous Kolbenbewegung

Folie 5 > Curso Ciemat Madrid > P.Heller

The real Stirling process

QErhitzer 5. Perdida interna por disipacin por

Qmaterial 6. Perdidas de calor atravez del Khler V

Folie 6 > Curso Ciemat Madrid > P.Heller

The real Stirling process

SOLO STIRLING 161 SOLAR

Absorber Recuperator Expansion Cylinder Gas cooler

Compresion Cylinder Crankcase Gas buffer

Folie 8 > Curso Ciemat Madrid > P.Heller

Folie 9 > Curso Ciemat Madrid > P.Heller

conv,net = conv , gross

Folie 10 > Curso Ciemat Madrid > P.Heller

Folie 11 > Curso Ciemat Madrid > P.Heller

Components: Heat exchanger (receiver)

Folie 12 > Curso Ciemat Madrid > P.Heller

Folie 13 > Curso Ciemat Madrid > P.Heller

Folie 15 > Curso Ciemat Madrid > P.Heller

Kinematic Motor of 4 cylinders

Folie 16 > Curso Ciemat Madrid > P.Heller

Free Piston Stirling

Helium 630C 4MPa Efficiency 33%

Folie 17 > Curso Ciemat Madrid > P.Heller

Elevations Lager Elevation Bearing

Stirling Support Tragwerk Stirling Ringtrger Ring Truss

Elevation Rail Antriebsschiene

Turn Table Drehstand

Antriebsschiene Rail Azimuth Azimut Azimuthantrieb

Folie 18 > Curso Ciemat Madrid > P.Heller

Folie 19 > Curso Ciemat Madrid > P.Heller

Folie 20 > Curso Ciemat Madrid > P.Heller

SOLO STIRLING 161 SOLAR

Blower (peak) Generator

Folie 21 > Curso Ciemat Madrid > P.Heller

Diseo y Construccin de Cavidad Ceramica

Folie 22 > Curso Ciemat Madrid > P.Heller

Motors (tracking and emergency)

Folie 23 > Curso Ciemat Madrid > P.Heller

Folie 24 > Curso Ciemat Madrid > P.Heller

Typical Power Output

Folie 25 > Curso Ciemat Madrid > P.Heller

Syxstem efficiency solar to electric: 22,5 %

7500 5000 2500 0 0 x-Axis [mm]

1500 1000 500 0 x-Axis [mm] 0

Flux Density x-Cut 2 [kW/m ]

Flux Density x-Cut 2 [kW/m ]

Folie 27 > Curso Ciemat Madrid > P.Heller

Flux Density y-Cut 2 [kW/m ]

10000 Flux Density y-Cut 2 [kW/m ]

2000 500 0 1000 1500 2000