Developing the Small Particle Heat Exchange Receiver for a Prototype Test · PROTOTYPE TEST...
Transcript of Developing the Small Particle Heat Exchange Receiver for a Prototype Test · PROTOTYPE TEST...
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SDSU Combustion and Solar Energy Laboratory 1
DEVELOPING THE SMALL PARTICLE HEAT EXCHANGE RECEIVER FOR A
PROTOTYPE TEST
Fletcher Miller, Principal Investigator Department of Mechanical Engineering,
San Diego State University
SunShot
Concentrating Solar Power Program Review 2013
Phoenix, AZ
Tuesday, April 23rd, 2013
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SDSU Combustion and Solar Energy Laboratory 2
Project Partners
Start Date: Sept. 1st, 2012
Michael McDowell Rocketdyne
Arlon Hunt Thermaphase
David Teraji Solar Turbines Andrew Clarkson
L-3 Brashear
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SDSU Combustion and Solar Energy Laboratory 3
Presentation Outline
• Concept of the Small Particle Solar Receiver • Project Objectives and Description • Lab-Scale Component Testing • Receiver window design (optical/mechanical) • Radiation heat transfer and thermo/fluid
dynamic modeling • Challenges & Future work
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SDSU Combustion and Solar Energy Laboratory 4
Solar Central Receivers
Solar One, Barstow, California Our proposed technology, a gas-small particle receiver, can efficiently deliver the temperatures needed for a high-efficiency, gas turbine (Brayton cycle).
“New” Receiver Concept
Commercial central receivers use either molten salt or steam as the coolant, and are limited to medium temperatures and moderate solar fluxes
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SDSU Combustion and Solar Energy Laboratory 5
Small Particle Receiver Under Renewed Development at SDSU
Advantages:
• Radiation is absorbed by sub-micron carbon particles, which act as selective, efficient absorbers of solar radiation.
• Extremely high temperatures and flux levels are possible, because the absorbers are expendable.
• The carbon particles oxidize once they reach high temperatures.
• The small particles are at thermal equilibrium with their surroundings (no resistance to heat transfer).
• Pressure drops are minimized by removing tubes or foam absorbers.
Schematic of a Small Particle Receiver Conceptual Small Particle Receiver
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SDSU Combustion and Solar Energy Laboratory 6
Comp
Receiver
Recp
B
1
2
3 4
7
Solar receiver goes in-line with the combustor.
Advantages for Gas Turbines: – High efficiency – Low water
consumption – Possible combined
cycle – Ease of Operation
Small Particle Receiver in a Gas Turbine Cycle
Recuperated Gas Turbine Cycle
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SDSU Combustion and Solar Energy Laboratory 7
Project Objectives
• The objective of this project is to design, construct, and test a revolutionary high temperature small particle solar receiver in the multi-MW range that can be used to drive a gas turbine to generate low-cost electricity.
• A secondary objective is demonstrating for the first time a pressurized solar receiver with a window greater than 1 m in diameter.
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SDSU Combustion and Solar Energy Laboratory 8
• Phase 1 – Lab-Scale Component Testing – Window and Seal Design – Full-scale Particle Generator Design – Receiver Modeling and Preliminary Design
• Phase 2 – Finalize Designs, Fabricate and Test Components
• Phase 3 – Assemble components and test receiver at the National Solar Thermal Test Facility at Sandia National Labs.
Project Description
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SDSU Combustion and Solar Energy Laboratory 9
Lab-Scale System
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SDSU Combustion and Solar Energy Laboratory 10
Single Particle Absorption Efficiency vs. Wavelength
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SDSU Combustion and Solar Energy Laboratory 11
Scanning Electron Micrograph (SEM) of Particles on a Filter
5 µm
Use two techniques to measure the size: • Angular Light
Scattering
• Count particles on the filter using ImageJ
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SDSU Combustion and Solar Energy Laboratory 12
Comparing DPS data to SEMs (DPS = Diesel Particle Scatterometer using angular light scattering)
• DPS data matches SEM analysis to within a few nanometers.
Nitrogen Flow Rate = 600 SCCM Temperature = 1000 degrees C
Natural Gas Flow Rate (SCCM) SEM Size (nm) DPS Size (nm) Difference (nm)
20 178 181 3
20 177 175 2
40 275 250 15
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SDSU Combustion and Solar Energy Laboratory 13 13
Window and Mount Design
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SDSU Combustion and Solar Energy Laboratory 14 14
Window Optical Analysis
• Start with optical constants (n and k) of quartz. • Use Generalized Fresnel Equations to determine
transmission, reflection, and absorption • MIRVAL calculates incident radiation from
heliostat field (modified for spectral calculations) • In-house code traces rays interacting with the
window and entering receiver.
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SDSU Combustion and Solar Energy Laboratory 15
Window Solar Absorption Maps
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SDSU Combustion and Solar Energy Laboratory 16 16
84
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90
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0 10 20 30 40 50 60 70 80 90
Tra
nsm
issi
on %
Cap Angle
Transmission for Ellipsoidal Window (HSQ 300) Transmission for Ellipsoidal Window (HOQ 310)
Transmission Transmission for Ellipsoidal Window
Transmission (HSQ 300) Transmission HOQ 310
Window Transmission vs. Cap Angle
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SDSU Combustion and Solar Energy Laboratory 17 17
Weibull Failure Probability
Stress Intensity Factor (Ki)
Apply Dynamic Fatigue
Determine Design Strength
Trade Study of Window Mount
FEA Structural Thermal
Implement
Verify Thru Small Scale Test
Detailed Design (Drawings, Assy Procedures, Etc.)
Window Mechanical Design Process R
elia
bilit
y Eng. D
esign
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SDSU Combustion and Solar Energy Laboratory 18
Hemispherical Cap window and Mount
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SDSU Combustion and Solar Energy Laboratory 19
Failure Probability • Based on Weibull Probabilistic Failure (Static Strength), characteristic
strength = 38MPa, m=10 • At .01% take FS of 2, arrive at 𝝈acceptable~7.5MPa
0.10%
0.01% 19
𝑃𝑓 = 1.0 − 𝑒 − 𝜎𝜎𝑜
𝑚
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SDSU Combustion and Solar Energy Laboratory 20
Principle Stresses in Spherical Cap
-50.00
-40.00
-30.00
-20.00
-10.00
0.00
10.00
20.00
0 10 20 30 40 50 60 70St
ress
es,M
pa
Φ
Bending Stresses in a Sphere with Fixed Edges P=5Bar,
φ=60o, aperture=1.5m
Sigma 1
Sigma 2
Sigma 3
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SDSU Combustion and Solar Energy Laboratory 21 21
Receiver Fluid Dynamic and
Radiation Modeling
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SDSU Combustion and Solar Energy Laboratory
Schematic of 2-D Receiver Model
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Concentrated Solar
Radiation
Air-Particle Inlet
Air-Particle Inlet
Flow Direction
Hot Air Outlet
0.6m
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SDSU Combustion and Solar Energy Laboratory 23
Model Program Overview
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Temperature (r,z) FLUENT -Energy -Momentum -Mass
MCRT (FORTRAN)
-Radiation
• MCRT solves radiative transfer equation
• Fluent solves energy, momentum, & mass equations
• Temperature data is passed to FORTRAN code
• Volumetric source terms (−𝛻 ∙ 𝑞𝑟) are passed to FLUENT
• Process iterates until convergence
Source Terms (r, z) (−𝛻 ∙ 𝑞𝑟)
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SDSU Combustion and Solar Energy Laboratory 24
Results - Mass-Flow Rate Variation • 4kg/s • 5 MW • 1547 K outlet • 86.3% receiver
efficiency
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• 6kg/s • 5 MW • 1325 K outlet • 90.4% receiver
efficiency
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SDSU Combustion and Solar Energy Laboratory 25
Results - Mass-Flow Rate Variation
• Input power is Gaussian-distributed 5 MW for all five cases
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80%
81%
82%
83%
84%
85%
86%
87%
88%
89%
90%
91%
1300
1350
1400
1450
1500
1550
1600
3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0
Rec
eive
r E
ffic
ienc
y
Out
let T
empe
ratu
re [K
]
Gas Mass Flow Rate [kg/s]
Gas Outlet Temperature vs. Mass Flow Rate
TemperatureEfficiency
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Capabilities of the newest Software
• Three-Dimensional Model.
• Arbitrary axisymmetric geometries.
• Solar irradiation from heliostat field • Window included in the MCRT model.
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SDSU Combustion and Solar Energy Laboratory 27
3-D Model Results
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SIMULATION CONDITIONS: Time: 12pm on March 21st Mass flow: 4kg/s RESULTS: Outlet temperature: 1450 K Efficiency: 90% Pressure drop: 91 Pa Maximum wall temperature: 1450 K
Temperature field (K)
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SDSU Combustion and Solar Energy Laboratory 28 28
Challenges to Date • Particle Generator does not work well at higher pressures.
– Undergoing redesign with Senior Project Team
• Exact optical constants of glass not available at all wavelengths.
– Did bracketing calculations. Evaluating measurement of constants.
• 3-D calculations take a long time (days)
– Considering GPU, supercomputer, and cluster options.
• Staffing may not match tasks exactly
– Working to strengths available
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SDSU Combustion and Solar Energy Laboratory 29 29
Future Work in Phase 1
• Use three-dimensional coupled model to perform preliminary receiver design
• Complete window thermal and mechanical design (includes seal)
• Redesign particle generator and perform component lab-scale testing at 5 atm.
• Design full-scale particle generator.
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SDSU Combustion and Solar Energy Laboratory 30
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Acknowledgements Google Re<C Program California Energy Commission DOE Sunshot Program Award # DE-EE0005800 Students in the SDSU Combustion and Solar Energy Laboratory: Adam Crocker Pablo Fernandez del Campo Lee Frederickson Milorad Dordevich Ahmet Murat Mecit Trent Martin E-Fann Saung Kyle Kitzmiller Alex Whitmore Ara Hovhannisian
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SDSU Combustion and Solar Energy Laboratory 31
Thank you for your Attention!