Process development for the manufacturing of 99.94% pure copper

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 Electrostatic cleaning system for removal of sand from solar panels Hiroyuki Kawamoto * , Takuya Shibata Department of Applied Mechanics and Aerospace Engineering, Waseda University, 3-4-1, Okubo, Shinjuku, Tokyo 169-8555, Japan a r t i c l e i n f o  Article history: Received 20 May 2014 Received in revised form 16 September 2014 Accepted 27 October 2014 Available online 7 November 2014 Keywords: Cleaner Electrostat ic force Mega solar Sand Solar panel a b s t r a c t An improved cleaning system has been developed that uses electrostatic force to remove sand from the surface of solar panels. A single-phase high voltage is applied to parallel wire electrodes embedded in the cover glass plate of a solar panel. It has been demonstrated that more than 90% of the adhering sand is repelled from the surface of the slightly inclined panel after the cleaning operation. The performance of the system was further improved by imp roving the electrode conguration and introducing natural wind on the surface of the panel, even when the deposition of sand on the panel is extremely high. The power consumption of this system is virtually zero. This technology is expected to increase the effective ef - ciency of mega solar power plants constructed in deserts at low latitudes. © 2014 Elsevier B.V. All rights reserved. Introduction Solar power generation has grown drastically in recent years owing to increasing energy demand as well as the environmental and economical concerns associated with fossil fuel consumption [1], and many meg a sol ar po wer gener ati on pla nts are bei ng plann ed and cons truc ted, especial ly in dese rts at low altitudes , where the sun shines the brightest. However, sand storms occur freq uent ly in dese rts, and solar panels can beco me covered by stirred-up sand, causing a drastic decreas e in the output power of a photovoltaic power generation plant  [2e7]. Because sand on solar panels is not cleaned by rain over a long period of time in an arid region, the capacity utilization of the power plant is reduced if the panels are not cleaned frequently. To mitigate this prob lem, we have develo ped an auto matic cleani ng sys tem that does not need scarce cleani ng water but instead utilizes an alternating electrostatic force  [8] . Transporting particles using electrostatic force was  rst developed and imple- men ted by Mas uda et al.  [9], and man y inv est igatio ns of thi s technology have subsequently been conducted mainly as a toner supplier in electrophotography  [10e21] . Numerous other applica- tions for the electrostatic particle transport have been proposed, including control of bubbles in dielectric liquid  [22], removal of radioactive dust in a fusion reactor  [23], transport of liquid droplet [24], movement of blood cells in liquid [25], cla ssi cat ion of par ticle size [26], separation of seed by-products derived from agricultural processes  [27], and dust removal from solar panel s and solar hydrog en generators  [28]. Theo retic al and numerical studies of electrostatic particle transport have been conducted to clarify the mechanism and to support the development by many researchers [10,12,13,21,29]. Cleaning of lunar or Martian dust on solar panels for space exploration is another potential application of this tech- nology [30e33]. It has been demonstrated that more than 98% of the dust on a glass plate can be removed using electrostatic trav- eling waves generated by a four-phase rectangular voltage applied to a trans pare nt conv eyer consis ting of tran spar ent indiu m tin oxide (ITO) electrodes printed on a glass substrate  [33]. However, this technology is not suitable for use in commercial mega solar systems because it requires prohibitively expensive ITO ele ctrodes, theend s of theelectrodes must be thr ee- dimens ional to prevent the intersection of phases, and the power supply and in- terconnections required are relatively complicated and expensive for large-scale commercial plants. To mitigate these issues we have developed an improved system that consists of a sand-repelling glass pla te wit h par all el wir e ele ctr ode s emb edd ed in a cov er glass plate of a solar panel and a high-voltage power supply that gener ates a sin gle-ph ase rec tan gul ar vol tage. The alt ernati ng electrostatic eld generates a standing wave that causes a ipeop motion of the sand particles on the device, and when airborne, the sand partic les are trans port ed down war d by grav ity [8]. This report des cri bes a bas ic pr inc ipl e and per for mance of the system, and how the performance of the system was further improv ed by improving * Corresponding author. Tel./fax:  þ81 3 5286 3914. E-mail address:  kawa@wa seda.jp (H. Kawamoto). Contents lists available at  ScienceDirect  Journal of Electrostatics journal homepage:  www.elsevier.com/locate/elstat http://dx.doi.org/10.1016/j.elstat.2014.10.011 0304-3886/ © 2014 Elsevier B.V. All rights reserved.  Journal of Electrostatics 73 (201 5) 65e70

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Process development for manufacturing 99.94% pure copper via

Transcript of Process development for the manufacturing of 99.94% pure copper

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    technology have subsequently been conducted mainly as a tonersupplier in electrophotography [10e21]. Numerous other applica-tions for the electrostatic particle transport have been proposed,including control of bubbles in dielectric liquid [22], removal ofradioactive dust in a fusion reactor [23], transport of liquid droplet

    use in commercialvely expensive ITOee-dimensional toer supply and in-ted and expensiveese issues we have

    developed an improved system that consists of a sand-repellingglass plate with parallel wire electrodes embedded in a coverglass plate of a solar panel and a high-voltage power supply thatgenerates a single-phase rectangular voltage. The alternatingelectrostatic eld generates a standing wave that causes a ipeopmotion of the sand particles on the device, and when airborne, thesand particles are transported downward by gravity [8]. This reportdescribes a basic principle and performance of the system, and howthe performance of the systemwas further improved by improving

    * Corresponding author. Tel./fax: 81 3 5286 3914.

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    Journal of Electrostatics 73 (2015) 65e70E-mail address: [email protected] (H. Kawamoto).panels are not cleaned frequently.To mitigate this problem, we have developed an automatic

    cleaning system that does not need scarce cleaning water butinstead utilizes an alternating electrostatic force [8]. Transportingparticles using electrostatic force was rst developed and imple-mented by Masuda et al. [9], and many investigations of this

    However, this technology is not suitable formega solar systems because it requires prohibitielectrodes, the ends of the electrodes must be thrprevent the intersection of phases, and the powterconnections required are relatively complicafor large-scale commercial plants. To mitigate thpanels is not cleaned by rain over a long period of time in an aridregion, the capacity utilization of the power plant is reduced if the

    to a transparent conveyer consisting of transparent indium tinoxide (ITO) electrodes printed on a glass substrate [33].Introduction

    Solar power generation has growowing to increasing energy demandand economical concerns associated[1], and many mega solar powerplanned and constructed, especiallywhere the sun shines the brightest.frequently in deserts, and solar pastirred-up sand, causing a drastic decphotovoltaic power generation planthttp://dx.doi.org/10.1016/j.elstat.2014.10.0110304-3886/ 2014 Elsevier B.V. All rights reserved.stically in recent yearsll as the environmentalfossil fuel consumptiontion plants are beingserts at low altitudes,ver, sand storms occurn become covered byn the output power of a. Because sand on solar

    [24], movement of blood cells in liquid [25], classication of particlesize [26], separation of seed by-products derived from agriculturalprocesses [27], and dust removal from solar panels and solarhydrogen generators [28]. Theoretical and numerical studies ofelectrostatic particle transport have been conducted to clarify themechanism and to support the development by many researchers[10,12,13,21,29]. Cleaning of lunar or Martian dust on solar panelsfor space exploration is another potential application of this tech-nology [30e33]. It has been demonstrated that more than 98% ofthe dust on a glass plate can be removed using electrostatic trav-eling waves generated by a four-phase rectangular voltage appliedElectrostatic cleaning system for remov

    Hiroyuki Kawamoto*, Takuya ShibataDepartment of Applied Mechanics and Aerospace Engineering, Waseda University, 3-4-

    a r t i c l e i n f o

    Article history:Received 20 May 2014Received in revised form16 September 2014Accepted 27 October 2014Available online 7 November 2014

    Keywords:CleanerElectrostatic forceMega solar

    a b s t r a c t

    An improved cleaning systsurface of solar panels. A sicover glass plate of a solarrepelled from the surface othe systemwas further impon the surface of the panelconsumption of this systeciency of mega solar powe

    journal homepage: wwwof sand from solar panels

    ubo, Shinjuku, Tokyo 169-8555, Japan

    has been developed that uses electrostatic force to remove sand from the-phase high voltage is applied to parallel wire electrodes embedded in theel. It has been demonstrated that more than 90% of the adhering sand ise slightly inclined panel after the cleaning operation. The performance ofed by improving the electrode conguration and introducing natural winden when the deposition of sand on the panel is extremely high. The powervirtually zero. This technology is expected to increase the effective ef-ants constructed in deserts at low latitudes.

    2014 Elsevier B.V. All rights reserved.

    le at ScienceDirect

    ctrostatics

    sevier .com/locate/elstat

  • the electrode conguration and introducing natural wind on thesurface of the panel, evenwhen the deposition of sand on the panelis extremely high. The power consumption of this system isextremely low compared to the output power of the solar panel.This technology is expected to increase the effective efciency ofmega solar power generation plants constructed in deserts at lowlatitudes.

    Fig. 1 shows a schematic diagram of the system. If the system isoperated intermittently, the sand that has adhered to the coverglass of the solar panels is repelled. On the other hand, if the systemis operated continuously, the sand that approaches the cover glassis also repelled, and thus, the system can protect solar panelsagainst the adhesion of sand.

    Six types of sand, collected from desert areas around the world,were used for evaluation. Photographs of the sand particles areshown in Fig. 2, and these specications are summarized in Table 1.

    Fig. 1. Schematic diagram of the electrostatic cleaning system that uses a standingwave and gravity to remove sand from a solar panel.

    Table 1Specication of sand used for experiments.

    Item Unit A B C D E F

    Area Namib Japan Eurasia Oceania North America AfricaRelative

    permittivity4.2 2.2 3.2 4.3 4.0 5.3

    Elongation 0.72 0.53 0.76 0.83 0.81 0.71Angle of

    reposedeg 36 38 39 31 34 35

    Bulk density g/cm2 1.5 1.4 1.4 3.0 1.7 3.0

    H. Kawamoto, T. Shibata / Journal of Electrostatics 73 (2015) 65e7066System conguration

    Parallel wire electrodes embedded in the cover glass plate of thesolar panel was employed instead of ITO electrodes to reduce themanufacturing cost of the cleaning plate. Although the wire elec-trodes create a shadow and disturb the absorption of light, this isminimized by using a ne wire and a wide pitch conguration. Thediameter chosen for the wire electrodes was 0.3 mm, and the sizechosen for the pitch between the electrodes was 7 mm.

    To mitigate the complexity of the electrode wiring, powersupply, and interconnections, we adopted a standing wave insteadof a traveling wave [34e36]. That is, a single-phase rectangularvoltage was applied to parallel wire electrodes. Because a travelingwave is not generated by the application of a single-phase voltage,particles are not transported in one direction but rather repelledfrom the plate, and when airborne the sand particles are trans-ported downward by gravity. We generated a single-phase rect-angular voltage by using a set of positive and negative ampliersswitched by semiconductor relays that were controlled by amicrocomputer. Because a high slew-rate is not required for thissystem, we employed conventional low-capacity onboard ampli-ers (HUR30-6, Matsusada Precision, Tokyo).Fig. 2. Six types of sand uSand A was commonly used in the experiments unless otherwisespecied.

    Results and discussion

    Effect of plate inclination

    We manufactured a small device for use in the basic investiga-tion of the system. The dimensions of the substrate glass plate were100 100 3 mm. After 0.3-mm-diameter copper wires werearranged on the plate, a thin glass plate, 0.1 mm in thickness, wasadhered using transparent adhesive to make the surface smoothand to prevent insulation breakdown. Cross-sectional drawing ofthe device is shown in Fig. 3.

    The device was inclined, and sand was uniformly scattered onthe cover glass. A single-phase rectangular voltage was thenapplied to the parallel electrodes. The experimentwas conducted inan air-conditioned laboratory (20e25 C, 40e60 RH). As shown inFig. 4, the sand particles on the glass plate were repelled andtransported downward, as conrmed by direct observation ofparticle motions using a high-speed microscope camera (Fastcam-max 120 K model 1, Photoron, Tokyo) [21,33,35] and numericalsed for experiments.

  • calculations. The numerical calculations were on the basis of athree-dimensional hard-sphere model of the distinct element

    dition of the location where the solar panels are installed, the

    Fig. 3. Cross-sectional drawing of cleaning device.

    Fig. 5. Relationship between the inclination of the panel and the cleaning efciency(100-g/m2 surface loading, 0.86 kVp-p/mm, 1 Hz).

    H. Kawamoto, T. Shibata / Journal of Electrostatics 73 (2015) 65e70 67method (DEM). Details of the numerical method are reported in theliterature [21,33,35]. The electrostatic eld that determines theCoulomb force and the dielectrophoresis force applied to the sandparticles is calculated by a two-dimensional differential elementmethod in a cyclic domain. Although the dynamic motion of theparticles cannot be conveyed by still images as shown in Fig. 4, weconrmed the calculated and observed motions are in qualitativeagreement by comparing calculated and measured movies. Asdescribed later, the calculated performance agrees well with themeasured results, not only qualitatively but also quantitatively.

    Fig. 5 shows the cleaning efciency, i.e., the ratio between theweight of the sand fed onto the panel for 30 s and that after thecleaning operation of the system, versus the inclination of the plate.A cleaning experiment using a four-phase traveling wave was alsoconducted for comparison with single-phase cleaning. High per-formance was achieved even when the plate was only slightly in-clined, and the performance achieved by standing wave cleaningwas almost the same as that for traveling-wave cleaning when theinclination was greater than 20. This suggests that the systemwould even be effective at low latitudes at which solar panels areinstalled at low inclinations.

    Effects of pitch, applied voltage, and frequency

    Figs. 6 and 7 show the cleaning efciency versus the averagedelectrostatic eld strength determined by the applied voltagedivided by the pitch of the parallel electrodes and the frequency ofthe applied voltage, respectively. The solid curves in Figs. 6 and 7show the calculated results, which agree well with the measuredresults. We observed that producing a high eld strength achievedhigh performance; however, saturation occurred at a high value.Because the applied voltage is limited by the insulation breakdown,which is determined by the electrostatic eld, the system perfor-mance is almost independent of the electrode pitch at the thresholdFig. 4. Observed and calculated motions of dust particles during operation of thesystem (20 inclination, 100-g/m2 surface loading, 0.8 kVp-p/mm, 1 Hz).voltage. The threshold voltage was 9.8 kVp-p for the 10-mm-pitchdevice and 8.4 kVp-p for the 7-mm-pitch device.

    The maximum cleaning efciency was approximately 80% andwas achieved at a low frequency (less than 20 Hz). The cleaningperformance decreased at higher frequencies because particlemotion cannot follow the high-speed change of polarity[21,33,35,36]. However, low-frequency operation is not an issuebecause high-speed cleaning is not necessary for this system.

    Improved device

    The cleaning performance of the system was further improvedby adopting a V-shaped conguration for the wire electrodes, asshown in Fig. 8. An angle of 0 corresponds to the horizontal(original) conguration and an angle of 90 corresponds to thevertical conguration. It is clear that a V-shaped conguration(with angles between 45 and 75) for the electrodes improved thecleaning performance of the system. Careful observation of particlemotion made using the high-speed microscope camera and nu-merical calculations suggest that when the V-shaped congurationis used, some particles on the panel are repelled not only down-ward but also toward the lateral sides of the panel, and this phe-nomenon increases the cleaning efciency.

    Effect of surface loading of sand

    El-Shobokshy et al. [37] reported a mean deposition rate of sandon solar panels of 0.387 g/m2/day and a cumulative dust depositionin one month of approximately 10 g/m2 in Riyadh, Saudi Arabia(latitude 24.9). A much higher level of cumulative sand deposition,more than 400 g/m2 in one month, has been recorded at Kuwaitinternational airport [38]. Because the amount of sand depositionon the panel depends on the geographic and meteorological con-Fig. 6. Measured and calculated relationships between the applied voltage (electro-static eld) and cleaning efciency (20 inclination, 100-g/m2 surface loading, 1 Hz).

  • Fig. 12. The ordinates of the gures represent the power con-

    Fig. 7. Measured and calculated relationships between the frequency of the appliedvoltage and the cleaning efciency (20 inclination, 100-g/m2 surface loading,0.86 kVp-p/mm).

    Fig. 9. Calculated and measured relationships between the surface loading of sand andthe cleaning efciency (20 inclination, 0.86 kVp-p/mm, 1 Hz). The photograph showsaggregated sand on the panel after operation. The sand bridges adjacent electrodes and

    H. Kawamoto, T. Shibata / Journal of Electrostatics 73 (2015) 65e7068appropriate design criterion for sand deposition is not clear;however, it is reasonable to assume that a cleaning system must beable to remove more than 100 g/m2 of sand. Thus, we conductedexperiments and calculations to examine the performance of thecleaning system in cases of high loadings.

    Fig. 9 shows the effect of the surface loading of the sand. If anamount of sand greater than 300 g/m2 accumulated on the coverglass, the performance of the cleaning system declined owing to theaggregation of sand that bridges the adjacent electrodes as shownin the photograph in Fig. 9 [24]. However, high performance wasachieved when the surface loading was less than 300 g/m2, whichcorresponds to a sand layer thickness of approximately 0.3 mm.

    Although the performance of the cleaning systemwas worse forhigh surface loading conditions, it was experimentally conrmedthat the cleaning performance improved when a weak wind, withthe velocity greater than 1e2m/s, owed parallel to the plate in theinclined direction while the electrostatic cleaner was in operation.It is reported that high speed wind increases the deposition of dust[39]; however, stirring dust particles by the alternating electrostaticforce in the presence of wind enhances the cleaning.

    Effect of particle diameter

    To determine the sizes of the particles that can be cleaned bythis system, the sand particles were classied into ve groups ac-cording to their particle sizes, determined using sieves, and thecleaning experiment was conducted using each classied sand size.Fig. 10 shows the cleaning efciency versus the particle size. Par-ticles smaller than 25 mm in diameter and those larger than 300 mmin diameter were not cleaned efciently. The reasons for theproblems cleaning solar panels with small and large particles areFig. 8. Relationship between the angle of the V-shaped conguration of the wireelectrodes and the cleaning efciency (20 inclination, 100-g/m2 surface loading,0.86 kVp-p/mm, 1 Hz).different. For small particles, the electrostatic image force andadhesion force are relatively large compared to the Coulomb anddielectrophoretic driving forces. As a result, these particles adhereto the surface of the glass plate, which reduces the performance ofthe cleaning system [33]. For large particles, the large gravitationalforce hinders their bouncing and transport. Because ner particleshave a greater impact than coarser particles on the performance ofa solar panel [2], the cleaning system and its operational schememust be improved and optimized to enhance its performance incleaning small particles from solar panels.

    Effect of sand characteristics

    The six types of sand shown in Fig. 2 and summarized in Table 1were evaluated to conrm the effectiveness of the cleaning systemfor a range of sand characteristics. Fig.11 shows a comparison of thecleaning performance for the six different types of sand considered.Because many factors affect the performance of the cleaning sys-tem, it is difcult to clarify the reasons for the differences observedin the cleaning performance; however, the electrostatic cleaningsystemwas shown to be effective for a variety of sands. The systemand its operational scheme must be modied and optimized to tthe environmental conditions of the site where the mega solarplant is located.

    Power consumption

    The power consumption of the cleaning system is shown in

    locks on the plate.sumption (the input power to the device) per unit area of the

    Fig. 10. Cleaning efciencies for the classied particle sizes (100-g/m2 surface loading,20 inclination, 0.7 kVp-p/mm, 0.2 Hz).

  • cleaning plate assuming that the power consumption is propor-tional to the area of the plate. Because the transient current owsimmediately after the polarity change, the power consumption isproportional to the frequency. On the other hand, the power con-sumption is proportional to the square of the applied voltage ifinsulation breakdown does not occur [33]. Because the voltage limitfor insulation breakdown is 8.4 kVp-p for the 7-mm-pitch elec-trodes, and the optimal frequency is less than 10 Hz, the powerconsumption is only 0.2 W/m2 under operational conditions of7 kVp-p and 1 Hz. An important factor that inuences the energyconsumption is the operational time of the system, which depends

    Fig. 11. Cleaning efciencies for six types of sand (300-g/m2 surface loading, 20

    inclination, 0.86 kVp-p/mm, 0.2 Hz).

    H. Kawamoto, T. Shibata / Journal ofon the operational scheme, i.e., the number of operational cyclesand the operational period. For example, if the system is operatedfor 30 min a day, the energy consumption is only 0.1 Wh/m2 a day.The energy consumption of this system is extremely low comparedto the typical energy output by the solar cell.

    Demonstration

    The performance of this system was demonstrated using anactual large solar panel (560 mm 320 mm). The left-hand side ofFig. 12. Power consumption of the electrostatic cleaning system.Fig. 13 shows the sand accumulated on the panel, and the right-hand side shows the panel after the cleaning operation wasapplied to the left half of the solar panel for 3 min. Fig. 13 clearlyshows that the cleaning system is effective in removing accumu-lated sand from a solar panel. The output power of the panel withthe cleaner plate (without dust) was 97% compared to that withoutthe cleaner plate and dust. The power was reduced to 60%when thedust covered the plate, and it was recovered to 90% after operation.Another experiment was conducted to demonstrate that the sandthat approaches the cover glass is repelled if the system is operatedcontinuously. The performance of the cleaning system was betterunder continuous operation than under intermittent operation.Field experiment must be conducted under desert conditions todetermine the optimal operational scheme and to demonstrate theeffectiveness of the system for the specic conditions of interest.

    If the surface of the plate gets wet owing to rainfall or dewfall, orif a sandstorm and rainfall occur simultaneously, the accumulatedsand will adhere strongly to the plate owing to liquid bridgingforce. Cleaning experiments conducted under these conditionsconrmed that high performance was achieved after the platedried.

    Concluding remarks

    An improved cleaning system for removal of the sand that ac-cumulates on solar panels using electrostatic force has beendeveloped. This system is suitable for use in mega solar powerplants constructed in deserts at low latitudes because it is poten-tially inexpensive, requires virtually no power, and operates auto-matically without water and other consumables.

    Acknowledgment

    The author would like to express his gratitude to HarunaTakahashi and Shogo Shibata (Waseda University) who helped tocarry out the experiments. This work was supported by JSPSKAKENHI Grant Number 23360116.

    Fig. 13. Demonstration of the effectiveness of the electrostatic cleaning system on alarge solar panel (150-g/m2 surface loading, 20 inclination, 0.7 kVp-p/mm, 0.2 Hz).

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    Electrostatic cleaning system for removal of sand from solar panelsIntroductionSystem configurationResults and discussionEffect of plate inclinationEffects of pitch, applied voltage, and frequencyImproved deviceEffect of surface loading of sandEffect of particle diameterEffect of sand characteristicsPower consumptionDemonstration

    Concluding remarksAcknowledgmentReferences