Shott Receiver Glass to Metal Seal

SCHOTT BUSINESS UNIT SOLAR

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Solar Thermal Power Plants


2

Kramer Junction (Ca):

- Output 150 MWel

- 900.000 m² aperture area

- 45.000 receiver


3

Parabolic Trough Power Plant- schema

A solar thermal power plant with a

capacity of 50 MWel consist of a mirror

area of approx. 360.000 m² and 15.000

Receivern (total length 60 km)

SCHEMA


4

Collector field and turbine at

Shuman in Meadi close to Cairo (1914)

5 loops à 62 m, steam turbine 120 PS

(technisches Archiv des Deutschen Museums)

Parabolic trough power plants are not new .......

Geschichte


5

There are different designs of parabolic troughs...

Parabolrinne mit Blechspiegel, IST

Fix mirror, tracking receiver (General

Dynamics)

2-axis tracking troughs

Ansaldo, Italy

Bauformen

2-axis tracking troughs

MAN, Germany


6

Receiver for Eurotrough

Technical data:length: ca. 100 m

Aperture area: 5,8 m

Concentration factor: approx.. 80 Eurotrough


7

Solar Thermal Power Plants – producing electricity over 20 years

Power Plants since 1984


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Cost development of SEGS plants


9

Energy Pricing Policy

•Energy prices and Tax Credits

collapsed

•SO#4 Contract (removed risk

of energy prices for 10 years)

suspended

•Investors return rising from

14% to 17%

•Short construction period

forced causing additional costs


10

The receiver is the core component

low thermal losses ( vacuum)

high solar absorption ( high transmission of glass cover )

minimal shading

Übersicht SH


11

SCHOTT PTR70 ReceiverReceicer designed according to the existing troughs (LS3, Euro trough, US-trough)

Übersicht SH

Characteristics of PTR 70 Receiver:Glass-to- metall –sealing

selective absorber coating

Antireflective coating ( high transmission)

bellow to compansate thermal expansion

Vacuum between steel and glass tube

diameter 70mm

length 4 m


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Known Problems

breakage of glass-to metal-seal

(2 - 2.5 %/a)

shading of radiation shields

(> 7% of length)

degradation of coatings

0%

1%

2%

3%

4%

5%

6%

7%

8%

9%

10%

1989 1991 1993 1995 1997 1999 2001 2003

Rec

eive

r G

lass

Fai

lure

s (%

of Fi

eld)

Other

Glass/Metal Seal Failure

Bowing

HR Related Failure

Unknown

Receiver failures at KJC, source: Hank Price, NREL

bellow shields

florescent absorber tubes


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New Receiver DesignBellows are compressed during operation which leads to further reduction of shading

Glass-to-metal-seal is protected against radiation

Active length of Receiver is more than 96%

glass

absorber

vacuum

glass-to-metal-seal glass

absorber

vacuum

glass

absorber

vacuum

glass-to-metal-seal


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New Glass-to-Metal Seal Improves Strength Properties

Breakage of glass-to-metal sealing (Housekeeper) is main

cause for damages of receivers in existing power plants

New approach with adapted CTE yields a sealing with low stress

Only one glass type necessary

Automated production process

Stainless Steel

CTE=16*10-6/K

Glas

CTE=5.5*10-6/K

Housekeeper - Method SCHOTT Approach

Glas

CTE=3.3*10-6/K

Metal

CTE=5.5*10-6/K


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Reliability Solar Receiver

silicon oil

glas tube

vacuum

absorption layer

steel tube

permeation barrier

radiation gain

radiation loss

gas convection loss ?

• sufficient H2 getter• optimize hydrogen barrier of steel tube

• Hydrogen permeation from cracked heat transfer fluid (oil) to evacuated tube is limiting factor for lifetime


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G/M-Seal - Thermal shock test

Intention: A thermal shock produces stress in the glass-to-metal seal

pieces with failures are detected and sorted out easily

Test conditions: sudden thermal shock from 225°C -> 25°C

The thermal shock resistance of the glass itself is about T= 220K.

Result: The glass-to metal seal is nearly as durable as the glass itself

0

50

100

150

200

250 thermal shockresistance GMV

thermal shockresistenceglass only


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Field Test with New Glass-to-Metal-Seal

100 Receivers operating in KJC

since October 03

No breakage


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Performance Test in Eurotrough-Collector(PSA, June 2004)

18 Receivers installed in June 2004

2 % increase in performance compared to UVAC


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Field Test with Pre-Production Prototyps192 Receivers installed in test loop at KJC in July and October 2004

no breakage

2.4% increase in preformance compared to previously installed tubes of competitor


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Receivers for Molten Salt TechnologySCHOTT tubes installed in 100m test loop at ENEA/Italy

goal: 500-550°C operating temperature


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Pilot Production since 2004

2004:

tubes for field test

1 MW power plant in Arizona

tubes for test loop ENEA (Italy)

2005:

spare parts for KJC/FPLE: 670 tubes

tubes for test loop ENEA

tubes for other customers

Pilot ProductionPilot Production

Evacuation

Welding

Glass-to-metalseal


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New Production Line

Beispiel: Prozess „Hüllrohr“

located in Germany

in operation in summer 2006

highly automated

capacity: 50.000 tubes per year

First supply for 64MW Nevada power plant


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Parabolic technology has a head start in the field of solar power...

Dish-Stirling-Systems - stand-alone system with up to 25 kWe

- marketable

- competing with photovoltaics

Solar Tower Technology - 0,5-12 MWe-systems in R&D

- no commercial operation

Fresnel Line Focus - feasibility study

(SolarMundo) - only 50-70% of „parabolic tube efficiency“

Competing Solar Technologies


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Receiver – Comparison of costs depending on grid- and local situation

10-45 %

(depending upon

technology)

0,05-0,3 €/kWhBio mass

45-55%ca. 0,03 €/kWhFossil Energy

10-16%

(with 100-180°C)

0,07-0,15 €/kWh (8.000 h/a)Geo Thermal

(Power Plant)

75-93%0,03-0,08 €/kWh (1-5 MW)

0,1-0,2 €/kWh ( 1 MW)

Hydro Power

0,06-0,13 €/kWh (on-shore)

Ca. 0,07 €/kWh (3MW, off-shore)

0,09-0,16 €/kWh

0,4-0,7 €/kWh (on-grid)

Ca. 1,0 €/kWh (solar home system)

Both indication for Central Europe

Costs per kWh

50%Wind Power

15-16%Solar Thermal Power Plants

15%Photovoltaics

EfficiencyTechnology


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Reasons for future power plantsRenewable Energy Portfolio Standards (RPS)

Übersicht SH


26

New Spanish Feed-In Law: RD 436/2004

Grants same tariffs for PV and CSP

from 100kW to 50MW

Cost covering with up to 0.21 €/kWh

Annual adaptation to

electricity price escalation

After implementation of first 200MW

tariff will be revised for subsequent plants

to achieve cost reduction


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ACS+SMAG2 x 50 MW AndaSol

SMAG 50 MWExtremaSol 1c

HC2 x 50 MW PT

Iberdrola7 x 50 MW PT

EHN+SolarGenix15 MW PT

SENERSolar Tres 15MW

Tower

Abengoa10MW Tower

2x20MW Tower50 MW PT

Spain: Within 12 months after publication of the feed-in law, more than a dozen projects started development


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AndaSol: Key data

Technology: „Solar-only“ Parabolic Trough

Power Plant

Installed Capacity:

49.9 MWel

Storage: Molten salt storage for 7.5 full load

hours

Project Site: Plateau of Guadix, Province

Granada

Net electricity production:

approx. 180 Mio. kWh/a


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First Parabolic Trough Project in Spain (AndaSol1) is moving forward, but one year in delay…

Reasons for delay :

project with cost > 250 Mio €

tedious process for bank financing

new technology

various permit procedures

new players and new partnerships to be established


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Existing SEGS354 MW

SolarGenix50 MW PT

SolarGenix1 MW PT

GEF Mexico25 MW PT

NAFTA: Projects in USA and MexicoDriving Force in USA: Renewable Energy Portfolio (RPS) in south-western states

1000 MW Initiative of Western Governer Association

Mexico: GEF Project

Problems:

Up to now no feasible imple-

mentation strategy for RPS

High risk for IPPs, bankability

15 % of all electricity generated in Nevada be derived from new renewables by the year2013.5% of the RPS must be from solar energy projects.

RPS Nevada


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Nevada ProjectSize: 64 MW solar only

IPP concept, PPA with Nevada Power

Garanty from State of Nevada for PPA in Dec. 04 enabled bankability of project

Start in 2006

Boulder City, NV


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Africa and AsiaAfrica:

Morocco project (GEF) most promising.

Prequalification for bidders completed, award in 2005

GEF project in Egypt in progress, bidding process should start in 2005

Algeria: attractive „Feed in Law“ for solar combined cycle plants

Asia:

GEF project in India with

low probability due to political difficulties

Gas-solar electricity export to Europe


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Reasons for new projectsWorld Bank-Projects: 200 Mio USD

Übersicht SH


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excellent good suitable not suitable

Sou

rce

: S

ola

r M

illenn

ium

AG

, E

rlangen

Sites for CSP are in the Sun Belt

Other factors:

industrialized countries

environmental awareness

and political commitment

incentives


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Egypt

0

5

10

15

20

25

30

2000 2010 2020 2030 2040 2050

Year

Ele

ctr

icity C

ost o

f N

ew

Pla

nts

[c/k

Wh

]

Photovoltaics

Wind

Wave / Tidal

Biomass

Geothermal

Hydropower

CSP Plants

Oil / Gas

Coal

LEC New Plants c/kWh 2000 2010 2020 2030 2040 2050Wind 6.2 5.2 3.8 3.7 3.7 3.6Photovoltaics 31.9 14.7 7.4 5.8 4.6 4.2Geothermal 19.1 7.4 5.3 4.5 4.4 4.3Biomass 7.6 6.2 5.4 5.3 5.2 5.2CSP Plants 7.9 7.1 5.2 4.5 4.1 4.0Wave / Tidal 0.0 0.0 0.0 0.0 0.0 0.0Hydropower 2.9 3.0 3.1 3.1 3.2 3.3

Oil / Gas 5.4 5.8 6.2 6.7 7.2 7.8Coal 4.0 4.2 4.5 4.8 5.1 5.5

Electricity Cost of Power Technologies (Example)

by courtesy of:MED-CSPMED-CSP


36 Thank you very much !

Shott Receiver Glass to Metal Seal

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