Optical design and optimization of parabolic dish solar concentrator with a cavity hybrid receiver

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1 Optical design and optimization of parabolic dish solar concentrator with a cavity hybrid receiver R. Blázquez, J. Carballo, and M. Silva Citation: AIP Conference Proceedings 1734, (2016); View online: View Table of Contents: Published by the American Institute of Physics Articles you may be interested in Performance tests and efficiency analysis of Solar Invictus 53S A parabolic dish solar collector for direct steam generation AIP Conference Proceedings 1734, (2016); / Development of a higher-efficiency tubular cavity receiver for direct steam generation on a dish concentrator AIP Conference Proceedings 1734, (2016); / Combining ray tracing and CFD in the thermal analysis of a parabolic dish tubular cavity receiver AIP Conference Proceedings 1734, (2016); / Reducing the convective losses of cavity receivers AIP Conference Proceedings 1734, (2016); / A detailed radiation heat transfer study of a dish-stirling receiver: The impact of cavity wall radiation properties and cavity shapes AIP Conference Proceedings 1734, (2016); / Reduction of convective losses in solar cavity receivers AIP Conference Proceedings 1734, (2016); /

2 Optical Design and Optimization of Parabolic Dish Solar Concentrator with a Cavity Hybrid Receiver R. Blázquez 1, a), J. Carballo 1 and M. Silva 2 1 CTAER Solar Department. Paraje de los Retamares s/n, 04200, Tabernas, Almería (Spain) 2 Department of Energy Engineering, University of Seville, (Spain) a) Corresponding author: rosa.blazquez@ctaer.com Abstract. One of the main goals of the BIOSTIRLING-4SKA project, funded by the European Commission, is the development of a hybrid Dish-Stirling system based on a hybrid solar-gas receiver, which has been designed by the Swedish company Cleanergy. A ray tracing study, which is part of the design of this parabolic dish system, is presented in this paper. The study pursues the optimization of the concentrator and receiver cavity geometry according to the requirements of flux distribution on the receiver walls set by the designer of the hybrid receiver. The ray-tracing analysis has been performed with the open source software Tonatiuh, a ray-tracing tool specifically oriented to the modeling of solar concentrators. INTRODUCTION The solar receiver is a central component in point-focusing concentrated solar power (CSP) technologies. Cavity receivers are one kind of the most widely used indirect-irradiation receivers, particularly in parabolic dish Stirling systems [1]. In spite of the significant progress during the last years, the cavity receivers still work with relatively high flux peaks on the absorber surfaces as well as high temperature differences between the absorber surfaces and the working fluid [1]. Since the surface temperature has an impact on both the allowable working temperature and the long-term durability of the material, it greatly limits the performance of the cavity receivers. Hence, a relatively homogeneous temperature distribution on the absorber surface of the cavity receiver is one of the most important design objectives. In previous works, most of the attention has been focused on the cavity geometrical optimization to achieve a relatively uniform light flux distribution [2]. This study proposes an attempt to optimize the shape of a cavity receiver and concentrator based on fulfilling the requirements of flux distribution on the receiver walls set by the designer of the hybrid receiver. SYSTEM MODEL IN TONATIUH The Raytracing Code Tonatiuh Tonatiuh is an open source program for the optical-energetic simulation of solar concentrating systems. It is being developed by CENER. Combining ray tracing techniques with the Monte Carlo method, it is able to simulate the optical behavior of a large variety of systems. Written in C++, it is easy to use, maintain, and extend [3, 4]. Optical System Model The present study considers a system composed of a parabolic dish concentrator with a cavity hybrid receiver placed at its focus. The analysis consists in an iterative process of simulations in order to optimize both the SolarPACES 2015 AIP Conf. Proc. 1734, ; doi: / Published by AIP Publishing /$

3 concentrator and receiver cavity geometry taking into account some optical requirements. The main requirements assumed for the optical design are: Low spillage; Relatively homogeneous flux on the receiver walls with flux peaks below 1300 kw/m 2, with higher flux areas placed closer to the cavity aperture and negligible or very low flux on the receiver bottom; The heat impinging the receiver walls is expected to be 40 kw at least; Concentrator optical parameters: o rim angle less than 45º at all points of the mirror aperture; o o 95.5% of reflectivity; concentrator slope error due to non-ideal orientation of the reflective surface of 1.7 mrad and 0.5 mrad of specularity error. An optical system must be defined for Tonatiuh simulations. This optical system has three different components: the concentrator, the hybrid receiver and the sun. The final concentrator geometry will be the result of an iterative process of simulations in order to reach a flux distribution on the receiver walls which is compatible with the restrictions. The optical parameters of the concentrator were defined as specified in the optical design (they have been defined previously). The hybrid receiver, placed at the focus of the concentrator, consists in an annular cylindrical solar receiver part and a burn gas heat exchanger. The solar part (modeled in this work) is a cylindrical cavity formed by 48 pipes distributed in two rows (24 pipes in each row). The main parameters are: the aperture diameter, the cavity length and the cavity diameter. The combination of these parameters permits to generate a variety of geometries. The reflectivity of the absorber walls is not taken into account in this study. The receiver is placed into a cylindrical housing envelope whose radius and length are 100 mm larger than the overall length of the receiver geometry (aperture excluded); to account for insulation material space, as shown in Fig 2. The part closer to the aperture cavity is the almost non-illuminated part of the receiver (hereinafter referred to as non active cavity wall ). This part receives much lower number of rays from the concentrator due to geometrical reasons. The inclusion of this surface ensures the utilization of the entire receiver walls. The insulating characteristics of the material to use in it should be appropriate for the operating conditions of the receiver. The flux peaks reached in this part vary depending on its length. (a) (b) FIGURE 1. Concentrator parameters (a) and receiver cavity parameters (b). A: inner radius; B: intermediate radius; C: outer radius; D: cheese cake angle; E: cavity radius; F: aperture radius; G: cavity length

4 FIGURE 2. Receiver model in Tonatiuh. a) Without aperture plane; b) with aperture plane; c) view of the non active wall (black surface in the receiver) A Buie sunshape is implemented in order to model the incoming solar radiation [5]. The circumsolar ratio parameter quantifying the amount of radiation coming from outside the solar disc is set to 5% [6]. The design point DNI is 1000 W/m 2. GEOMETRICAL OPTIMIZATION ANALYSIS Once the most important requirements of the optical system are set, a parametrical analysis is needed in order to define the main geometrical data for the receiver cavity (length of the annular cavity, cavity diameter and cavity aperture diameter) and for the concentrator (outer and inner diameters, focal lengths, etc.). Other important parameter to take into account in this analysis is the spillage at the aperture of the receiver cavity. The analysis consists in an iterative process of simulations in order to optimize both the concentrator and receiver cavity geometry. The first goal of the works performed is to explore the possibility to comply the previous requirements with relatively simple concentrator geometries and to get a first estimate of the minimum length of the cavity. The possibility of designing a concentrator with several focal lengths to achieve a flux distribution on the cavity walls as homogeneous as possible is explored as well. Ray tracing simulations with different concentrator and cavity geometries are carried out. Once the cavity length and diameter are set, the concentrator is optimized for that cavity geometry and the spillage and flux distributions on the receiver walls are calculated. The last step consists in the optimization of the relative position of the cavity aperture and non active length in order to place the maximum peak of the distribution where is more suitable for the receiver requirements. Simulations The purpose of the preliminary analysis is to define a geometry which fulfills the requirements of rim angle and heat absorbed by the walls receiver to begin the simulation process. This first design did not take into account the heat losses inside the receiver. The first simulations were carried out for a single focal length concentrator without central opening, however the results showed that in order to get a more suitable flux distribution on the walls receiver an option would be to work with a double focal length concentrator with a central opening. In this way, a lower number of photons would reach the bottom of the receiver where the requirements of flux set a flux as low as possible

5 (a) (b) FIGURE 3. Photon distribution on the receiver walls. Differences between the distribution on the bottom of the receiver due to the simulation. Concentrator (a) without and (b) with central opening (a) FIGURE 4. (a) Flux distribution on the walls receiver. (a) For a single focal length; (b) for a double focal length The combination of all of these parameters (inner, intermediate and outer diameter, cheese cake angle, inner and outer focal length, rim angle and effective area) is able to create a wide variety of geometries which were taken into account in a comprehensive analysis in order to determine the best shape for the concentrator, considering the desired flux distribution on the receiver walls. At the same time, the cavity geometry was optimized. During this process geometrical parameters such as length and diameter of the cavity were studied to provide relevant information concerning the geometrical limits to the designer. Preliminary Results Regarding the cavity length (see Fig. 5), the preliminary results suggested that an 'active' length of 200 to 300 mm would be enough to absorb most of the directly incoming flux without a relevant increase of the flux on the bottom wall of the receiver. A maximum cavity depth of 400 mm was set by the receiver designer. It had to be considered that the areas of the cylinder walls closer to the receiver aperture have relatively low flux. This fact suggests the possibility of displacing the receiver a few centimeters away from the aperture and shortening the receiver length. Regarding the cavity diameter, a range between 0.16 and m was studied. The results showed a very light variation of the maximum flux on the bottom of the cavity. In the case of the cylinder walls the variation was greater (an increase of 100 kw/m 2 if the cavity diameter was reduced to 0.16 m). A more detailed study should have been carried out, however finally the designer set the value of diameter cavity in m. That is why this parameter would be considered fixed in future analysis. As shown in Fig 6. the maximum flux on the bottom of the cavity and on the cylinder walls (for different cavity lengths) is lower for a bifocal concentrator. (b)

6 FIGURE 5. Maximum flux on the receiver surfaces for different cavity lengths (4.8 m focal length; m diameter cavity; m diameter aperture; total optical error, TOE=2.24 mrad ) FIGURE 6. Comparison between the maximum flux on the cylinder walls and on the bottom of the cavity for two cases: (a) a single focal length of 4.8 m (yellow and green lines) and (b) 2 focal lengths of 4.8 and 4.7 m (red and blue lines) and different aperture diameters (0.12, 0.15 and 0.19 m). TOE=

7 FINAL OPTIMIZATION The final study focused on the fulfillment of the requirements in terms of rim angle and heat absorbed by the walls, but in this case the heat losses were taken into account in the analysis. The preliminary results are used as starting point. Cavity Receiver Analysis Considering the preliminary results, the designer sets the main geometrical parameters for the receiver cavity (diameter and length) within the range determined in the preliminary study. So, the parameters to be optimized in this study would be the aperture diameter and the non active section length (it is the almost non-illuminated part of the receiver). The inclusion of this surface ensures the utilization of the entire receiver walls. The receiver cavity is m depth and m in diameter. These values have been optimized along the different stages of the optical design process and set by the receiver designer in the last step of the process. It must be clarified that for these calculations, the inherent reflectivity of the receiver material (Inconel, 7%) has not been taken into account. As shown in the following figure, a parametrical study for the non active section length (0.066 m, 0.1 m and 0.12 m) was performed: FIGURE 7. Parametrical study for the non active section length (for 0.15 m in cavity aperture diameter) The flux on the bottom of the cavity decreases, as the non active length increases. However, there is a disadvantage: the flux on the non active wall is higher. It could reach up to 3.5 kw for a 0.12 m long non active section. Therefore, it is very important to take into account the technical properties of this insulation material before making a decision. The non active section should start at the focal length plane. The lowest spillage is achieved with a 190 mm diameter aperture cavity (see Table 1), however for this aperture diameter, the flux that reaches the bottom of the cavity is higher. For a 150 mm aperture diameter, the flux on the bottom of the cavity is lower and the spillage is around 5-8%

8 TABLE 1. Spillage for different cavity aperture diameters (insulation length of 0.1 m) Cavity aperture diameter (m) Spillage (%) Concentrator Analysis The preliminary analysis demonstrated that a reduction of the cavity length involved an increase of the maximum flux (kw/m 2 ) on the bottom of the cavity. On the other hand, the lowest spillage was achieved with a 190 mm aperture cavity. However, for this aperture diameter the flux that reached the bottom of the cavity was higher. Therefore, it was necessary to reach a balanced situation, where the flux on the cylinder walls was as high and homogenous as possible and the flux on the bottom of the cavity and spillage as low as possible. The design requirements for the hybrid receiver can be met with a monopole structure. The concentrator must have a section of 30º removed to permit the dish rotation, and an effective area of m 2. The concentrator, defined for a 44º rim angle, is oversized in order to take into account the radiative heat losses in the receiver (estimated in 10 kw approximately). It is a double focal length concentrator, 5.5 outer focal length and 5.4 m inner focal length, an inner diameter of 2.2 m and an outer diameter of 8.97 m. The main parameters must fulfill with the following equation: f 1 = (1) d ψ 4 tan rim 2 Where, f: focal length; d: parabola aperture diameter; ψ rrr : rim angle. EVALUATION Herein the main results for the system evaluation. These calculations have been realized for a non active section 0.1 m long and a cavity diameter aperture of 0.15 m, for which it is expected a 5% of spillage. The flux distribution on the cylinder walls complies with the requirements in terms of homogeneity (with a maximum peak flux of 41.5 kw/m 2 ); the peak is placed close to the aperture plane, according to the indications of the designer. Regarding to the receiver bottom, the flux obtained is as low as possible with a flux peak of kw/m 2. FIGURE 8. Flux distribution on the cylinder walls (Maximum flux on the cylinder walls, kw/m 2 )

9 TABLE 2. Main results obtained SURFACE POWER (kw) for 48 PIPES First row pipes Second row pipes Bottom wall 1.99 Cylinder walls 2.34 Non active section 3.22 TOTAL RECEIVER CAVITY SPILLAGE (%) 5.02 FIGURE 9. Flux distribution on the bottom wall (Maximum flux on the bottom wall, kw/m 2 ) CONCLUSIONS A ray tracing study of the BIOSTIRLING-4SKA parabolic dish system to optimize the concentrator and receiver cavity geometry according to the requirements of flux distribution on the receiver walls set by the designer of the hybrid receiver has been performed. The approach for the optimization has been iterative, carrying out ray-tracing simulations taking into account different geometrical parameters from the concentrator and receiver cavity, in order to identify the best range for different parameters. In the case of the receiver cavity, the designer made the last decision within the optimized range of values obtained previously. In an upcoming study, the present methodology should include the optical properties of the receiver walls and an economical optimization of the system

10 ACKNOWLEDGMENTS This work has been performed in the frame of the European Commission FP7 project BIOSTIRLING-4SKA. A cost effective and efficient approach for a new generation of solar dish-stirling plants based on storage and hybridization. Grant Agreement number: REFERENCES 1. W. Wang et al, An inverse design method for a cavity receiver used in solar dish Brayton system in Solar Energy, vol. 110 (2014), pp Y. Shuai et al, Radiation performance of dish solar concentrator/cavity receiver systems in Solar Energy, vol. 82, no. 1, (2008), pp M.J. Blanco et al, "Experimental validation of Tonatiuh using the Plataforma Solar de Almería secondary concentrator test campaign," 2010 International SolarPACES Conference, September 21-24, Perpignan, France. 4. M.J. Blanco et al. "Preliminary validation of Tonatiuh", 2009 International SolarPACES Conference, September 15-18, Berlin, Germany. 5. D. Buie, A. Monger, and C. Dey, Sunshape distributions for terrestrial solar simulations, in Solar Energy, vol. 74, no. 2, (2003), pp Wilbert S, Pitz-Paal R, Jaus J, Circumsolar radiation and beam irradiance measurements for focusing collectors in Cost Wire ES1002 Workshop on Remote Sensing Measurements for Renewable Energy, May 2012, Risoe, Denmark

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