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HITECO PROJECT

HITECO PROJECT. Rome 30 th October, Final Workshop HITECO. INDEX. HITECO PROJECT WHAT?; WHY?; WHO?; HOW?. PROJECT EVOLUTION AND RESULTS FUNCTIONALITY AND DESIGN BASIS DEFINITION DESIGN OF CRITICAL COMPONENTS DEFINITION OF SELECTIVE AND AR COATING

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HITECO PROJECT

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  1. HITECO PROJECT Rome 30th October, Final Workshop HITECO

  2. INDEX • HITECO PROJECT • WHAT?; WHY?; WHO?; HOW? • PROJECT EVOLUTION AND RESULTS • FUNCTIONALITY AND DESIGN BASIS DEFINITION • DESIGN OF CRITICAL COMPONENTS • DEFINITION OF SELECTIVE AND AR COATING • CONCEPTUAL DESIGN OF A NEW SUPORTING STRUCTURE • DESIGN AND CONSTRUCTION OF PRE-INDUSTRIAL COATING MACHINES • TESTING IN LABORATORY (OFF SUN) • VALIDATION PROCESS AND ANALYSIS OF ALTERNATIVES. FROZEN DESIGN • MANUFACTURING OF COMPONENTS • TESTING ON FIELD (ON SUN) • FUTURE STEPS AND COMMERCIALIZATION Rome 30th October, Final Workshop HITECO

  3. WHAT IS HITECO? HITECO is an European project funded under the 7th Framework that has as main target to develop and validate a new solar receiver for parabolic-trough technology HITECO project extends from November 2010 to November 2014 Budget: Total costs: 5.25 M€ EC contribution: 3.30 M€ HITECO aims develop and validate a new technology for medium and high temperature operation (400ºC and 600º c) with an optimal energy cost ratio. -OBJECTIVES- Rome 30th October, Final Workshop HITECO

  4. WHY TO DEVELOP HITECO PROJECT? • Because the future of CSP depends directly of: • To increase the general efficiency • To decrease the cost of the critical components • To improve the storage capability • Nowadays parabolic-trough technology needs an strong redesign to overcome the current crisis situation and to reduce the cost of the energy produced. • HITECO absorber tube is focused on this target. Rome 30th October, Final Workshop HITECO

  5. WHY TO DEVELOP HITECO PROJECT? THE MANUFACTURING PRICE WILL BE AROUND 30% MINOR COMPARED TO CURRENT ABSORBER TUBES PRICE THE AVAILABILITY OF THE PLANT IS ESTIMATED 3,5% BIGGER THAN CURRENT CONCEPTS, INCREASING THE ENERGY PRODUCTION THE OPEX WOULD BE REDUCED IN SOLAR FIELDS • Easier to manufacture • No hydrogen accumulation • Reduction of components and critical processes THE EFFICIENCY IS INCREASED COMPARED TO OTHER SOLAR COLLECTOR CONCEPTS • Tube works in controlled and less critical conditions RELIABILITY EFFICIENCY • Elimination of glass-to-metal union (GTMS) and H2 getters • Lower functional failure rate and more predictable • Greater effective length • No losses by misalignment with respect to theoretical focus BENEFITS OF HITECO ABSORBER TUBE Rome 30th October, Final Workshop HITECO

  6. WHO HAVE PARTICIPATED IN HITECO? • HITECO consortium brings together industrial partners and research organizations from: • Spain, Italy, Germany, Switzerland and the Czech Republic. • The consortium has been coordinated by Aries Ingeniería INDUSTRIAL PARTNERS RESEARCH ORGANIZATIONS Rome 30th October, Final Workshop HITECO

  7. HOW WAS BEING MANAGED HITECO PROJECT? WP1DESIGN AND REQUIREMENT ANALYSIS WP2 SELECTIVE AND ANTI-REFLEXIVE COATINGS WP3 VACUUM, CONNECTIONS AND EXPANSION CONTROL WP4 GLASS CLOUDING, SEALING AND INSULATION WP9 DISSEMINATION AND EXPLOITATION WP10PROJECT MANAGEMENT WP5 MODELING & CORRELATION WP6 SYSTEM INTEGRATION AND LAB VALIDATION WP7 PRE-INDUSTRIAL PROCESS DEVELOPMENT WP8 INTEGRATION IN PROTOTYPE AND PRE-INDUSTRIAL VALIDATION

  8. PROJECT LIFE CYCLE • R&D Tasks (WP 1,2,3,4,5) • Demo (WP 6,7,8) • Management (WP 9, 10)

  9. PROJECT EVOLUTION AND RESULTS • FUNCTIONALITY AND DESIGN BASIS DEFINITION • DESIGN OF CRITICAL COMPONENTS • DEFINITION OF SELECTIVE AND AR COATING • CONCEPTUAL DESIGN OF A NEW SUPORTING STRUCTURE • DESIGN AND CONSTRUCTION OF PRE-INDUSTRIAL COATING MACHINES • TESTING IN LABORATORY (OFF SUN) • VALIDATION PROCESS AND ANALYSIS OF ALTERNATIVES. FROZEN DESIGN • MANUFACTURING OF COMPONENTS • TESTING ON FIELD (ON SUN) • FUTURE STEPS AND COMMERCIALIZATION

  10. A - FUNCTIONALITY AND DESIGN BASIS DEFINITION • HITECO aimed to develop a solar absorber tube to work at medium and high temperatures, being the innovations of the concept focused on: • a) To increase the performance and to provide a more reliable product • b) To develop a simpler and cheaper device • c) To simplify the manufacturing process making more flexible the production • The new concept of absorber tube is under patent protection in China and in USA accepted and now pending of publication (In process in EU) 10

  11. A - FUNCTIONALITY AND DESIGN BASIS DEFINITION • Innovations involved in the new concept: • New geometrical approach. The length of the tube is the length of the semicolector. • Total independence between the internal tube (steel) and external tube (glass). • Dynamic vacuum in the interanular space done (in batch) during the operation on field. • Less severe working conditions, lower vacuum requirements and flexible in operation. • Continuous control of the state of the tube by monitoring its performance. 11

  12. B. DESIGN OF CRITICAL COMPONENTS The critical components that forms the absorber tube has been developed in close contact with the suppliers and partners of HITECO. These components are: It has meant to achieve a definition of the pieces from an initial stage of conceptual and basic engineer trough a validation stage up to detailed engineering. For that reason some approaches have been tested during the project overcoming, in each step, the problems found.

  13. B. DESIGN OF CRITICAL COMPONENTS (SEALING JOINTS)

  14. B. DESIGN OF CRITICAL COMPONENTS (CERAMIC PIECE)

  15. B. DESIGN OF CRITICAL COMPONENTS (GLASS TUBE)

  16. B. MECHANICAL DESIGN OF CRITICAL COMPONENTS (BELOWS AND VACCUM)

  17. C. DEFINITION OF SELECTIVE AND AR COATING • Definition of Selective layers searching the optimum optical results by simulation (CODE). • Three different selective coating research paths were defined: • SiO2-Mo • SiN-Ti/Mo • TiCON • Tasks done: • Deposition on flat laboratory stacks • Optical and mechanical characterization of samples • Pre definition of ageing tests (25 years at cycles between 650ºc and 100ºc) • It has been defined an Anti-Reflexive coating consisting in a transparent SiO2 film applied using organic precursors. The first optical measurements of transmittance was promising increasing the value from 92.2% to 96,5% • Now in the latest steps for definition of deposition process by sol-gel method

  18. D. CONCEPTUAL MECHANICAL DESIGN OF A NEW SUPORTING STRUCTURE • Adaptable to different apertures • Configurations based in tetrahedroms • 3D concept using steel bars • Unions of bars with aluminium nodes ENERGY INCREASED (DNI 900)

  19. E. DESIGN AND CONSTRUCTION OF PRE-INDUSTRIAL COATING MACHINES • The coating prototype PVD machine applies selective coatings in 4 meters steel tubes with enough homogeneity an repeatability. The prototype has 4 sputtering evaporators for 4 different materials and a reactive deposition controller being able to obtain high deposition rates in the transition zone.

  20. E. DESIGN AND CONSTRUCTION OF PRE-INDUSTRIAL COATING MACHINES • The coating machine applies AR coating in 6 meters glass tubes with enough homogeneity an repeatability. • In the deposition process is controlled the composition and temperature of the mixture to maintain the viscosity of the fluid. In addition one key factor is the extraction speed of the tube to control the thickness of the layer.

  21. F. TESTING IN LABORATORY (OFF SUN) • For validation purposes a prototype of 12 meters has been assembled. This device reproduce the conditions of heating that the tube has with a thermal fluid. • The objectives of the testing were the next: • Analysis of thermal losses • Out gassing process study • Tightness and leak control • Checking of mechanical performance

  22. G. TESTING IN LABORATORY (OFF SUN) • During testing it was checked the selective coating proposed in the initial stage. The result of the test was that the coating initially proposed didn´t support the normal working conditions • It was defined the expansion of tubes and the performance of bellows for the design of pieces in the on sun test.

  23. G. TESTING IN LABORATORY (OFF SUN) It was defined the operation for out gassing as well as the limitations of the sealing joints.

  24. G. TESTING IN LABORATORY (OFF SUN) The thermal losses related to the pressure and composition in the chamber has been analyzed placing the starting point for the analysis on – sun. The temperature of critical components in steady state conditions have been defined being a critical input for the final design of components to be used on field.

  25. G. VALIDATION PROCESS AND ANALYSIS OF ALTERNATIVES. FROZEN DESIGN • Before an after the off sun testing were carried out validation activities in order to freeze the design. • The check thermal losses on ceramic pieces • To confirm the tightness of bridles in several conditions • To check the permeation of components and its contribution in tightness • To analyze the ageing of the coatings in working conditions • To validate the behavior of bellows

  26. E. VALIDATION PROCESS AND ANALYSIS OF ALTERNATIVES. FROZEN DESIGN • During the process have appeared different limitations in the functioning of pieces that have been overcome successfully. The action was based in a proper initial analysis and a redesign of the components, change of materials and others.

  27. H. FRONZEN DESIGN AND MANUFACTURING OF COMPONENTS • On February 2014 started the manufacturing stage of the components that were going to be used in the validation test on field

  28. I. TESTING ON FIELD (ON SUN) --- MANUFACTURING OF TUBES --- The manufacturing process of tubes for the validation testing has been done in ENEA’s facilities without special requirements. The process has not needed complex operations like it happens in current concepts

  29. I. TESTING ON FIELD (ON SUN) --- ASSEMBLY PROCESS ---

  30. H. TESTING ON FIELD (ON SUN) --- START UP ---

  31. H. TESTING ON FIELD (ON SUN) - RESULT 1 - • The feasibility of produce high vacuum in a chamber placed on field and maintain it has been confirmed • It means that it was validated, between others, the use of bridles and polymeric sealing joints instead the typical GTMS

  32. H. TESTING ON FIELD (ON SUN) - RESULT 2 - • The out gassing can be produced in field (not necessary in a factory) having proper operative values

  33. H. TESTING ON FIELD (ON SUN) - RESULT 3 - • Mechanical behaviour • The tracking has not affected the general performance of the device • The ceramic pieces work without damage the steel tube • The bridles provide the same tightness in tracking or with the system static • The system has been used by now up 500ºC without any mechanical problem

  34. H. TESTING ON FIELD (ON SUN) - RESULT 4 - • Technical performance • The tests done (some pending) show values in line with the results obtained on the off-sun • The thermal losses have been analyzed in terms of participation of each mechanism. This is because the validation should be done in the terms included in the patent. • Dynamic vacuum at higher working pressures --- CONVECTION --- • Independence between internal and external tube --- CONDUCTION --- • Analyze the participation of the coating to SEPARATE its influence in the final result (The tube can use any selective coating available in the market). • The energy gain is under study being the factor involved in the tube the absorbance, the transmittance of glass and the effective area.

  35. H. TESTING ON FIELD (ON SUN) - RESULT 4 - • Technical performance - Thermal losses • CONVECTION- The extra thermal losses by the operative described in HITECO (to work between 1 and 10 mbar of Kr) means to admit around 46 W/m more at 400ºC. • (Experimental results) • CONDUCTION- The arms in HITECO are in contact with the bridle at around 100ºC, on the other hand, in current concepts the arm are in contact with the steel at around 400ºC. It means to have around 35 W/m less thermal losses. • (Modelling) • The tube has similar thermal losses to current concepts using a similar coating

  36. H. TESTING ON FIELD (ON SUN) - RESULT 4 - • The values obtained on field for the operation with different composition of gases confirm the proper functioning of the device • RADIATION- Considering that values of global thermal losses are around 320 W/m at 400ºC and the tube has 80mm instead the typical diameter 70mm (87.5% exposed area), it means a little degradation of coating by ageing increasing the emittance

  37. H. TESTING ON FIELD (ON SUN) - RESULT 4 - • Technical performance - Energy gain • The energy gain is under validation being by now insufficient the data for extract a conclusion. • In any case, considering that HITECO is a new concept available to use any coating (in glass and steel), the study can be easily reduced to evaluate the extra effective area . • Effective length in HITECO is around 2.4% bigger than current 4 meters concept at incidence angle=0. • In addition is important to consider the no losses for misalignment that is suffered by all the tubes working with a union between glass and steel.

  38. TESTING ON FIELD -- MURPHYS’s LAWS • TUESDAY 28th OCTOBER • (3 days ago) • The HTF management system brakes having a leak of Molten Salts. • The repair will need around 15 days up to return to the initial conditions.

  39. FUTURE STEPS • TO CONTINUE WITH TESTING • TO FIND AN INDUSTRIAL-FINANCIAL PARTNER FOR THE EXTRAPOLATION TO A MASS PRODUCTION SCALE

  40. THANK YOU FOR THE ATTENTION • For further information, please contact with: • Hugo Cachafeiro • Head of Innovation & Technology department • Energy Division • ARIES INGENIERÍA Y SISTEMAS, S.A. • Pº Castellana, 130 MADRID, SPAIN • 28046 • Tel. +34 915702737 • Tel. +34 699847740 • Mails: • hcachafeiro@aries.com.es • hcachafeiro@hitecoproject.com

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