Optimizing Solar Thermal Power Plants: Influences on Parabolic Mirror Shape Accuracy

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1 Optimizing Solar Thermal Power Plants: Influences on Parabolic Mirror Shape Accuracy Simon Schneider DLR (German Aerospace Center), Institute of Solar Research, Cologne ANSYS Conference & 33. CADFEM Users Meeting Bremen, 25th June 2015

2 DLR.de Chart 2 Parabolic Trough Solar Collector Concentrating Solar Power (CSP) 1.5 m 1.6 m 1.7 m 150 m Parabolic mirrors concentrate sunlight on absorber, where a heat transfer fluid is heated up to 400 C Collector tracks the sun over the day Heat is used in heat exchanger to directly generate electricity or stored in thermal storage Pioneers of technology: USA Spain Morocco South Africa

3 DLR.de Chart 3 Concentrating Solar Power Technology As at end of 2014 Parabolic Trough Linear Fresnel Dish-Stirling Solar Tower

4 Langrock / Solar Millenium AG DLR.de Chart 4 Andasol, Andalusia, Spain (since 2008) 150 MW el, mirrors, 1.5 mill m 2 solar field, 8 h Thermal Storage Andasol 2 Andasol 3 (already built) Andasol 1 Power Block & Storage System 1.3 km

5 Volker Quaschning DLR.de Chart 5 Parabolic Trough Solar Power Plant Modular configuration possible

6 DLR.de Chart 6 Cost Optimization for CSP plants Reduction of optical losses Loss in revenue (30 years): 17 mill Oil 2136 kwh per m 2 and year = 22 cm Loss in revenue (1 year): m 2 Andasol 150 MW annual efficiency 15 % 1 % loss: 4.8 GWh Electricity provided per year: 480 GWh feed-in tariff: 0.12 /kwh Revenue: 58 mill

7 DLR.de Chart 7 Parabolic Trough Solar Collector (Euro Trough) 1.5 m 1.7 m 1.6 m 150 m

8 DLR.de Chart 8 Total beam width RP3 mirror, standard quality 7% 7% 7% 7% 20% 20% 2% 6% 2% 6% 17% 17% 41% 41% 0% 0% Mirror Shape* Mirror Shape* Beam Spread Beam Spread Mirror Support* Mirror Support* Absorber Position Absorber Position Collector Torsion (Loads) Collector Torsion (Loads) Module Alignment Module Alignment Tracking Accuracy Tracking Accuracy Sun Sun σ in mrad a i σ² in mrad Mirror Shape* Beam Spread Mirror Support* Absorber Position 2 4 Collec tor Torsion (Loads) 1 1 Module Alignment 2 4 Tracking Accuracy 2 4 Sun Total Interc ept Fac tor 96.0% Combination of standard deviations to total beam width: σ total 2 = a i σ i 2 i

9 DLR.de Chart 9 Motivation & Aim of study Improving Mirror Shape Accuracy 80 mm Causes of mirror deformations Mechanical stress Dead load (depending on collector angle and type and stiffness of support structure) Reaction forces from mirror mounting elements Additional forces due to mounting inaccuracies 80 mm Possible outcome & Research goals Influences on mirror shape in collector are better understood Performance prediction (influence on annual yield), e.g. influence of deformation due to collector orientation when tracked over the day Production tolerances for optical components of solar collectors updated Structural improvements, e.g. six instead of four mirror mounting points

10 DLR.de Chart 10 Quality Parameter: Slope Deviation from sun n ideal n real Total Deformation in mm displacements scaled 150x

11 DLR.de Chart 11 Quality Parameter: Slope Deviation sdx (k) = n real,xz (k), nideal,xz (k) n k=1 SDx = sdx (k) 2 goal: < 2 mrad 0.1 a k A total

12 DLR.de Chart 12 Finite Element Model (Euro Trough Solar Collector) Outer Mirror (Float Glass) Inner Mirror (Float Glass) Side view of mirror mounting: Mirror (Float Glass) Mounting Pad (Steatit Ceramic with Silicone Adhesive) Bracket (Structural Steel) Cantilever Arm (Structural Steel) Cantilever arms (Structural Steel) Fixation Component-wise acceleration for simulation of dead load in different collector positions Rotational and translational joints as well as contact modification for simulation of mounting inaccuracies Limitations No screws or other connecting elements included yet Torque-Box not included yet

13 DLR.de Chart 13 Simulation: Assembly of mirror on support structure Reality 1. Pads glued to rear site of mirror in factory 2. Delivery to construction site 3. On-site assembly of mirrors on support structure Simulation in ANSYS 1. Deactivate contact between pad and bracket 2. Rotate pad until surfaces coplanar 3. Activate contact between pad and bracket 4. Perform displacement and rotation of bracket 5. Activate gravitational acceleration

14 DLR.de Chart 14 Automatic workflow for evaluating mirror shape Parameter Results Displacements Mirror shape Optical performance Postprocessing ANSYS Displacement of FE- Nodes for specified loads and boundary conditions MATLAB Processing of displacements to obtain values describing mirror shape accuracy SPRAY Ray tracing based on surface normal vectors MATLAB Visualisation of results and estimation of impact on annual yield ANSYS-Automation via Mechanical APDL faster evaluation (for simpler models or optimization processes) Workbench Journal supports workbench functionality

15 DLR.de Chart 15 Model validation (mirrors in laboratory setup) Measured Slope Deviation in mrad Modelled Validation of FE-Model already done for laboratory setup Internal material stress measured and subtracted from measured case Slope Deviation in mrad

16 Slope Deviation in mrad Displacements in mm DLR.de Chart 16 Influence of collector orientation (zenith position) displacements scaled 1000x +90 (horizon position) displacements scaled 1000x SDx (Outer) = 0,80 mrad SDx (Inner) = 1,60 mrad SDx (Outer) = 1,01 mrad SDx (Inner) = 0,85 mrad

17 DLR.de Chart 17 Influence of collector orientation on mirror shape

18 DLR.de Chart 18 Dead load + mounting inaccuracies Two brackets with deviations, collector in zenith position Inner Mirror Pad Rotation (mrad) Bracket Rotation (mrad) Bracket Position (mm) Outer Mirror

19 DLR.de Chart 19 Summary and Further Steps Slope Deviation (RP3 Inner Mirror) Dead load Dead load + 10 mrad angular deviation of Z-brackets Dead load + 10 mrad angular deviation of pads Dead load + 2 mm positional deviation of Z-brackets 1.65 mrad 1.70 mrad 1.91 mrad 3.20 mrad Different values for parameter result in different slope deviation Use optimization algorithm to find parameter that have lead to measured mirror shape Use of strain gauges to validate FE-Model Reality FEM

20 DLR.de Chart 20 Conclusion & Outlook Finite-Element-Analysis with different loads and boundary conditions useful method for predicting mirror shape deformation Impact of loads on resulting slopes of the parabolic mirrors Focus quality affected; less energy on absorber Impact on electricity production & annual yield Performance prediction for solar power plant (Influence on annual yield) Deriving design criteria and tolerances for concentrating collectors optimizing mirror shape specifying tolerances for assembly increased competitiveness of CSP technology

21 Thank you for your attention The financial support for this work by the German Federal Ministry for Economic Affairs and Energy is gratefully acknowledged.

22 DLR.de Chart 22 References [1] Meiser, S.; Kleine-Büning, C.; Uhlig, R.; Lüpfert, E.; Schiricke, B.; Pitz-Paal, R. (2013), Finite Element Modeling of Parabolic Trough Mirror Shape in Different Mirror Angles, J. Sol. Energy Eng., 135(3): [2] Meiser, S.; Schneider, S.; Lüpfert, E.; Schiricke, B.; Pitz-Paal, R. (2015); Evaluation and assessment of gravity load on mirror shape of parabolic trough solar collectors, 7th International Conference on Applied Energy, Abu Dhabi, United Arab Emirates

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