Daniel S. Codd

Transmissive spectrum splitting multi-junction solar module for hybrid CPV/CSP system

A new scalable, modular hybrid solar power system is designed to generate electricity through two pathways, CPV and CSP, in order to better meet grid energy demands for reliable renewable energy. The key element, a transmissive, spectrum-splitting multi-junction solar module, is modeled and simulated to analyze its electrical, optical, and thermal properties. Optimized designs are proposed to deliver high efficiency visible light-to-electricity conversion while transmitting infrared light to a thermal receiver. Prospective challenges in the upcoming development and fabrication are discussed.

Concentrated solar power on demand demonstration: Construction and operation of a 25 kW prototype

Currently, the majority of concentrated solar power (CSP) plants built worldwide integrate thermal energy storage (TES) systems which enable dispatchable output and higher global plant efficiencies. TES systems are typically based on two tank molten salt technology which involves inherent drawbacks such as parasitic pumping losses and electric tracing of pipes, risk of solidification and high capital costs. The concept presented in this paper is based on a single tank where the concentrated sunlight is directly focused on the molten salt. Hot and cold volumes of salt (at 565 °C and 280 °C, respectively) are axially separated by an insulated divider plate which helps maintain the thermal gradient. The concept, based on existing technologies, seeks to avoid the listed drawbacks as well as reducing the final cost of the TES system. In order to demonstrate its feasibility, Masdar Institute (MI) and Massachusetts Institute of Technology are developing a 25 kW prototype to be tested in the Masdar Solar Platform...

Direct Absorption Volumetric Molten Salt Receiver With Integral Storage

A new design is presented for a concentrating solar power central receiver system with integrated thermal storage. Concentrated sunlight penetrates and is absorbed within a passive molten salt pool, also acting as a single-tank assisted thermocline storage system. The receiver has a relatively small aperture, open to the environment without requiring a transparent window to isolate the system, exhibiting low losses while achieving high temperatures needed for efficient power generation. The use of an insulated divider plate provides a physical and thermal barrier to separate the hot and cold salt layers within the receiver. The position of the divider plate is controlled throughout the day to enhance the natural thermocline which forms within the salt. As a result, continuous, high temperature heat extraction is possible even as the average temperature of the salt is declining. Experimental results are presented for an optically heated 5 L capacity sodium-potassium nitrate salt volumetric receiver equipped with a movable divider plate.Copyright

Seam Welding and Cooling-Control Heat-Treatment of Martensitic Stainless Steel

From a production standpoint, many high-strength welded (GTAW, GMAW, laser, etc.) assemblies require post-weld mechanical forming operations. Complications often arise when using Advanced High Strength Steels (AHSS), whose chemical composition may lend it to fully martensitic, extremely brittle as-welded microstructures. Martensitic Stainless Steels (MSS) are a particular class of AHSS susceptible to high fusion and heat-affected zone (HAZ) hardness after welding. The focus of this study is to provide a relatively straightforward way to improve the ductility of as-welded air-hardenable martensitic stainless steel joints without subjecting the weld to a separate costly and timeconsuming off-line pre-or-post weld heat treatment. The additional ductility afforded by such a method can greatly expand the design opportunities using commercially available martensitic stainless alloys, which are capable of strengths in excess of 1400 MPa after a final solution heat treatment.

Thermal characterization of concentrated solar absorbance using resistive heaters

Thermal management of concentrated photovoltaics (CPV) is necessary in order to optimize cell performance and prevent thermal damage. In order to evaluate the performance of cooling methods, physical simulations of cell heating are used to reproduce the thermal profile without the need of a high flux solar simulator or actual cells. Through using resistive heaters built into the same geometry as a CPV module, cooling system designs can be tested achieving similar power distributions as those predicted through multiphysics modeling. Further, the physical model allows for the testing of thermal and solar power limits and performance in a range of non-ideal condition.

CSPonD demonstrative project: Start-up process of a 25 kW prototype

The current concept of commercial concentrated solar power (CSP) plants, based on the concept of a solar field, receiver, storage and power block, experienced significant growth in the past decades. The power block is the most well know part of the plant, while solar field depends on the receiver technology. The dominant receiver technologies are parabolic troughs and central towers. Most thermal energy storage (TES) relies on two tanks of molten salts, one hot and one cold serviced by pumps and piping systems. In spite of the technical development level achieved by these systems, efficiency is limited, mainly caused by thermal losses in piping, parasitic losses due to electric tracing and pumping and receiver limitations. In order to mitigate the these issues, a new concept called Concentrated Solar Power on Demand (CSPonD), was developed, consisting of a direct absorption Solar Salt CSP receiver which simultaneously acts as TES tank. Currently, in the frame of the flagship collaborative project between the Masdar Institute (UAE) and the Massachusetts Institute of Technology (USA) a 25 kW demonstrative prototype is in its final building phase at the Masdar Institute Solar Platform. The present paper, explains the demonstration prototype based on the CSPonD concept, with emphasis on the planned start-up process for the facility.The current concept of commercial concentrated solar power (CSP) plants, based on the concept of a solar field, receiver, storage and power block, experienced significant growth in the past decades. The power block is the most well know part of the plant, while solar field depends on the receiver technology. The dominant receiver technologies are parabolic troughs and central towers. Most thermal energy storage (TES) relies on two tanks of molten salts, one hot and one cold serviced by pumps and piping systems. In spite of the technical development level achieved by these systems, efficiency is limited, mainly caused by thermal losses in piping, parasitic losses due to electric tracing and pumping and receiver limitations. In order to mitigate the these issues, a new concept called Concentrated Solar Power on Demand (CSPonD), was developed, consisting of a direct absorption Solar Salt CSP receiver which simultaneously acts as TES tank. Currently, in the frame of the flagship collaborative project between ...

Optical Design and Validation of an Infrared Transmissive Spectrum Splitting Concentrator Photovoltaic Module

A new modular, hybrid solar power system is designed to generate both electrical and thermal energy by utilizing the full solar spectrum. The key element, an infrared-transparent concentrator photovoltaic (CPV) module, acts as a spectrum splitter, dividing solar radiation into two parts. The ultraviolet and visible light (“in-band”) are converted to electricity with high efficiency in CPV cells, while the infrared light (“out-of-band”) is transmitted directly to a thermal receiver, where thermal power may be converted to electricity by a suitable heat engine or used directly for industrial process heat applications whenever needed. Here, we describe the optical design, modeling, fabrication, and performance validation of this novel spectrum splitting CPV module. A transfer matrix style approach, cumulative transmission model, is built to study the reflection, absorption, and transmission in each layer of the CPV module. To optimize the optical performance, different materials for module superstrate/substrate, encapsulant, cell substrate, and cooling fluids are compared in order to enhance the transmission of out-of-band light through the CPV module by minimizing absorption. Six antireflection coatings along with front and backside electrical contact grids are designed to maximize transmittance of in-band light to the cell and out-of-band light to the thermal receiver. The final design, currently being prototyped, predicts out-of-band light transmission to the thermal receiver of 74.1% (for the passively cooled version) and 65.3% (for the actively cooled version). When epitaxial liftoff technology is applied, the transmission will change to 80.8% (passively cooled) and 71.9% (actively cooled). Experimental prototypes show good agreement with modeled optical performance.

Experimental Investigation of Divider Plate Assisted Thermocline Storage

A new type of single-tank thermal energy storage (TES) with an actuated, loose-fitting insulated divider plate positioned between the hot and cold fluids is described, based on the CSPonD volumetric molten salt thermal receiver with integrated TES concept. A 240 L lab-scale assisted thermocline tank was fabricated and tested using water as the working fluid, connected to a 5 kW heat addition and extraction loop. The axial position of the divider plate was controlled to follow the thermocline interface as energy was added or removed under various charge-store-discharge profiles. For 6 hour storage cycles, the divider plate tank exhibited a round-trip storage efficiency of 0.53, compared to 0.46 for the baseline tank, a 14% improvement. Output temperatures remained within 90% of initial values for 89% of the divider plate tank volume, as compared to only 58% for the baseline case, representing a 53% improvement in usable storage capacity. Internal conduction losses were found to be less for the divider plate tank and correlated well with models (measured 83–93% values vs 86% internal loss prediction).Copyright