raising the lifetime of functional materials for

RAISELIFE Dissemination Workshop, Madrid, 17th of May 2017

Raising the Lifetime of Functional Materials for Concentrated Solar Power

17th of May 2017, Madrid

F. Sutter (DLR)


Agenda

Central questions will be discussed by the groups

Session leaders summarize outcomes of discussions

9:00 Greetings from José Manuel Pingarrón Carrazón, Vice-

Chancellor for Transfer of Knowledge and

Entrepreneurs

9:10 RAISELIFE project overview

09:30 Durability of solar reflectors for CSP

10:30 Coffee break

11:00 Absorber coating durability

12:00 Durability issues related to Molten Salt

13:00 Group picture

13:05 Lunch

14:00 Impact of degradation on plant performance and

economics

15:00 Coffee Break

15:30 Discussion session: Solar reflectors and Molten Salt

16:30 Discussion session: Absorbers and Impact of

degradation

17:30 Final session – summary

18:00 End

Presentations from consortium members and externals (will be uploaded on www.raiselife.eu)

http://www.raiselife.eu/


Workshop participants

71 participants in total

Consortium members (of which 22% are industry partners)

Industry (external)

R&D (external)

National Institute of Chemistry IK4-Tekniker International University of Rabat IMDEA Energy Institute Tecnalia Protermosolar GTER

Salzgitter Mannesmann COBRA EBL Valspar Rioglass Suntrace Abengoa Sandvik Sener


Project facts

Duration: 48 months Start date: 01/04/2016 End date: 31/03/2020

Budget: Total cost: 10.5 M€ EU contribution: 9.3 M€

Funded by: EU H2020 program, Call: NMP-16-2016 Nanotechnologies, Advanced Materials and Production

Main project goals:

• Durability testing newly developed functional materials for CSP (TRL4-6)

• Analysis of their failure modes and producing a second generation of life-time optimized materials

• Deriving performance prediction models of the RAISELIFE materials

• Computing the economical impact of material degradation

• Improvement of production process and O&M: automatic coating machine for absorber coatings, sensor development to monitor corrosion in molten salts, definition of a catalogue of best practices to reduce in-service degradation

2nd and final Dissemination Workshop will be held at the end of the project!


Reflectors 8 different back coatings

2 anti-soiling coatings

1 ultra-thin glass with

composite backing structure

Absorbers 4 absorber coatings

(up to 750ºC)

5 molten salt coatings

1 abrasion resistant AR

coating

2 selective absorber

coatings (up to 400ºC)

Secondary Reflector 2 silver reflectors

stable up to 400ºC

System simulation to derive economic impact of RAISELIFE materials


RAISELIFE consortium


Distribution of tasks


Glass Base coat Ag Cu

Silvered-glass reflectors

[Flabeg]

New in RAISELIFE:

• Cost optimized 2 layer systems (for

sites of low corrosivity)

• Multiple layer system (for sites of

extreme corrosivity)

• Lead free layer system


Ultra-thin glass (100 – 200 µm) Silver

layer

Reduced protective layer system Composite (ca. 2cm)

Ultra-thin glass mirrors

Glass

thickness

[mm]

ρs,h

[%]

0.1 95.9

0.2 96.0

2 95.2

4 94.8

5 94.3


Lifetime prediction testing

Methodology for mirror lifetime testing

Testing campaign at 11 sites:

- Spain (2)

- France (1)

- Israel (1)

- Morocco (5)

- Chile (2)




• Neutral Salt Spray (NSS) ISO 9227

• Copper-accelerated acetic acid salt

spray (CASS) ISO 9227

• Condensation ISO 6270-2

• UV and humidity test ISO 16474-3

• Thermal cycling/condensation (AENOR draft)

• Thermal cycling IEC 62108 (Test 10.6 TCA3)

• Damp Heat IEC 62108 (Test 10.7b)

• Sand erosion test

• …

• Combinations of the tests above




Microscopic comparison to determine if

accelerated aging test excites the same

mechanism as outdoors

Selecting the most appropriate test for each

mechanism separately!




Micropit densitiy of aluminum reflectors

Accelerated aging exposure time [h]

Outdoor exposure time [h]


Measuring of soiling

rates and cleaning

every 2 weeks

Anti-soiling coatings for solar reflectors

Hydrophobic anti-

soiling coating [Sarver et al]


Outdoor testing of anti-soiling coatings

• During the first 3 years of exposure anti-soiling

coatings show a clear benefit regarding dust

adhesion compared to non-coated samples

• 2 new anti-soiling coatings will be tested in

RAISELIFE

PSA, Almeria


TRACS measurement system installed in Almeria and Missour (MA)

Pyrheliometer facing the mirror samples

Rotating sample holder containing coated and non-coated reference

Pyrheliometer facing the sun

Anti-soiling coating characterization


Development of uncooled secondaries (up to 400ºC)

Thermal analysis

• Temperature field

Accelerated aging tests

• Environmental durability (climate chambers)

• Solar furnace tests under high flux

Improved reflectors

• Accelerated aging tests

• Solar furnace tests

Secondary reflectors


Absorber coatings (up to 750°C)

Hot oxidation

Failure of receiver coating during operation

Corrosion Flaking

4 new receiver coatings

Inorganic paint coating (Brightsource)

Aluminid coating (INTA) + Inorganic paint coating on top (Brightsource)

Solar selective PVD coating (Fraunhofer)

Multi-metallic diffusion coating applied with the powder pack cementation process (Dechema)

Inc617

T22

T91

VM12


• Distal II test facility, PSA • SAAF test facility, PROMES, Odeillo


• 100 cycles from 200 – 650°C (750°C for Inconel 617)

• Solar flux: 250 kW/m² • Max. heating/cooling rate: 8°C/min • 2 hours per cycle

• Testing at 650°C (750°C for Inconel 617)

• Higher flux (500kW/m²) and quick variation of the flux : 250kW/m²/s

• high thermal gradients of 25°C/s • 4 minutes per cycle


• Hydrophobic AR coatings (Contact angle >100°)


Taber Abrader

• AR coatings with improved abrasion resistance


• Selective absorber coating designed to operate in air

• Sol-gel coating applied with mobile device

• Absorptance αs = 95.5%

• Emittance ε = 13% (250°C)


0

10

20

30

40

50

60

70

80

90

100

250 500 750 1000 1250 1500 1750 2000 2250 2500

Hem

isp

he

ric

al re

fle

cta

nc

e

Wavelength (nm)


• New AR and selective absorber coating will be tested under accelerated aging in climate chambers and in-service in a long term test in Soltiguas facilities in Italy



Corrosion in molten salt • 3 aluminide coatings and 2 metallic diffusion coatings will be tested to potentially

reduce receiver cost

• Testing in the standard molten salt mixture (60wt.% NaNO3/40wt.% KNO3) and a cost optimized salt mixture

• Static and cyclic furnace tests

• Advanced corrosion tests (Slow strain rate testing to study stress corrosion cracking)


500 ºC 60wt.% NaNO3/40wt.% KNO3

Preliminary tests

P91

- 300 ppm Cl- / 300 ppm SO42-

- 500 ppm Cl- / 500 ppm SO42-

- 700 ppm Cl- / 700 ppm SO42-

Selected impurity levels

250 h

560 ºC P91

Ongoing tests

t = 0 h t = 1000 h

1500 ppm Cl- / 1500 ppm SO4

2-

133 ppm Cl- / 59.2 ppm SO4

2-

The effect of molten salt impurity


The cost of solar reflector degradation Example: 100 MW power plant, 40% annual capacity factor

Annual electricity production: 100 MW · 8760 h · 0.4 = 350,400 MWh

0.2% mirror degradation per year (linear decay) ≙ 350.4 MWh less production per year

49,056 US$ / year loss due to degradation (estimated feed-in tariff 0.14 US$/kWh)

~1 Mio. US$/ 20 years

[NREL]

RAISELIFE will focus on:

• Deriving service performance

estimations for RAISELIFE materials

• Definition of reference plants

• Take entire system, replacement, re-

coating, O&M, … into account to

develop more reliable cost predictions


Economic impact of degradation

Economic benefit of RAISELIFE materials

• Ray tracing simulation with

Raytrace3D (Fraunhofer ISE)

Thermal FEM simulation (DLR)

System simulation in ColSim CSP (F-ISE)


Thank you for your attention!

raising the lifetime of functional materials for

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