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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Design Basis Document / Owner’s Technical Specification for Nitrate Salt Systems in CSP Projects (Final Technical Report)

The number of commercial coal, gas, and nuclear projects built over the past 100 years number in the thousands. As such, there is a large database, available to a wide range of commercial engineering contractors, on proven designs. In essence, unsuccessful designs have, through generations of iterations, been identified and then deleted from further consideration. In contrast, the number of commercial parabolic trough projects using nitrate salt for the thermal storage media is perhaps 60. Further, the number of commercial central receiver projects using nitrate salt as the working fluid is on the order of 20, including estimates for China. Given the relative immaturity of salt technology, and commercial pressures to successfully bid new solar projects into a mature electricity market, solar projects often promise more than has been delivered. The Design Basis Document / Owner’s Technical Specification is a first step in the iteration process. The report describes the successful features of commercial projects, outlines a range equipment and system failures in projects that didn’t operate as intended, and provides a draft set of design changes intended to correct the known problems. The product of the study is 3 volumes of technical material; one volume is on parabolic trough technologies; a second is on central receiver technologies, and the third is on potential design changes to parabolic trough and central receiver projects. The 3 volumes, which total some 590 pages, can be found at https://www.solardynllc.com/csp-plant-technologies. One of the principal topics in the report is the use of functional or prescriptive specifications. Functional specifications describe what the equipment needs to do, consistent with the minimum legal requirements of the local jurisdictions. The details of how this is to be accomplished is developed by the engineering contractor. Prescriptive specifications, which are developed by the Owner, prescribe to the engineering contractor how the functional requirements are to be met. This arrangement ensures that the favorable experience from a previous project is repeated. One example is the design code for the hot salt tank in central receiver projects. The closest design basis is API Standard 650 Welded Steel Tanks for Oil Storage. However, the maximum design temperature in API 650 is 260 °C. As such, solar projects have typically adopted a hybrid Code approach, in which allowable material stresses are taken from ASME Section II Materials. Further, since the tanks experience daily changes in temperature and in (static) pressure, and since portions of the tank can operate at stresses beyond the elastic range, the low cycle fatigue life of the tank is conducted using the rules of Section VIII Division 2. However, in a recent study by NREL, the principal damage mechanism was identified as creep rather than fatigue. Further, design stresses permitted under Section VIII Division 2, corresponding to a fatigue life of 30 years, result in projected creep lifetimes of only 2 to 5 years. An alternate design approach, prescribed by the Owner, would be based on Code sections intended for high temperature service in the creep regime. A candidate is Section III Division 5. Granted, this is a nuclear code section, and it’s use would not likely be mandated by local jurisdictions. However, the effects of creep have been deemed to be of sufficient importance that one nuclear project developer, and one central receiver project developer, have stipulated in the tank design specification that the equipment be designed to the requirements of Section III Division 5.

14 SOLAR ENERGY↗
DOE OSTI2024

Wind Loading on CSP Collectors

The project significantly enhanced the community's understanding of the fundamental physics drivers underlying the wind-loading experienced by concentrating solar power (CSP) collector structures (i.e., parabolic troughs and heliostats) as well as their support structures. This project had two overarching objectives: (1) detailed measurements to characterize the prevailing wind conditions and resulting operational loads on collector structures, and (2) development and validation of a computationally efficient, high-fidelity modeling tool capable of predicting wind-loading in deep-array installations. Over three years, we conducted comprehensive at-scale field measurements of the atmospheric turbulent wind conditions, and the resulting wind loads on parabolic troughs and heliostats. Two at-scale measurement campaigns yielded first-of-its-kind, high-resolution, long-term datasets that are used to characterize the complex flow field and wind loading on parabolic-troughs and heliostats in operational power plants. The high-resolution measurements collected during these campaigns were used to validate the high-fidelity computational models developed at NREL. These open-source computationally efficient models were shown to be accurate in predicting wind-driven loads on collectors without the need for a large supercomputer.

14 SOLAR ENERGY↗
DOE OSTI2024

Studying Wind Loading on CSP Collectors to Improve Performance and Reliability

Electricity generation through Concentrating Solar-thermal Power (CSP) adds the advantage of thermal energy storage and heat production. CSP collector costs constitute nearly one-third of total plant costs. Managing wind loading, especially dynamic wind loading caused by the turbulent wind flow, is a significant design challenge. Traditional collector designs rely on wind tunnel experiments and numerical simulations, which do not fully capture dynamic effects. Here, we provide an overview of NREL's activities on wind loading on CSP collectors, aiming to improve their reliability and cost-efficiency. We present insights from field measurements at operational parabolic trough and power-tower CSP plants. Over two years, we measured turbulent wind fields and resulting structural loads in a parabolic trough plant, revealing wind, turbulence, and collector field interactions. Similar measurements are ongoing at the Crescent Dunes heliostat field. These campaigns show how atmospheric turbulence, wind direction, and collector orientation affect dynamic wind loading. Upwind collector structures can generate turbulent structures, causing fluctuating loads at downstream collectors, impacting fatigue lifetime and optical efficiency. Preliminary results indicate that interior collectors experience higher turning moments than those at the edges, suggesting higher drive wear. At Crescent Dunes, we use instrumented heliostats at the field's edge and interior to study the translation of turbulent wind to dynamic structural loads. The campaign is still ongoing, and we will present first findings. Another focus of our work is tying the experimental wind loading findings to optical performance of the collectors, using simulation tools. For example, we derive torsional errors of the parabolic troughs - the angular offset from the sun position along a collector row. This error is impacted by wind-induced mirror deformations. Future work will focus on continuing the measurement efforts and combining them with computational fluid dynamic simulations. By providing detailed field measurements and validated models, our efforts aim to enhance understanding of wind loading on CSP collectors, improving their structural integrity and optical performance.

CSP↗
DOE OSTI2018

Experimental Study on Performance Enhancement of Evacuated Tube by Constant Heat Flux Mode

The evacuated tube collector with U shape copper absorber tube is considered for the analysis. The experimental investigation is conducted on parabolic trough collector with U shape tube as absorber tube. The effect of the sudden fluctuations in the solar radiation on the performance of the collector is reduced by means of evacuated tube collector filled with thermic fluids. The analysis is performed with different thermic fluids such as dowtherm, therminol66, glycol water and ethylene glycol, are filled in the annular space between inner glass tube and U shape copper absorber tube. The experimentation is carried out at various mass flow rates from 20 to 100 LPH with the step-up flow rate of 20 LPH. A comparative study is carried out on various parameters such as effect of mass flow rate over instantaneous efficiency, useful heat gain and work input, etc. The characteristic curve of cylindrical parabolic trough collector (PTC) is also discussed. Experimental results show that, ethylene glycol gives better efficiency over mass flow rate and therminol66 gives best power heat ratio. Heat transfer mediums and its properties [specific heat capacity, thermal conductivity and dynamic viscosity] for all specified heat transfer fluids are also discussed. The results obtained with various specified heat transfer fluids filled in the annulus space of evacuated tube are compared with plain evacuated tube. It is observed that there is significant enhancement of overall instantaneous collection efficiency of the parabolic trough collector.

14 SOLAR ENERGY↗
DOE OSTI2016

Second Generation Novel High Temperature Commercial Receiver & Low Cost High Performance Mirror Collector for Parabolic Solar Trough

Norwich Technologies (NT) is developing a disruptively superior solar field for trough concentrating solar power (CSP). Troughs are the leading CSP technology (85% of installed capacity), being highly deployable and similar to photovoltaic (PV) systems for siting. NT has developed the SunTrap receiver, a disruptive alternative to vacuum-tube concentrating solar power (CSP) receivers, a market currently dominated by the Schott PTR-70. The SunTrap receiver will (1) operate at higher temperature (T) by using an insulated, recessed radiation-collection system to overcome the energy losses that plague vacuum-tube receivers at high T, (2) decrease acquisition costs via simpler structure, and (3) dramatically increase reliability by eliminating vacuum. It offers comparable optical efficiency with thermal loss reduction from ≥ 26% (at presently standard T) to ≥ 55% (at high T), lower acquisition costs, and near-zero O&M costs.

14 SOLAR ENERGY↗
DOE OSTI2020

SAM™ (System Advisor Model™) [SWR-16-02, SWR-10-13]

See the SAM™ website to build a desktop version of the National Laboratory of the Rockies' (NLR's) System Advisor Model™ (SAM). https://sam.nlr.gov/ The System Advisor Model™ (SAM™) is a free techno-economic software model that facilitates decision-making for people in the renewable energy industry: -Project managers and engineers -Policy analysts -Technology developers -Researchers SAM can model many types of renewable energy systems: -Photovoltaic systems, from small residential rooftop to large utility-scale systems -Battery storage with Lithium ion, lead acid, or flow batteries for front-of-meter or behind-the-meter applications -Concentrating Solar Power systems for electric power generation, including parabolic trough, power tower, and linear Fresnel -Industrial process heat from parabolic trough and linear Fresnel systems -Wind power, from individual turbines to large wind farms -Marine energy wave and tidal systems -Solar water heating -Fuel cells -Geothermal power generation -Biomass combustion for power generation -High concentration photovoltaic systems SAM's financial models are for the following types of projects: -Residential and commercial projects where the renewable energy system is on the customer side of the electric utility meter (behind the meter), and power from the system is used to reduce the customer's electricity bill. -Power purchase agreement (PPA) projects where the system is connected to the grid at an interconnection point, and the project earns revenue through power sales. The project may be owned and operated by a single owner or by a partnership involving a flip or leaseback arrangement. -Third party ownership where the system is installed on the customer's (host) property and owned by a separate entity (developer), and the host is compensated for power generated by the system through either a PPA or lease agreement. For a more detailed description of SAM, see Blair et al. (2018), System Advisor Model (SAM) General Description (Version 2017.9.5), NREL/TP-6A20-70414. https://www.nrel.gov/docs/fy18osti/70414.pdf

Ryberg, David↗
DOE OSTI2020

Concentrating Solar Power Best Practices Study

The primary objective of this Concentrating Solar Power Best Practices Study is to publish best practices and lessons learned from the engineering, construction, commissioning, operations, and maintenance of existing concentrating solar power (CSP) parabolic trough and power tower systems. To accomplish this objective, information was solicited from many owners, operators, and engineering, procurement, and construction (EPC) contractors, independent engineers, and other stakeholders of parabolic trough and central receiver plants (also commonly referred to as power towers). Information was gathered through in-person or online meetings, site visits, and questionnaires sent to participants. The project team held about 50 information-gathering sessions with participants over the course this effort; and in the process, it collected information from participants representing nearly 80% of CSP plants operating worldwide.

14 SOLAR ENERGY↗
DOE OSTI2018

Performance of Cylindrical Parabolic Collector with Automated Tracking System

Parabolic solar collector collects the radiant energy emitted from the sun and focuses it at a point. Parabolic trough collectors are the low cost implementation of concentrated solar power technology that focuses incident sun light on to a tube filled with a heat transfer fluid. However, the basic problem with the cylindrical parabolic collector without tracking was the solar collector does not move with the orientation of sun. Development of automatic tracking system for cylindrical parabolic collectors will increase solar collection as well as efficiency of devices. The main aim of this paper is to design, fabricate and analyze the performance of parabolic collector with automated tracking system. The automated tracking mechanism is used to receive the maximum possible energy of solar radiation as it tracks the path of sun. The performance of the parabolic trough collector is experimentally investigated with the water circulated as heat transfer fluid. The collector efficiency will be noted.

14 SOLAR ENERGY↗
DOE OSTI2017

SAM Process Heat Model Development and Validation: Liquid-HTF Trough and Direct Steam Generation Linear Focus Systems

Two new solar industrial process heat (SIPH) models have been added to the System Advisor Model (SAM) energy simulation tool. The two process heat models were: i) liquid-heat transfer fluid (HTF) parabolic troughs; and ii) direct steam generation (DSG) linear-focus collectors. The DSG model can simulate either DSG parabolic troughs (PT) or DSG Linear Fresnel (LF) fields, based on the optical characteristics supplied. These models help to meet the need for independent, validated tools that reliably simulate the effects of adding a solar field to provide heat for potential IPH applications. During the pre-validation of the liquid-HTF model, operational data was provided and preprocessed by SPF and evaluated at ZAE Bayern. The beta liquid-HTF model provided excellent agreement between the simulations and the operational data for the solar thermal yield generation on a yearly and monthly basis (4.4% difference). The final liquid-HTF process heat model has been further optimized with test users such as ZAE Bayern and SPF. Key improvements in the SIPH models to better model SIPH fields include the use of smaller piping systems and heat capacities, a single collector field, and a higher time-step resolution than for electricity generation (down to 10 minutes). Both the final liquid-HTF and DSG models were successfully validated against operational data for respective solar fields, and showed less than 5% deviation to actual results. A brief application where the liquid-HTF process heat model is used for a brewery in California and the value of reliably simulating a potential SIPH solar field are highlighted.

14 SOLAR ENERGY↗
DOE OSTI2024

Photovoltaic device for enhancing power output of concentrating solar thermal power plants

A photovoltaic retrofit device for a concentrating solar thermal power plant having a parabolic trough reflector, and a fluid receiver with working fluid therein spaced from the reflector and positioned at a focal point of the reflector. The photovoltaic device includes a plurality of adjustable angle dichroic mirrors positioned between the parabolic trough reflector and the fluid receiver. A photovoltaic receiver assembly has multiple photovoltaic panels in angular relationship to each other. A photovoltaic temperature regulating system includes a fluid medium to regulate temperature of the photovoltaic panels.

Otanicar, Todd↗
DOE OSTI2024

Measurement of Wind Loading on Heliostats at the Crescent Dunes Power Plant: An Overview

The cost of solar collectors constitutes almost one third of the total cost of a CSP plant. One of the ongoing challenges in the design of these collectors is wind loading on mirrors, support structures, and drives. A particular challenge is dynamic wind loading, caused by the turbulent wind flow. To date, the design of solar collector structures has relied on wind tunnel experiments and numerical simulations that do not entirely capture the dynamic effects observed at scale. The CSP industry has shown increased interest in validating the idealized assumptions with measurements obtained in operational settings to improve wind load assumptions and increase reliability and cost-efficiency of the collector design. Further, performance models need realistic assumptions about wind loading and its impact on optical performance. In a parabolic trough field campaign, NREL successfully collected a wealth of long-term, high-resolution wind and loads data [2], that are publicly available and that can be used for the above-mentioned purposes. Heliostats are impacted differently by wind than parabolic troughs, due to their different shape, size, and field layout. To study the impact of wind and turbulence on heliostats, we initiated another field campaign in an operational power- tower plant, Crescent Dunes, in Nevada, USA. In this work, we present an overview of the measurements, first results, and potential implications of wind driven loads on Heliostats.

concentrated solar power↗
DOE OSTI2022

Distant Observer™ [SWR-12-09]

Distant Observer™ (DO) is an optical measurement tool, designed for parabolic trough solar collectors, that determines reflector slope error, absorber position error, and the combined errors based on images of the receiver-tube reflection taken from different angles. We have demonstrated that DO can provide a measurement accuracy of 0.25 mrad for the slope and receiver position errors. DO has two implementation versions: ground-based and drone-driven. As we pursue efforts to lower the capital and installation costs of parabolic trough solar collectors, it is essential to maintain high optical performance. The Distant Observer™ (DO) tool, developed by engineers at NREL, is a fast and highly accurate tool that provides complete characterization of the performance of the optical components which include the mirror panels and thermal receiver. This tool is very useful for testing both prototype and operational modules. The Distant Observer™ is an optical measurement tool for parabolic solar collectors that measures reflector slope error, absorber position error and the combined errors. Reflector slope errors occur for many reasons including imperfection in structural frame design, manufacturing and assembly. Absorber position error can be caused by poor structural design, poor installation, sag from the absorber weight, or change in the structure over time.

Ihas, Benjamin↗
DOE OSTI2015

Scattering Solar Thermal Concentrators

This program set out to explore a scattering-based approach to concentrate sunlight with the aim of improving collector field reliability and of eliminating wind loading and gross mechanical movement through the use of a stationary collection optic. The approach is based on scattering sunlight from the focal point of a fixed collection optic into the confined modes of a sliding planar waveguide, where it is transported to stationary tubular heat transfer elements located at the edges. Optical design for the first stage of solar concentration, which entails focusing sunlight within a plane over a wide range of incidence angles (>120 degree full field of view) at fixed tilt, led to the development of a new, folded-path collection optic that dramatically out-performs the current state-of-the-art in scattering concentration. Rigorous optical simulation and experimental testing of this collection optic have validated its performance. In the course of this work, we also identified an opportunity for concentrating photovoltaics involving the use of high efficiency microcells made in collaboration with partners at the University of Illinois. This opportunity exploited the same collection optic design as used for the scattering solar thermal concentrator and was therefore pursued in parallel. This system was experimentally demonstrated to achieve >200x optical concentration with >70% optical efficiency over a full day by tracking with <1 cm of lateral movement at fixed latitude tilt. The entire scattering concentrator waveguide optical system has been simulated, tested, and assembled at small scale to verify ray tracing models. These models were subsequently used to predict the full system optical performance at larger, deployment scale ranging up to >1 meter aperture width. Simulations at an aperture widths less than approximately 0.5 m with geometric gains ~100x predict an overall optical efficiency in the range 60-70% for angles up to 50 degrees from normal. However, the concentrator optical efficiency was found to decrease significantly with increasing aperture width beyond 0.5 m due to parasitic waveguide out-coupling loss and low-level absorption that become dominant at larger scale. A heat transfer model was subsequently implemented to predict collector fluid heat gain and outlet temperature as a function of flow rate using the optical model as a flux input. It was found that the aperture width size limitation imposed by the optical efficiency characteristics of the waveguide limits the absolute optical power delivered to the heat transfer element per unit length. As compared to state-of-the-art parabolic trough CPV system aperture widths approaching 5 m, this limitation leads to an approximate factor of order of magnitude increase in heat transfer tube length to achieve the same heat transfer fluid outlet temperature. The conclusion of this work is that scattering solar thermal concentration cannot be implemented at the scale and efficiency required to compete with the performance of current parabolic trough CSP systems. Applied within the alternate context of CPV, however, the results of this work have likely opened up a transformative new path that enables quasi-static, high efficiency CPV to be implemented on rooftops in the form factor of traditional fixed-panel photovoltaics.

14 SOLAR ENERGY↗
DOE OSTI2024

Design Basis Document / Owner’s Technical Specification for Nitrate Salt Systems in CSP Projects: Hypothesis of Hot Tank Failure

Work has begun on a Design Basis Document / Owner’s Technical Specification for parabolic trough and central receiver power plants using nitrate salt as the heat transport fluid and the thermal storage medium. A principal topic of recent interest is the failures of the hot salt tanks in central receiver projects. The paper outlines a hypothesis for the source of the failures, and discusses a range of possible solutions.

14 SOLAR ENERGY↗
DOE OSTI2014

Commercialization of High-Temperature Solar Selective Coating: Cooperative Research and Development Final Report, CRADA Number CRD-08-300

The goal for Concentrating Solar Power (CSP) technologies is to produce electricity at 15 cents/kilowatt-hour (kWh) with six hours of thermal storage in 2015 (intermediate power) and close to 10 cents/kWh with 12-17 hours of thermal storage in 2020 (baseload power). Cost reductions of up to 50% to the solar concentrator are targeted through technology advances. The overall solar-to-electric efficiency of parabolic-trough solar power plants can be improved and the cost of solar electricity can be reduced by improving the properties of the selective coating on the receiver and increasing the solar-field operating temperature to >450 °C. New, more-efficient selective coatings will be needed that have both high solar absorptance and low thermal emittance at elevated temperatures. Conduction and convection losses from the hot absorber surface are usually negligible for parabolic trough receivers. The objective is to develop new, more-efficient selective coatings with both high solar absorptance (α > 0.95) and low thermal emittance (ε < 0.08 @ 450 °C) that are thermally stable above 450 degrees C, ideally in air, with improved durability and manufacturability, and reduced cost.

14 SOLAR ENERGY↗
DOE OSTI2016

On the Path to SunShot: Advancing Concentrating Solar Power Technology Performance and Dispatchability.

Since the SunShot Vision Study (DOE 2012) was published, global deployment of concentrating solar power (CSP) has increased threefold to nearly 4,500 MW, with a similar threefold increase in operational capacity to 1,650 MW within the United States. Growth in U.S. CSP capacity has primarily been driven by policy support at the state and federal levels. State-driven renewable portfolio standards (RPSs), combined with a 30% federal investment tax credit (ITC) and federal loan guarantees, provided the opportunity for CSP developers to kick-start construction of CSP plants throughout the Southwest. Figure ES-1 demonstrates that deployment and private- and public-sector research and development have led to dramatic cost reductions that have placed CSP well on the path to reaching the U.S. Department of Energy’s SunShot Initiative goal of 6 cents/kWh by 2020. In comparing the estimated capital costs from the SunShot Vision Study and the current analysis, we find that parabolic trough solar-field costs have fallen more rapidly than predicted, although the drop in solar-field costs was offset by the additional costs of moving from a wet-cooled power block in 2010 to a more expensive dry-cooled power block in 2015. The predicted 2015 decline in tower costs was in line with expectations, primarily driven by reduced heliostat costs. Figure ES-1 shows the reduction in levelized cost of electricity (LCOE) for both parabolic trough and tower systems, in addition to the projected 2020 SunShot target.

14 SOLAR ENERGY↗
DOE OSTI2016

On the Path to SunShot: Advancing Concentrating Solar Power Technology, Performance, and Dispatchability

Since the SunShot Vision Study (DOE 2012) was published, global deployment of concentrating solar power (CSP) has increased threefold to nearly 4,500 MW, with a similar threefold increase in operational capacity to 1,650 MW within the United States. Growth in U.S. CSP capacity has primarily been driven by policy support at the state and federal levels. State-driven renewable portfolio standards (RPSs), combined with a 30% federal investment tax credit (ITC) and federal loan guarantees, provided the opportunity for CSP developers to kick-start construction of CSP plants throughout the Southwest. Figure ES-1 demonstrates that deployment and private- and public-sector research and development have led to dramatic cost reductions that have placed CSP well on the path to reaching the U.S. Department of Energy’s SunShot Initiative goal of 6 cents/kWh by 2020. In comparing the estimated capital costs from the SunShot Vision Study and the current analysis, we find that parabolic trough solar-field costs have fallen more rapidly than predicted, although the drop in solar-field costs was offset by the additional costs of moving from a wet-cooled power block in 2010 to a more expensive dry-cooled power block in 2015. The predicted 2015 decline in tower costs was in line with expectations, primarily driven by reduced heliostat costs. Figure ES-1 shows the reduction in levelized cost of electricity (LCOE) for both parabolic trough and tower systems, in addition to the projected 2020 SunShot target.

14 SOLAR ENERGY↗