SOLAR THERMAL UTILIZATION PAST PRESENT AND FUTURE

Dr. (MRS) K.S.RAJAMHEAD SURFACE ENGINEERING DIVISION NATIONAL AEROSPACE LABORATORIES

BANGALORE

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1. REPORT DATE SEP 2010

2. REPORT TYPE N/A

3. DATES COVERED -

4. TITLE AND SUBTITLE Solar Thermal Utilization: Past, Present and Future

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) 5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Surface Engineering Division National Aerospace LaboratoriesBangalore, India

8. PERFORMING ORGANIZATIONREPORT NUMBER

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)

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12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release, distribution unlimited

13. SUPPLEMENTARY NOTES See also ADA560467. Indo-US Science and Technology Round Table Meeting (4th Annual) - Power Energyand Cognitive Science Held in Bangalore, India on September 21-23, 2010. U.S. Government or FederalPurpose Rights License

14. ABSTRACT

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT

SAR

18. NUMBEROF PAGES

49

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a. REPORT unclassified

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Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

WHY SOLAR ?

OUR RESPONSIBILITIES – TO PROTECT THE EARTH FOR FUTUREGENERATION

WHY SOLAR ? WHY NOW ?

ENERGY INDEPENDENCE

ENERGY SECURITY

GLOBAL WARMING

ELECTRICITY PRICES

GOVERNMENT INITIATIVES / SUPPORT

What Energy ?G

loba

l ave

rage

….and 80% of energy supplies come from limited resourcesknown for environmental pollution !

Biomass

Gas

Nuclear

Coal

Oil

*Renewable

Degrading Environment….

Imagine the earth to be a spaceship .

Limited supply of air, water and energy .

All thrash generated carried onboard .

Increase population ∞ energy demand .

Non –renewable resources to last 100 yrs.But long before that the pollution caused by use of fossil fuels will have caused a serious problem .

THE BURNING OF FOSSIL FUELS IS HAVING

A LARGE IMPACT

End of an Era

100 years of exponential growth in fossil fuel use will soon be ending due to environmental and economic constraints

oe=~::~==~~~~ 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050

lous48 DEurope I Russia Dother DM:ast I Heavy I Deepwater DPolar I'.IP-t.GLI

Every second 657 million tons of hydrogen are converted to 653 million tons of helium in our sun .The missing 4 million tons are converted to light and heat energy via \Einstein’s E=MC2 equation and Radiated into space .At an average distance of 93million miles from the sun ,the earth collects approximately 4lbs.of total energy ,which supports lifeOn earth as we know it .

For every kWh of electricity generated by solarenergy ,the following emissions are avoided sincethat kWh need not be generated from a fossil fuelpower plant. In one year ,the approximate avoided emissions in lbs/year are :

360620063002,580,0001MW

36520630258,000100kW

3.6526325,80010kW

0.365.26.32,5081kW

PARTICULATES

SOxNOxCo2SOLAR POWER PLANT SIZE

You assume the diameter of the earth is 8000 miles and using 2240lb/ton(British ton ),the 4lbs . Can be calculated using the following

formula:

4x106xπx(8x103)2

= 4.14lbs.4xπx(93x106)2 x 4

WHY SOLAR ?

WHY SOLAR ?

>> In a single one hour period, thesun sends enough energy to ourplanet to meet all of ourenergy needs for an entire year.

>>The availability and cost of deliveringenergy from the sun to our planet hasremained amazingly constant for 4 billion years.

Solar Radiat ion in India

• India receives 3000 hrs* of sunshine every year , equivalent to 5000 trillion KWH.

• Most parts in India receive 4 - 7 KWh of solar radiation per sq. meter per day with 250 - 300 sunny days in a year

•http:/1\\'AW .solatiOOtaontne .com;

The Energy aoo R~~Jrces ln.s:Utute (TfRI)

sourct. Sol~r entrgy Pc~t.n :\31 1n tndltl. Tfftl

I!Wh t t q . rn

• 66 · 1.1,.1 . 6-t 'C,J

• 6 2 ! .0 t!J 6 0 . S.S

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GJ ~? · S.O

U t O· 4.9 U iei · II.O

CJ I G- 1...1

• We will pool all our scientific, technical and managerial talents, with financial sources, to develop solar energy as a source of abundant energy to power our economy and to transform the lives of our people" - Dr.Manmohan Singh, Prime Minister of India.

JAWAHARLAL NEHRU NATIONAL SOLAR MISSION

Ø 20GW BY 2020

Ø 100GW BY 2030

Ø 200GW BY 2050

Ø 20 MILLION SQ.METER SOLARTHERMAL COLLECTORS (20GW power)

Ø 20 MILLION SOLAR LIGHTS

LAUNCHING OF SOLAR INDIA

SOLAR THERMAL APPLICATIONS ( PAST )

the widespread use of solar power for heating.

Solar Thermal Applications (present)

Rankine cycle refrigerationAbsorption air conditioningIndustrial dryingIndustrial processesSmall power engine

Medium Temperature (80oC-200oC)NALSUN

Industrial processesSolar power plant

High Temperature (>200oC) TANDEM ABSORBERS

Swimming pool heatingDomestic hot water heatingHouse heatingCrop DryingWater Distillation

Low Temperature (20oC-80oC)NALSUN

ApplicationsThermal Conversion range

SOLAR ENERGY COLLECTORS40- GO•C

UNGLAZED COLLECTORS

60- 90•C

SOLAR POND

60-SO•C NON-FOCUSSING

FLAT PLATE

/ (FPC) 100- 150•C

For low temperature 50- 200•C COMPOUND

applications PARABOLIC EVACUATED CONCENTRATOR

~ (ETC) 100- 250•C

8•1Y!:IBI"·~I2\ 100- SOO•C LINEAR

'\ ]-< FRESNEL TYPE

For fJigh and medium SINGLE AXIS

temperature applications / TRACKING 100- SOO•C

FOCUSSING PARABOLOIC

TROUGH

(CONCENTRATING) 300-1000•C

300- 2000•C PARABOLIC DISH REFLECTOR

TWO-AXIS TRACKING j----1 500- 2000•C

HELIOSTAT FIELD COLLECTOR

SOLAR THERMAL APPLICATIONS

SOLAR WATER HEATING

HEART OF THE SYSTEM – SELECTIVELY COATED ABSORBER

SELECTIVE ABSORBER COATINGS1. BLACK NICKEL (POOR MOISTURE RESISTANCE )

2. BLACK CHROMIUM. (NANO COMPOSITE OF CHROMIUM AND CHROMIUM OXIDE)

DRAWBACKS OF BLACK CHROMIUM DEPOSITION

1. HIGH CURRENT DENSITY (3A/in2)

2. LOW TEMPERATURE (150C)

3. ORGANIC ADDITIVES (STABILITY?)

ADDRESSED THE ABOVE PROBLEMSDEVELOPMENT OF NALSUN TECHNOLOGY

ADVANTAGES OF NALSUN COATING

SUITABLE FOR BATCH PRODUCTION & CONTINUOUS FOIL COATING

High absorbtivity,α < 0.95Low emissivity,ε <0.15Long term Thermal stabilityRoom temperature bathGood covering powerSimple bath maintenance & controlStability against atmospheric corrosionCost-effective coatingEasy to apply on the required substrateReproducibilityGood resistance against rubbing and handling

NALSUN & ITS SOCIETAL IMPACTTECHNOLOGY TRANSFER – 26 ENTREPRENEURS

SMALL MEDIUM AND LARGE SCALE HOT WATER

SYSTEMS – INSTALLED. (HOMES , HOSPITALS ,

HOTELS, RESORTS, CONVENTION CENTERS ,

INDUSTRIAL CANTEENS,HOSTELS ETC )

VIRTUAL POWER STATION

“A WATT SAVED IS A WATT GENERATED”

100lpd - DOMESTIC 3000lpd - DHARAMSHILAHOSPITAL

7000lpd –TAJ HOTEL 50000lpd –BATRA HOSPITALDELHI

5000lpd –ISKCON TEMPLEBANGALORE

PORTION OF THE 1.1LAKH LITERS PER DAY SOLAR WATER HEATING SYSTEMS INSTALLED AT M/S SRI VENKATESWARA

HATCHERIES, VELIJULA, BY M/S SURYODAYA HITECH ENGINEERS PVT.LTD., HYDERABAD USING NALSUN

COATED COLLECTORS

PORTION OF THE 1.2 LAKH LITERS PER DAY SOLAR WATER HEATING SYSTEMS INSTALLED AT M/S GODAVARI

FERTILIZERS&CHEMICAL,KAKINADA BY M/S SURYODAYA HITECH ENGINEERS PVT.LTD., HYDERABAD USING NALSUN COATED COLLECTORS

SOLAR STEAM GENERATION USING NALSUN(K G INDUSTRIES COAIMBATORE )

Renewable energy at a glance In lndl a

COMMERCIALLY SUCCESSFUL –

26 ENTREPRENEURS

23 lakhs sq.m collector area

1400 Lakhs sq.m. collector area

AchievementPotential

1 MW≈ 1000 sq.m

2300MW23 lakhs sq.m

Energy SavingsCollector area

MARKET UTILIZATION – NALSUN COATINGS – 90%

SOLAR WATER

HEATING

ENERGY

SAVINGS

Jaideep Malaviya

~-------------------------____, India's coating Ra!ihmi ~ Vardlishnu industry has:

lndusbies [5%) India [4%) Engil1l!l!I'S [3%1 shown impressive growth rates over the last ten years:. Just one manufacturer of selective coating dominated the industry a decade ago: Solchrome, who had obtained the technology from Canada. Today, a manufacturers are using the Nalsun technology developed by the

'---------------------~ NAL.

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• A mep Pf'OJOtl. 1tdwdog n ftodwc.11 for Sot¥ E~ lJb./.dtOft thtou~ NctWOI'bli (T!IP·SUN)'. ~

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• SeYQ!'Jit new~ do~ t~ch.....UC fllh ready b' «m~~ j)"'d..c:ll(w"l

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I Mlnlatry of Sclonce and Tochnology and Ministry of Earth Sciences

~l'ilhc...v. -- Govotnmontollndla

SOLAR THERMAL +

SOLAR PV

Kee in the Li hts On - 2007

SOLAR THERMAL POWER (FUTURE)

Solar thermal can contribute considerable

Heating and Cooling Transport • Electricity

31%

AEE - Institute for Sustainahle Techno-~: EREC. 200eJ

u ; 1

THE TECHNOLOGYVARIOUS TYPES OF SOLAR THERMAL (CSP ) TECHNOLOGY

Tawer

• Array of individually tF!iiCkin g mi ITOFI

• Less land requir;;ITIOnt • Small se&lo dill!m o

plants oplll!rati ng • Molmn salt ltorago

capal::ility • Highor opgrating temp

Dish

• Oistribumd systoms PQ!Miiblo

• Highilllr mmplllra:l:ur;; • Higher cCI!Id: • Not provllln at scal9 • Limitlilld storage

o::apal:li lily • SLtitatfe for o1f-grid

gonoration

Fresnel

• LOW!lllr rafficiilllncy • L01111er cost • Unprowntech

From: Solel (USA)

Parabolic Trough Technology for Solar Power Generation

High temperature solar selective coating

Salient Features of Absorber Tubes

• Typically, a long SS tube with solar selective coating surrounded by evacuated glass tube

• Glass-to-metal seal to achieve vacuum and metal bellows to heat exchanger

• Vacuum = 10-4 Torr

Challenges:• Glass-to-metal seal failures due to insufficient protection• Hydrogen release related failures• Sputtering on large tubes – Large investment & infrastructure

From: Solel (USA)

No Indigenous Efforts on Sputter Deposited Solar Absorber Tubes

Evacuated tube

Glass-to-metal seal

Absorber coating

Parabolic Trough

Need for Newer Solar Absorbers for Power Generation

High Temperature Stable Solar Absorber Coatings (>400°C)

• Private industries such as Space Age, Maharaja Techno Group, KG Industries, many more and BARC approached NAL for sputter deposited high temperature solar selective coatings

Concentrating Solar Power (CSP) Technologies

Parabolic DishSolar Power Tower

Basic Requirements of a High Temperature Solar Absorber• High solar absorptance (>0.90)• Low thermal emittance (<0.05, e.g., on Cu) : Radiative losses α T4

• High thermal stability (>400ºC)• Long-term stability at higher operating temperatures• High corrosion resistance

Coating α/ε Thermal StabilityNi-Al2O3 0.94/0.06 500°C in air

Pt-Al2O3 0.92/0.14 600°C in H2

Mo-Al2O3 0.96/0.16 500°C in vacuum

W-Al2O3 0.93/0.024 -

W-SiO2 0.916/0.027 -

W-AlN 0.93/0.10 500°C in vacuum

SS-AlN 0.95/0.13 500°C in vacuum

Important Cermet based High-Temperature Solar Selective Coatings

Long Term Thermal Stability Not Known in Public Domain

Australian patent

ABSORBER-REFLECTOR TANDEM

It is a combination of two materials, one highly

absorbing in the visible region and the other highly

reflecting in the infrared.

Infrared reflector (metal)

Absorber layer

Incident radiation

NAL Initiatives on High Temperature Solar Selective Coatings(Sputter Deposited Nanostructured Tandem Absorbers)

Novelty• Transition metal nitrides and oxy-nitrides• Compositional stability at high temp.• FIRST OF ITS KIND

Patent filed in India, Germany & Australia - 2006

SiO2

TiAlN

TiAlON

Si3N4

Epoxy BF

XTEM

12345

6

7

8

Coating α/ε Stability in air

*TiAlN/TiAlON/Si3N4 0.95/0.07 550°CTiAlN/CrAlON/Si3N4 0.95/0.07 450°CNbAlN/NbAlON/Si3N4 0.95/0.06 500°CTiAlN/AlON 0.94/0.06 550°C

64 nm

34 nm24 nm

Nanocrystalline

Motivation• Technology for high temp. SSC not available in

the Country

Tandem Absorber

Bar

shili

aet

al.

App

. Phy

s. L

ett.

89(2

006)

1919

09

SAD*Ideal Coating for Solar Power Generation

~120 nm Thickness

30 mm

Laboratory Scale Sputter Deposited Solar Selective Coatings

Long Term Thermal Stability in Air…

• Stable up to 525°C for 50 hrs450°C for 150 hrs350°C for 225 hrs

• Stability in vacuum: 750°C for 2 hrs• No phase transformation up to 800°C

• Graded refractive indices• TiAlN as the main absorber layer

• TiAlN acts as a diffusion barrier for metal

• Interdiffusion between TiAlN/TiAlON and TiAlON/Si3N4 is very low up to 600°C

• TiAlN, TiAlON and Si3N4 exhibit very high oxidation resistance: 750, 900 & 1400ºCMagnetron Sputtering System

30 mmNb- based

Why?

Other Initiatives - Multilayer Absorbers & Nanocermets for Low- and Mid-Temperature Applications

Cr2O3 (64 nm)

Cu substrate

Cr2O3 (28 nm)

Cr (13 nm)

High metal volume fraction

Low metal volume fraction

Semitransparent metal layer83% Cr and 17% O

51% Cr and 49% O

Salient Features:• α/ ε = 0.91/0.06• Stable up to 325°C in air for 2 hrs and 250°C for 250 hrs• Coating process can be scaled up for domestic hot water applications

Coating α/ε Stability

CrxOy/Cr/Cr2O3 0.91/0.06 325°C *AlxOy/Al/ Al2O3 0.97/0.06 350°CHfOx/Hf/ HfO2 0.92/0.05 400°C

Ag/Al2O3 0.92/0.05 300°C

CrxOy/Cr/Cr2O3AlxOy/Al/Al2O3

*Green Technology : Potential Candidate for Replacement for Black Chrome

Scaling Up of The Laboratory Process for the Deposition of Nanostructured Solar Selective Coatings on 6” Long Tubes

Novelty• A dry, clean and green process for

manufacture of solar selective coating• New coating combination• High solar selectivity• High thermal stability• Long service life at higher operating

temperature (Theoretical)

6 inches SS tube

Ti target

Magnetron

α/ε = 0.90/0.14TiAlN/TiAlON

Supported by MNRE, New Delhi

Semi-Industrial Magnetron SputteringSystem

10th FYP, CSIR

(Indigenous Development)

PATENTSNALSUN IV.K.William Grips, Indira Rajagopal and S.R. Rajagopalan

Indian Patent No: 167895 (1.11.1991)

U.S.A Patent No: 5019223 (28.5.1991)

Australian Patent No: 611957 (5.11.1991)

European Patent No: 323683 (8.9.1993)

Canadian Patent No: 2006130 (12.5.1998)

NALSUN II

V.K.William Grips, Indira Rajagopal and S.R. Rajagopalan

Indian Patent : No. 195681 (21.4.2006

V.K.William Grips, Indira Rajagopal and S.R. Rajagopalan

Indian Patent : No. 202362 (23.2.2007

NALSUN III

TANDOM ABSORBERS

Harish barshilia , V.W.Grips , K.S.RajamUS Patent #7,585,568 B2 (2009)

New challenges

The need to consider a new future

New O,BPO l!lnities