Geyer Eurotrough

EUROTrough Progress and NEXTrough Opportunities for an Euro-American Trough Alliance
Trough Meeting SUNLAB Madison, June 18, 2000

Michael Geyer DLR Deutsches Zentrum fr Luft- und Raumfahrt Plataforma Solar de Almeria
2000-06-18
Trough Workshop Madison
Parabolic Trough Market Cost Reduction Perspectives

0,18 Subsidized Introductory Markets Green Power Markets Initial Competetive Markets Sustained Global Markets
0,16
Euro/kWh
0,12
GEF & Prefered Financing
0,08
Green Pricing
0,04
Competetive Price Range for Grid- Connected Intermediate Load Power
0,04 Euro/kWh
0,00 2000
2000-06-18 Trough Workshop Madison
2005
2010 Year
2015
2020
Parabolic Trough Cost Reduction Perspective

Cost Reduction Potentials of Parabolic Trough Technology Cost Reduction Potentials of Parabolic Trough Technology
0,12 EURO/kWh
Improvement of Current Collector Design
Euro/kWh
Increase Plant Size 80 to 200 MW
Change from HTF to DSG
Build Multiple Plants per Year
2000-06-18
Today
Year 2020
Market Competition
0,04 Euro/kWh
EUROTrough I+II Objectives

2x6 Segment EUROTrough II 150m-Collector 2x4 Segment EUROTrough I 100m Collector
End Pylon
12m Segment
Central Drive Pylon
Interconnecting Pylon
EUROTrough Phase I
1.8.1998 - 31.1.2001 Cost: 3 Mio Euro (40%Partners, 40%EU, 20%BMWi) Develop 100m/8segment EUROTrough Collector Design Deliverable: Manufacturing Dwgs Build one half EUROTrough at Plataforma Solar Deliverable: 50m Prototype Test in PSAs HTF Loop Deliverable: Qualification Tests Partners: Inabensa, Pilkington, SBP, Fichtner, Ciemat, CRES, DLR
EUROTrough Phase II
1.10.2000 - 31.12.2002 Cost: 2 Mio Euro (50%Partners, 50%EU) Develop 150m/12segment EUROTrough Collector Design Deliverable: Manufacturing Dwgs Add 2 segments to EUROTrough prototype at Plataforma Solar Deliverable: 50+25m Prototype Test in PSAs HTF Loop Deliverable: Qualification Tests Partners: Inabensa, Iberdrola, Pilkington, SBP, Solel, Ciemat, DLR
LS-3 State of the Art

100 Meter
Flexible Hose
Central Oil Pipe & Temperature Sensor
Absorber Tube (HCE)
Mirror Panels
Absorber Tube (HCE)
Mirror Panels
V-Truss
Local Controller Drive Pylon Intermediate Pylon
Hydraulic Drive System
2000-06-18
LS-3 State of the Art: Weights

100 Meter
LS-3 Collector V-Truss Weight Drive Pylon Typical Pylon Degree of Material Use (Survival/Stow) Maximum Wind Bending Maximum Wind Torsion Surface Maximum Wind Torsion Axis
Strong 1350 kg 315 kg 135 kg 93% 6.9mm 5.4mrad 5.3mrad
Regular 1068 kg 265 kg 92 kg 99% 10.2mm 5.5mrad 7.7mrad
Design Options
LS-3 Space Frame LS-2 Torque Tube
ET Torque Box
2000-06-18
EUROTrough Design Procedure Elaboration of conceptual design criteria Elaboration of design options Layout of three different structures FEM - analysis of the various structures Comparison of design options concerning
overall collector mass, deformation in operation, stress under survival loads
Comparison of design options with LS-3 collector Consideration of manufacturing, assembly, transportation and erection cost
2000-06-18
Decision on design options
Why the Torque Box Design?

Summary of the FEM Optimizations
Axis C
Weight Use of Sections (Survival /Stow) Maximum Wind Bending Distortion Point A Maximum Wind Bending Distortion surface Maximum Wind Torsion Distortion surface Maximum Wind Torsion Distortion Axis C
LSS-3 Space Frame Design 1045 kg 32% 10,5 mm 4,15 mrad 4,2 mrad 4,4 mrad
LS-2 Torque Tube Design 895 kg 55,5 35,0 mm 1,6 mrad 1,9 mrad 2,0 mrad
ET Torque Box Design 915 kg 48% 7,08 mm 1,6 mrad 1,7 mrad 1,69 mrad
FEM Optimization: Wind Bending and Torsion

LS-3 Space Frame LS-2 Torque Tube Maximum Wind Bending ET Torque Box
Maximum Wind Torsion
2000-06-18
Wind Tunnel Tests

Measuring Segment
3 different wind directions 5 different positions in the field (front, 3 in front, 5 in front and single)
Tests performed by: Wind Tunnel Facility: Model scale: Test conditions: Cost:
Wacker Ingenieure, Birkenfeld, Germany Wind Tunnel University of Karlsruhe 1 : 86 Atmospheric boundary layer 40000 EURO
EUROTrough Design Selection

Torque box design allows weight reduction compared with existing collector design Torque box design has the lowest deformations under dead and wind loads Torque box design will allow additional collector elements per drive Higher structural stiffness will improve collector performance Necessary assembly jigs will be more simple and less costly compared with the LS-3 collector
Torque box selected

Final Wind Load Assumptions for EuroTrough

Operation Wind Wop: Definition: Wind speed: 0 m/s 14,3 m/s Criteria No design criteria Position: any Economic Design Wind W90%: Definition: Wind speed: 7 m/s Criteria: Transient Wind Wtrans: Definition: Wind speed: 21 m/s Criteria: Survival Wind Wsurv: Definition: Windspeed: 31,3 m/s Criteria: Stress within tolerances Position: Stow Position: any Stress within tolerances + maximum drive power Deformations (energetic losses) within tolerances Position: any
Loading and Material Safety Coefficients Safety coefficients were reduced compared to EURO-CODE for structural engineering
EUROTrough Design Tolerances

Deformation Tolerances for 12 Segment Collector
Load Max. Global Torsion mrad 5 Avg. Surface Distortion mrad 2 3 Maximum Displacement mm 4 6
Dead Load Dead Load + Design Wind Load
Manufacturing and Installation Tolerances

Reflector Error: Position of Absorber tube x,y Lateral deviation of the outer reflector edge Tracking error
average < 3 mrad 10mm, 10mm 5mm < 3 mrad
Bending at 120
Gravity, No Wind
Gravity, 7m/s Wind
Collector Length vs Torque and Torsion

M Torque
Torsion
Increase of torque and deformation due to wind forces for EUROTROUGH with 8 segments per drive
Drive Pylon
Torque Torsion M
Increase of torque and deformation due to wind forces for EUROTrough with 12 segments per drive
Drive Pylon
Mirror Stress Reduction by 50% vs LS2/LS3

Optimization of Mirror Fixation
Mirror stress level under survival conditions Position: Stow; Wind: 31,5 m/s
EUROTrough Design Innovations

150 Meter
3% Land Slope North-South
Torque box with less bending/torsion and reduced weight Increase of Collector length up to 150m/12segments 50% reduced mirror stress by new pad fixations Installation on 3% ground slope with new bearings Suitable for HTF and DSG Structural part items minimized to reduce transport cost Rig cost and assembly cost reduced New tracking control
EUROTrough Prototype Test at PSA

2 Segment EUROTrough II Extension at PSA 4 Segment EUROTrough I at PSA
DI SS
Te st
Lo
op
CESA-I
Half of 100m EUROTrough Collector Half of 150m EUROTrough Collector
EU RO
Dis h
ACUREX ConTESt
DISTAL II
EUROTrough Prototype Testloop at PSA

New hardware and measurement equipment in EUROTrough II: Parallel comparative testing of EUROTrough II and LS-3 Torque, bending, twisting, stress, acceleration and vibration measurement on 4 existing and the additional EuroTrough II collector segments
VENTING VALVE
VE4
El. drive
VE3
ET I TE E1 TE E2
ET I TE E3
P
ET I TE E4
ET I TE E5
ET II TE E6
ET II TE E7
DRAINING VALVE
DAS
DAS
DAS
DAS
DAS
DAS
DAS
DAS
TE 01
DAS
PDT E2
El. drive
VENTING VALVE
VE2
VE1
V1 DRAINING VALVE
LS-3
LS-3
DAS
LS-3 TE 02
HAND VALVES
(22 bar)
LS-3
MAGNETIC CHECK VALVES
DAS
TE 03
V2
LC
TE 17 TE 16
DAS
RELIEF VALVE
PT E1
LC
PI 04 TE 07
TT 05
DAS
DAS LC
PT 02
LC
TE 04
V3
N2-Station
DAS
TE 08
N2
OILTANK
15 m^3
DAS
V15
TE 15
V14
DAS
TE 06
LC
LI 01
V4 V5
OILHEATER
40 kW DAS
TDE 01
DAS
TE 12
V13
TE 14
F
PI Doubling of 01 03 Pump Capacity

DAS LC
PT
LC
TE 11
DAS
TE 10
V8
DAS
TE 09
V11
V10
FILTER
FILTER
Doubling of Cooling Capacity

V7 OILCOOLER
225 kW VE6 VE5
DAS
TE 13
DAS
FT E1
DAS
FT 01
OILPUMP V9
V12
OILCOOLER
??? kW
Drain
Tank
MANUAL
METEO DATA
I Dir T Amb v Wind alpha Wind
PUMP NOTES DAS - DATA ACQUISITION SYSTEM LC - LOGIC CONTROL INSTALLATIONS OF ET- MEASUREMENTCOMPONENTS IN LS-3 CIRCUIT ADDITIONAL INSTALLATIONS FOR THE ET II
V6
LS-3 & EUROTrough II HTF TEST LOOP P&I DIAGRAM

02/11/99 AUTHOR: CHR. SPITTA
2000-06-18
Consortium Agreement Marketing Strategy International Cooperation
2000-06-18
AndaSol32: 1st Project with EUROTrough & DSG

Collectors with Direct Steam Generation Solar Field with Thermal Oil Solar Superheater Steam Turbine
Boiler (optional)
Condenser
Fuel
Steam Generator Solar Preheater Deaerator Solar Reheater Expansion Vessel
Low Pressure Preheater
AndaSol32 Partners: Gamesa, Iberdrola, Agrosol, Pilkington/Flabeg, Solar Millennium AG, DLR, Ciemat
AndaSol32: 235000m EUROTrough & 16000m DSG

16350m in 5 parallel loops with direct steam absorbers
Power Block 32 MW Rankine Cycle
832 m
Headers
235440m Solar Field: 432 EUROTrough collectors in 54 loops
945 m
Solar Thermal Market Problems
Solar Thermal (like all Renewables) is not competitive with least cost conventional alternatives needs financial subsidies (grants, kWh premiums, tax credits, soft loans, credit warranties, ) needs political support from national, multinational (I.e EU) or multilateral organisations to achieve market introduction
2000-06-18
Solar Thermal Market Problems National Governments dont like subsidize with their national taxes foreign suppliers (1cent/kWh premium fo a 50MW solar plant is 1 Mio USD subsidy per year) want to earn merits and votes with creation of jobs, local hitec, etc. dont support any not invented here Multinational Donors (like EU) want involvement of their members Multilateral Institutions (like World Bank, GEF) fair competition
Solar Thermal Market Problems In this phase, solar thermal industrial developers must avoid create a broad jealousy of the non-profiting companies in the renewable scene, who will intervene against subsidy and support at the national level
2000-06-18
EUROTrough Approach Based on these lessons learnt in Spain and in Brussels, the EUROTrough partners have committed themselves in their consortium agreement to open the EUROTrough platform (as the PC platform) intend to distribute the design widely by giving every partner the right to license the design to any client (even the competitors of other partners) in order to give a broad community the chance to make money with solar thermal thru EUROTrough Example: ANDASOL proposal
How Can the Partners Nevertheless Make Money? The EUROTrough Consortium follows the principle: Give Away Kerosene Lamps and Sell Kerosene Give Away Cell-Phones for 1$ and Profit from the Calls Open the Trough Platform like in the PC Business to competition and gain a market Make EUROTrough national anywhere Make EUROTrough invented there Involve from the beginning other national and international players to gain their lobbying support
Consortium Agreement
The EUROTrough Consortium does not want to make the money with the EUROTrough design itself, but wants to sell equipment (mirrors, structures, absorbers, trackers) and to sell services (project development, engineering, management, operation, construction, ) Like in the PC business, where nobody wants to invent himself a costly operating system or hardware bus, power project developers dont want to spend their money in reinventing and requalifying the parabolic trough. They want to spend minimum money in that and would rather use standard solutions. (Only within the solar thermal community we all have the desire to invent our own collector and solar concept)
Offer of EUROTrough to US Firms

In view of the limited resources for solar thermal, the EUROTrough Consortium advocates to join forces between Europe and US avoid duplication of efforts The EUROTrough Consortium offers to fully share the EUROTrough Design with interested US partners bring it into a joint NEXTrough US-European effort The EUROTrough Consortium proposes prequalify the EUROTrough in a prototype test at PSA demonstrate a loop of 8 Collectors at Kramer Junction jointly develop commercial scale projects
2000-06-18
Solar Thermal Market Problems
2000-06-18

Geyer Eurotrough

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Geyer Eurotrough

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EUROTrough Progress and NEXTrough Opportunities for an Euro-American Trough Alliance

Trough Meeting SUNLAB Madison, June 18, 2000

Trough Workshop Madison

Parabolic Trough Market Cost Reduction Perspectives

Competetive Price Range for Grid- Connected Intermediate Load Power

Parabolic Trough Cost Reduction Perspective

Improvement of Current Collector Design

Increase Plant Size 80 to 200 MW

Change from HTF to DSG

Build Multiple Plants per Year

Trough Workshop Madison

EUROTrough I+II Objectives

Central Drive Pylon

LS-3 State of the Art

Central Oil Pipe & Temperature Sensor

Absorber Tube (HCE)

Absorber Tube (HCE)

Hydraulic Drive System

Trough Workshop Madison

LS-3 State of the Art: Weights

Strong 1350 kg 315 kg 135 kg 93% 6.9mm 5.4mrad 5.3mrad

Regular 1068 kg 265 kg 92 kg 99% 10.2mm 5.5mrad 7.7mrad

LS-3 Space Frame LS-2 Torque Tube

Trough Workshop Madison

Decision on design options

Trough Workshop Madison

Why the Torque Box Design?

FEM Optimization: Wind Bending and Torsion

Maximum Wind Torsion

Trough Workshop Madison

Wind Tunnel Tests

EUROTrough Design Selection

Torque box selected

Final Wind Load Assumptions for EuroTrough

EUROTrough Design Tolerances

Dead Load Dead Load + Design Wind Load

Manufacturing and Installation Tolerances

average < 3 mrad 10mm, 10mm 5mm < 3 mrad

Gravity, 7m/s Wind

Collector Length vs Torque and Torsion

Mirror Stress Reduction by 50% vs LS2/LS3

EUROTrough Design Innovations

3% Land Slope North-South

EUROTrough Prototype Test at PSA

Half of 100m EUROTrough Collector Half of 150m EUROTrough Collector

EUROTrough Prototype Testloop at PSA

PI Doubling of 01 03 Pump Capacity

Doubling of Cooling Capacity

LS-3 & EUROTrough II HTF TEST LOOP P&I DIAGRAM

Trough Workshop Madison

Consortium Agreement Marketing Strategy International Cooperation

Trough Workshop Madison

AndaSol32: 1st Project with EUROTrough & DSG

Steam Generator Solar Preheater Deaerator Solar Reheater Expansion Vessel

Low Pressure Preheater

AndaSol32: 235000m EUROTrough & 16000m DSG

Power Block 32 MW Rankine Cycle

235440m Solar Field: 432 EUROTrough collectors in 54 loops

Solar Thermal Market Problems

Trough Workshop Madison

Trough Workshop Madison

Offer of EUROTrough to US Firms

Trough Workshop Madison