2012-Direct Steam Generation-Technology Overview

Direct Steam Generation (DSG)
Technology Overview
SFERA Summer School 2012
June 28, 2012, Almer, Spain
(Jan) Fabian Feldhoff
www.DLR.de/SF Slide 2 > SFERA Summer School 2012 > Direct Steam Generation (DSG) > Fabian Feldhoff > June 28, 2012
STE Status
- Many market players
- Need for significant cost reduction
- More automated production and construction
- Optimized collector designs
- New heat transfer fluids
- Direct Steam Generation (DSG)
- Molten Salt
-
Today: DSG
Solarlite: TSE-1
Overview
-
Introduction
DSG History
DSG Characteristics and two-phase flow
Plant concepts
Research Overview
- Once-through
- Steam Parameters
- Operation/Control
- Storage concepts
- Final Remarks and Outlook
Solarlite: TSE-1
Parabolic Trough Plants with Oil
Solarlite: TSE-1
Parabolic Trough Plants with Molten Salt
Parabolic Trough Plants with DSG
Solarlite: TSE-1
DSG Advantages and Drawbacks

Oil
DSG
+ Commercially applied
+ One-phase flow
+ Easily scalable
+ No heat exchangers
+ High temperatures
+ High efficiency
+ Non-toxic fluid
+ Simple overall configuration
- Two-phase flow
- Higher control effort
- Thermal storage expensive (so far)
- Higher temperature gradients
- Heat exchanger batteries

- T < 400C
- Efficiency/process limit reached
- Hazardous to environment
Milestones in DSG development

The very beginnings DSG was first!
John Ericsson
- New York, USA, 1870 and 1883
- 3.25-m2-aperture collector
- Driving a small 373-W engine.
Frank Shuman
- Meadi, Egypt, 1912-1913
- 5 collectors 62x4m
- driving a steam engine (~40 kW)
used to pump water for irrigation
Shuman Collector
Fernndez-Garca, A., Zarza, E., Valenzuela, L., et al., 2010,
"Parabolic-trough solar collectors and their applications," Renewable and Sustainable Energy Reviews, 14, pp. 1695 - 1721.

Revival in the 80s
Solar One, Barstow, USA
- 10 MWe, 425 C
- Once-through boiler
- 4 hours storage (sensible)
- In operation 1982-1988

Experiments with DSG in horizontal tubes
Benson test facility at Siemens

Goebel et al: Direkte Dampferzeugung in Parabolrinnensolarkraftwerken.
Forschungsverbund Sonnenenergie Themen 96/97, page 110 ff

DISS project: 500 m/100 bar/400 C

Planning of demonstration plant
INDITEP
- Application of design
tools
- 5 MWe, 410C / 78 bar
- Recirculation with
decentral separators
- Another 200m for DISS
Zarza, E., Rojas, M. E., Gonzlez, L., et al., 2006, "INDITEP:
The first pre-commercial DSG solar power plant," Solar Energy, 80 (10), pp. 1270-1276.

Commercial tower implementations
PS10: 40 bar saturated steam, 11 MWe

PS20: 45 bar saturated steam, 20 MWe
http://www.abengoasolar.com/corp/web/en/nuestras_plantas/plantas_en_operacion/espana/PS10_la_primera_torre_comercial_del_mundo.html

DSG Component tests at 500 C
2010/2011
Real-DISS test facility
112 bar / 500 C
PCM
storage
system
Concrete storage system

Linear Fresnel plants
PE-1: 1 MW, 55 bar, saturated steam

PE-2: 30 MW, 55 bar, saturated steam
Both plants with Linear Fresnel technology by Novatec Solar
Source: DLR

Linear Fresnel plants
Kimberlina 5 MWe
106 bar, 400 C
(higher values announced)
Technology by Areva Solar
Source: Areva Solar

The first parabolic trough plant with superheating
TSE-1, Thailand
5 MWe
34 bar, 340 C
Technology by Solarlite
Source: Solarlite
DSG Status Its commercial!

Topics for industry:
- Higher steam parameters (up to 110 bar /500 C)
- Parameter Optimization Pressure and temperature vs. Piping cost
- Improvements in plant configurations and costs
Topics for R&D:
- Solar Field Optimization Optimized recirculation, once-through
- Operation Optimization Start-up, Control
- Thermal Energy Storage Costs, Performance
- Plant integration options Hybrid, TES
Loop Characteristics > What its all about
Solarlite: TSE-1
Loop Characteristics > Temperature/pressure

- Temperature and pressure along loop (1500m, 500C/112 bar outlet)
Solarlite: TSE-1
600
120%
500
100%
400
80%
300
60%
200
40%
Temperature
Steam Quality
100
Steam Quality
Temperature in C
Loop Characteristics > Temperature/Steam Quality
20%
0%
0
10
Loop length in No of collectors

Solarlite: TSE-1
Flow Patterns in horizontal tubes

Bubble Flow
Plug Flow
Stratified Flow
To be avoided
Wavy Flow
Slug Flow
Annular Flow
Desired
Drop/Spray Flow
Based on VDI Heat Atlas, 10. Aufl. 2006, Hbb
Loop Characteristics > Temperatureprofile

- Four regions
I. Wetted heated
II. Wetted not heated
III. Dry not heated
IV. Dry heated
- Asymmetric temperature profile
around cross section
Heated Region
III
IV
II I
Wetted Region
Two-phase flow in horizontal pipes

Internal-heat transfer
345
Fall 1
Fall 2
340
case 2
335
Temperature [C]
case 1
330
325
320
315
310
45
90
135
180
225
270
Circumference Angle []
315
360
Loop Characteristics > Do you understand?

- Question of the day
- Which is the most
desirable flow pattern
in DSG loops with
high steam quality?
- Answer:
Annular Flow
due to its complete
wetted inner surface.

Flow pattern map
10
10
Ringstrmung
Annular
10
Blasenstrmung
Bubble
10
evaporation
10
10
10
Wellenstrmung
Wavy
-1
10
T, Fr*
Verdampfungsweg
Desired path of
-2
Schwallstrmung
Plug
Schichtstrmung
Stratified
0
10
-3
10
10
-2
10
-1
10
10
10
10
10
4
10
-3
Martinelli-Parameter X
Taitel, Y., and Dukler, A. E., 1976, "A model for predicting flow regime transitions in
Horizontal and near horizontal gas-liquid flow," AIChE Journal, 22 (1), pp. 47-55.:

Pressure loss
dp/dl
[mbar]
Pressure Loss
over
length (mbar/m)
berhitzer
Super7
heating
Evaporation
Verdampfer
Preheating
Vorwrmer
5
4
3
2
1
0
1000
1200
1400
1600
1800
2000
2200
Enthalpie [kJ/kg]
2400
2600
2800
3000
Plant Concepts > How you could run DSG plants
Solarlite: TSE-1
Once-Through
(classic)
Injection
Once-Through
Recirculation
Recirculation
Plant Concepts > Classical approaches
Eck, M., and Zarza, E., 2002, "Assessment of Operation Modes for Direct Solar Steam Generation
in Parabolic Troughs, 11th SolarPACES, Zurich, Switzerland
Plant Concepts > State-of-the-Art Concepts

Recirculation
Once-Through
DLR, Feldhoff
Plant Concepts > State-of-the-Art Comparison

Recirculation
Once-Through
+ Very robust operation

+ Commercially applied
+ Easily scalable
+ Fast start-up
+ Low investment
- Relatively high investment

- Relatively high design effort
- Not that robust

- End of evaporation not fixed
Based on: Eck, M., and Zarza, E., 2002, "Assessment of Operation Modes for Direct Solar Steam Generation in Parabolic Troughs,
11th SolarPACES Intern. Symposium on Concentrated Solar Power and Chemical Energy Technologies, Zurich, Switzerland
Plant Concepts > Recirculation with central field

separators
DLR, Feldhoff/Hirsch
Plant Concepts > Recirculation with decentral

separators
Zarza, E., Rojas, M. E., Gonzlez, L., et al., 2006, "INDITEP:

The first pre-commercial DSG solar power plant," Solar Energy, 80 (10), pp. 1270-1276.
Plant Concepts > Once-Through

- With 1 or 2 injections
- Only one type of loop
DLR, Feldhoff
Once-through > The better DSG concept?
Solarlite: TSE-1
Once-through > The DUKE Project

- DUKE: Durchlaufkonzept Entwicklung und Erprobung
(Once-Through Concept Development and Demonstration)
- Goals
- Analysis and demonstration of Once-through concept under real
irradiation conditions
- Partner
- DLR & Solarlite GmbH
- Together with CIEMAT
- Period:
- May 1, 2011 to April 30, 2014
Once-through > Demonstration at DISS Facility
BOP und
Control room
Installation and
storage space
New Solarlite 4600+

collectors (3x 100m)
North
Once-through > Main Changes DISS Solar Field

New injection
instrumentation
Temperature along end of

evaporation and around
cross sections
New balljoints
New receivers
New SH
injection
Relocation of
inlet valves
New BOP
injection
Once-through > Main Demonstration Experiments

- Component qualification
- Design and validation of dynamic models
- Test and validation of control concepts
System evaluation of once-through concept
Parameter Optimization > One step ahead
Parameter Optimization > Why that?

- Power Block:
Carnot efficiency
increases with
temperature
- Solar field:
efficiency decreases with
temperature
Find the optimum
Look at real-life
thermodynamics and
costs together!
Parameter Optimization > Power Block

8'124
120 bar
0.40
100 bar
0.38
HTF Reference
0.36
60 bar
0.34
40 bar
Heat Rate [BTU/kWhel]
Gross Power Block Efficiency [-]
0.42
0.32
0.30
350
375
400
425
450
475
500
11'373
525
Main Steam Temperature [C]
Feldhoff, J. F., Benitez, D., Eck, M., et al., 2010, "Economic Potential of Solar Thermal Power Plants
With Direct Steam Generation Compared With HTF Plants," Journal of Solar Energy Engineering, 132 (4), pp. 041001-9.
Mean Solar Field Efficiency [%]
Parameter Optimization > Solar Field (Rec.)

61.5
61.0
40 bar
60.5
60 bar
60.0
100 bar
59.5
59.0
58.5
58.0
57.5
350
375
400
425
450
475
500
525
Live Steam Temperature [C]
Parameter Optimization > Heat Balance Tool
Parameter Optimization > Overall efficiencies

- Comparison of annual net
efficiencies
- Thermodynamics: pressure
increase more efficient
than temperature increase
- Costs: piping for higher
pressure more expensive
System Analysis > Comparison with oil trough

Annual Yield Results for 100 MWe, Daggett (USA), 9h of thermal energy
storage (TES):
- DSG solar field size -5.3 %
- DSG net electricity output +2.5 to +2.9 %
- Net plant efficiency +8.3 %
Feldhoff, J. F., Schmitz, K., Eck, M., et al., 2012, "Comparative system analysis of direct steam generation and synthetic oil
parabolic trough power plants with integrated thermal storage," Solar Energy, 86 (1), pp. 520-530.
System Analysis > Cost Comparison to Oil Trough

- 100 MWe, 9h TES, Daggett/USA
- Large solar fields sizes (450 MWth and more) are close too current
design pressure limits
Choose DSG for sizes up to about 50 MWe and long term storage
- TES not yet commercially available
Concepts under development
Short term projects should focus on short term storage or hybridisation
Oil trough without TES at least 5-10% more expensive than DSG
Feldhoff, J. F., Schmitz, K., Eck, M., et al., 2012, "Comparative system analysis of direct steam
generation and synthetic oil parabolic trough power plants with integrated thermal storage," Solar Energy, 86 (1), pp. 520-530.
Control > The secret to better performance
Control > Solar Field

- One loop simulated
- Cascaded superheating
temperature controller
Higher temperature
gradients than in normal
multiple loop plant
Birnbaum, J., Feldhoff, J. F., Fichtner, M., et al., 2011, "Steam temperature stability in a
direct steam generation solar power plant," Solar Energy, 85 (4), pp. 660-668.
Control > Adaptive Controllers

- Adaptive PI controllers with DNIdependent feedforward are
reliable for recirculation and
injection mode [1, 2]
time constant of adaptive PI controler

nominal state
350
300
250
200
150
gain of adaptive PI controler

nominal state
50
0.2
-3
x 10
0
X: 1.04
Y: 650
Z: 105.3
100
0.6
0.8
400
1.2
mdot
K
X: 1.04
Y: 650
Z: -0.001343
-1.5
1000
800
600
0.4
-0.5
-1
X: 1.367
Y: 850
Z: 80.13
1.4
1.6
200
dni
Parameter range for adaptive PI controller
X: 1.367
Y: 850
Z: -0.001765
1000
-2
800
-2.5
0.2
600
0.4
0.6
0.8
400
1.2
mdot
1.4
1.6
200
qdni
[1]: Valenzuela, L., Zarza, E., Berenguel, M., et al., 2005, "Control concepts for direct steam generation in parabolic troughs," Solar Energy, 78 (2), pp. 301-311.
[2]: Eck, M., 2001, Die Dynamik der solaren Direktverdampfung und berhitzung in Parabolrinnenkollektoren, VDI Verlag Dsseldorf.
Graphics: DLR, Feldhoff/Trebing
Control > Experience from real recirculation plants

- Outlet temperature can be kept very stable even with easy controllers
- Multiple loops and header piping smooth the temperature significantly
no problems in recirculation plants
very robust operation in recirculation plants
DSG TES > Upgrading STE Plants

- TES = Thermal Energy Storage
DSG TES > Sytem Overview
Birnbaum, J., Eck, M., Fichtner, M., et al., 2008, "A Direct Steam Generation Solar Power Plant
with Integrated Thermal Storage," 14th Bienial SolarPACES Symposium, Las Vegas, USA.
DSG TES > Storage development

Phase change material storage
Phase change material
Demonstrated at DLR:
- NaNO3 - KNO3 - NaNO2
142 C
- LiNO3 - NaNO3
194 C
- NaNO3 - KNO3
222 C
- NaNO3
306 C
Experimental validation
- 5 test modules with 140 2000 kg PCM
- Worlds largest high temperature latent heat
storage with 14 tons of NaNO3 (700 kWh)
operating since 2010
DLR-TT
DSG TES > Plant Integration
DLR, FF
DSG TES > Plant Integration

Variant 1:
- PH: Concrete
- SG: PCM
- SH: Concrete
Variant 2:
- PH: Salt
- SG: PCM
- SH: Salt
Variant 3:
- PH: PCM
- SG: PCM
- SH: Salt
Project DETOP
DSG TES > Power Block Operation
Birnbaum, J., Eck, M., Fichtner, M., et al., 2008, "A Direct Steam Generation Solar Power Plant
with Integrated Thermal Storage," 14th Bienial SolarPACES Symposium, Las Vegas, USA.
Outlook and Market > Somebody must build it
Solarlite: TSE-1
DSG Companies
- Solarlite, Germany
- Recirculation, trough, superheated steam
- Novatec Solar, Germany
- Recirculation, Fresnel, saturated steam, probably superheated in future
- Areva Solar, France/Australia
- Once-through, Fresnel with multiple tubes/counter flow receiver,
exact parameters are unknown
- Solar Power Group, Germany
- Recirculation, Fresnel, no commercial plant realized so far
- Abengoa Solar, Spain
- Recirculation, trough, superheated steam, only tests at Solucar
Solarlite: TSE-1
Final Remarks on DSG

- DSG has reached commercial status!
- For short to mid-term:
- STE plants without or with small storage
- Integrated Solar Combined Cycle (ISCC) or fuel
saver plants (Dont use oil for that!)
- For long term DSG perspective:
- Development of economic PCM storage system
- Solar field optimization
- Overall parameter optimization including TES
- There is still a need for research
- There is still a need for a reliable and detailed
comparison of alternative STE configurations
Solarlite: TSE-1
Solarlite: TSE-1
Questions and Discussion

- Contact: [email protected]
By Ron Tandberg
DSG History > Add-on

- An uncomplete list of projects and contents
DSG activities 1/4

Duration
Partner
Target
GUDE
1993-96
DLR, Siemens,
TUM, ZSW
Thermo-hydraulic effects in
horizontal receiver tubes
PRODISS/
ARDISS
1996-99
DLR
Modelling, simulation and control of

a collector loop
CIEMAT, DLR,
Flagsol, Iberdrola,
ZSW,
Siemens/KWU
Planing and erection of DISS plant

Prove of concept
Evaluation of different operation
concepts
Validation and improvement of
modeling capabilities
DISS I/II
1996-2002
DSG activities 2/4

Duration
Partner
Target
INDITEP
2002-05
CIEMAT, DLR,
Flagsol, Iberdrola,
Siemens, ZSW
Detailed engineering of a demo loop

Component development (separator,
ball-joints, receiver)
Socio-economic analysis
SOLDI
2004-06
DLR, (Siemens)
Evaluation of separation concepts

Process heat generation
Dynamic model library
DISSTOR
2004-07
DLR, Zblin, SGL

Carbon, CIEMAT,
Iberdrola, Flagsol,
CNRS, Solucar
Development, erection and operation

of a latent heat storage system
DSG activities 3/4

Duration
Partner
Target
DIVA
2005-07
SCHOTT, DLR,
(Flagsol, KK&K)
Receiver development for 500 C

Detailed system analysis
ITES
2006-09
DLR, Zblin,
Siemens
Planing, erection and operation of a

integrated storage system
Optimized control strategies
FRESDEMO
2006-08
MAN, SPG, (DLR,

FhG-ISE, PSE)
Planing, erection and operation of a

Fresnel collector with DSG
Qualification of the collector
DSG activities 4/4

Duration
Partner
Target
DETOP
2009-10
Solar Millennium,
Flagsol, DLR,
Schott Solar, Zblin
Preparation of a demo plant

Detailed system analysis
FRESDEMO
2
2009-13
Schott Solar, DLR,

Novatec Solar,
FhG-ISE
Optimization of Linear Fresnel

Technology and operation
DUKE
2011-14
DLR, Solarlite
(CIEMAT)
Extension of DISS plant to 1000 m

Demonstration of once-through
operation

2012-Direct Steam Generation-Technology Overview

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Direct Steam Generation (DSG)

Parabolic Trough Plants with Oil

Parabolic Trough Plants with Molten Salt

Parabolic Trough Plants with DSG

DSG Advantages and Drawbacks

- Heat exchanger batteries

Milestones in DSG development

Milestones in DSG development

Milestones in DSG development

Benson test facility at Siemens

Milestones in DSG development

Milestones in DSG development

Milestones in DSG development

PS10: 40 bar saturated steam, 11 MWe

Milestones in DSG development

Concrete storage system

Milestones in DSG development

PE-1: 1 MW, 55 bar, saturated steam

Milestones in DSG development

Source: Areva Solar

Milestones in DSG development

DSG Status Its commercial!

Loop Characteristics > What its all about

Loop Characteristics > Temperature/pressure

Loop Characteristics > Temperature/Steam Quality

Loop length in No of collectors

Flow Patterns in horizontal tubes

Loop Characteristics > Temperatureprofile

Two-phase flow in horizontal pipes

Loop Characteristics > Do you understand?

Two-phase flow in horizontal pipes

Two-phase flow in horizontal pipes

Plant Concepts > How you could run DSG plants

Plant Concepts > Classical approaches

Plant Concepts > State-of-the-Art Concepts

Plant Concepts > State-of-the-Art Comparison

+ Very robust operation

- Relatively high investment

- Not that robust

Plant Concepts > Recirculation with central field

Plant Concepts > Recirculation with decentral

Zarza, E., Rojas, M. E., Gonzlez, L., et al., 2006, "INDITEP:

Plant Concepts > Once-Through

Once-through > The better DSG concept?

Once-through > The DUKE Project

Once-through > Demonstration at DISS Facility

New Solarlite 4600+

Once-through > Main Changes DISS Solar Field

Temperature along end of

Once-through > Main Demonstration Experiments

- Design and validation of dynamic models

- Test and validation of control concepts

System evaluation of once-through concept

Parameter Optimization > One step ahead

Parameter Optimization > Why that?

Parameter Optimization > Power Block

Heat Rate [BTU/kWhel]

Gross Power Block Efficiency [-]

Main Steam Temperature [C]