Central Receiver System Solar Power Plant Using Molten Salt as ...

Central Receiver System Solar Power
Plant Using Molten Salt as Heat
Transfer Fluid
J. Ignacio Ortega
SENER,
Severo Ochoa 4,
P.T.M., Tres Cantos, 28760 Madrid, Spain
e-mail: ignacio.obasagoiti@sener.es
J. Ignacio Burgaleta
SENER,
Avenida Zugazarte 56,
Las Arenas, 48930 Vizcaya, Spain
e-mail: ignacio.burgaleta@sener.es
Félix M. Téllez
CIEMAT,
Avenida Complutense 22,
28040 Madrid, Spain
e-mail: felix.tellez@ciemat.es
Of all the technologies being developed for solar thermal power
generation, central receiver systems (CRSs) are able to work at
the highest temperatures and to achieve higher efficiencies in
electricity production. The combination of this concept and the
choice of molten salts as the heat transfer fluid, in both the receiver
and heat storage, enables solar collection to be decoupled
from electricity generation better than water/steam systems, yielding
high capacity factors with solar-only or low hybridization
ratios. These advantages, along with the benefits of Spanish legislation
on solar energy, moved SENER to promote the 17 MW e
Solar TRES plant. It will be the first commercial CRS plant with
molten-salt storage and will help consolidate this technology for
future higher-capacity plants. This paper describes the basic concept
developed in this demonstration project, reviewing the experience
accumulated in the previous Solar TWO project, and
present design innovations, as a consequence of the development
work performed by SENER and CIEMAT and of the technical
conditions imposed by Spanish legislation on solar thermal power
generation. DOI: 10.1115/1.2807210
Keywords: solar power plant, CRS, central tower, molten salt,
tube receiver, solar TRES
Introduction
The Solar TRES demonstration project based on central receiver
system CRS technology inherited the lessons learned
from the previous Solar TWO experimental project and takes advantage
of the experience in molten-salt experiments and testings
carried out in the U.S. and Spain in the late 1980s and early 1990s
1–10.
The Solar TWO project 11,12 was a collaborative venture for
the design, construction, testing, and short term operation of a
10 MWe CRS power tower solar plant using molten salt as its heat
transfer and storage medium Fig. 1. The engineering, manufac-
Contributed by the Solar Energy Engineering Division for publication in the JOUR-
NAL OF SOLAR ENERGY ENGINEERING. Manuscript received October 31, 2006; final
manuscript received September 12, 2007; published online February 12, 2008. Review
conducted by Manuel Romero Alvarez. Paper presented at the Solar PACES
2006, Seville, Spain.
turing, and construction of Solar TWO lasted from 1992 to 1995,
with initial startup and testing beginning in 1996. Solar TWO
operated from April 1996 to April 1999. Despite its many successes,
the operation of Solar TWO was not without problems,
mainly related to component startup issues, including heat tracing,
piping, and the steam generator, which delayed routine operation
of the plant for more than a year. At the end, all of the issues were
essentially overcome with some combination of redesign and/or
rework, improved operating procedures, or work-arounds for fixes
that could not be implemented at Solar TWO 13.
Some of the key results of Solar TWO that constitute the starting
point for Solar TRES 14 were as follows:
Receiver efficiency was measured at 88% in low-wind conditions
and 86% in allowable operating winds, matching
design specifications.
Storage system efficiency was measured at over 97%, also
meeting design goals.
Gross Rankine-turbine cycle efficiency was at 34%, matching
performance projections.
Measured plant peak-conversion efficiency was 13.5%.
The plant successfully demonstrated its ability to dispatch
electricity independent of collection. On one occasion, the
plant operated around-the-clock for 154 h straight.
Plant reliability was also demonstrated. During one stretch
in the summer of 1998, the plant operated for 32 days out of
39 days 4 days down because of weather, 1 day because of
loss of off-site power, but only 2 days down for maintenance.
Despite its short test and evaluation phase, which did not
allow annual performance to be determined or operating and
maintenance procedures to be defined, the project identified
several areas for simplifying the technology and improving
its reliability.
Besides the technological background in the U.S., both SENER
and CIEMAT have had a long experience in developing systems
for solar power plants, in the heliostat design, construction, and
operation, since the 1980s. CIEMAT has well-known and reputed
capabilities in CRS design and operation and in operation with
molten-salt systems.
In addition to validating the design and technical characteristics
of molten-salt receiver and storage technology, Solar TWO has
also been successful in promoting commercial interest in power
towers. Two of the project’s key industrial partners, the Boeing
Company and Bechtel Corporation, agreed with a Spanish company
called GHERSA to pursue the commercial deployment of
molten-salt technology taking advantage of Spanish prices for renewable
power premiums and incentives. The initial project,
called “Solar TRES,” was predesigned according to the Spanish
incentive framework applicable at that time, which did not allow
hybridization to obtain high-capacity factors. The project was proposed
to the EC Fifth R&D Framework Program for partial financing
and was approved. Nevertheless, during project development,
some legal issues changes in Spanish renewable
legislation along with other issues related to the partners themselves
led to some reorientation of the project and the promoter’s
consortium. This process came to an end in the year 2005 and
concluded with an entirely European development team Spanish,
French, and German companies and is now working under the
leadership of SENER.
The final absence of contributions from the U.S. companies,
participating in Solar TWO, multiplied the challenges for designing
and building a new feasible molten-salt plant. The most delicate
development components were identified as a reliable and
durable receiver and a low-cost heliostat.
To overcome these challenges, SENER and CIEMAT signed a
parallel agreement for developing and testing a prototype receiver
module about 4 MW th as a component acceptance milestone in
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Fig. 1 Solar TWO molten-salt power tower system „schematic
diagram…
Solar TRES construction, which also includes the interaction involved
in developing a 120 m 2 low-cost heliostat with their own
technology.
Heliostats remain to be one of the crucial economic aspects of
this technology, since they are the most significant cost component
of a CRS plant, accounting for 30–40% of capital investment,
of which 40–50% is tied to the cost of the drive system
gears, motors, etc.. However, there was a rather limited experience
in developing industrial programs for manufacturing these
components at a large scale. For that reason, SENER decided to
make a significant effort to evaluate current technologies and develop
an innovative low-cost heliostat design solution. During the
past years, SENER has designed and tested a new 120 m 2 lowcost
heliostat and drive system, shown in Fig. 2, at its location in
Plataforma Solar de Almería PSA, and thoroughly described in
Ref. 15.
CIEMAT’s contribution to receiver development was based on
its expertise in both development and testing of several tube
16–21 and salt receivers 22–24 and in materials technology
22–26. Furthermore, the test facilities at PSA, which are well
known for their expertise in the concentrating solar community,
constitute the natural place for receiver panel acceptance testing
and heliostat evaluation and performance diagnostics.
Spanish Legal Framework for Solar Electricity
Demonstration projects in Europe are conceived as semicommercial
units, involving new technologies that are not yet fully
commercial but that must operate under commercial conditions
lifetime and annual availability in order to show the commercial
readiness of the technology.
In the renewable energy field, these requirements imply that the
plant must show its capability for uninterrupted, commercial-scale
megawatt-size power generation that could be fed into the grid
for a period equivalent to the usual lifetime of a power plant.
For that reason, before any demonstration project in the solar
thermal power STP sector could be developed, the Spanish Energy
Authorities had to define the legal and economic framework
for STP plants as part of a national renewable energy plan, since
this technology, still regarded as being in the research and development
stage, was not initially included in the legislation regulating
power generation in Spain since 1997 Law 54/97, although
there was a full section for power generation with renewable energy
and combined heat and power CHP units. In the year 2002,
this was finally changed to include STP in the “feed-in tariff”
scheme supporting renewable power plants.
Fig. 2 SENER heliostat and drive mechanism „detail…
Further changes in legislation forced plant construction to be
postponed, as it posed some fundamental technical and economic
uncertainties for the promoters. These issues were finally resolved
in the Spring of 2004 Royal Decree 436/2004 and, hence, STP
plants became a real alternative for renewable energy in Spain,
provided they qualify as a “renewable energy producer” and receive
an adequate price for the electricity produced by meeting
the following conditions:
Maximum installed power of 50 MW.
No hybrid plants.
A small percentage of natural gas 12–15% on primary energy
basis may be used in plants involving heat storage
systems only to maintain the thermal storage temperature
during nongeneration periods. By Royal Decree 2531/2004,
natural gas can also be used for power production during
none or low-irradiation periods.
Solar thermal electricity generators that deliver their production
to a distributor may receive a fixed tariff of 300% of the
reference price for the first 25 years after startup and 240%
afterward. Solar thermal electricity generators that sell their
electricity on the free market may receive a premium of
250% of the reference price for the first 25 years after startup
and 200% afterward, plus a 10% incentive. The average
electric tariff or reference for the year 2004 was
7.2072 c€/kW h.
Following this regulation, the project design had to be reviewed.
Molten-Salt Central Receiver Systems Compared to
Competing Technologies
According to SENER estimates, CRS power plants with
molten-salt storage are, even at the design stage, the winning
choice for STP plants in terms of energy efficiency, cost per unit
produced, and surface required for power production.
Moreover, high-capacity molten-salt storage makes it possible
for the plant to provide dispatchable power, which, from the utilities’
point of view, is crucial for the deployment of these plants as
capable of secure, predictable, and programmable power supply,
avoiding the problems for the national grid caused by other renewable
sources of power, such as wind or photovoltaic.
According to the European Concentrated Solar Thermal Road
Mapping study entitled ECOSTAR 27,28, cofunded by the EC,
the U.S. 10 MW pilot plant experience has made the molten-salt
technology the best developed CRS today. Based on cost estimates
provided by U.S. colleagues and the ECOSTAR evaluation,
even small-scale 17 MWe costs leverized electricy cost LEC
of 18–19 cents/kW h look relatively attractive. This is mainly
due to very low thermal energy storage costs, which benefit from
a three times larger temperature rise in the CRS compared to the
parabolic trough systems. Furthermore, a higher annual capacity
factor than in parabolic trough systems is possible due to the
smaller difference between summer and winter performances. The
highest risk is associated with expected plant availability, which
could not be proven in the Solar TWO demonstration due to a
variety of problems linked to the molten salt and the age of the
heliostat field. However, technical solutions have been identified
addressing these issues. To further reduce molten-salt power tower
costs, they must take advantage of economies of scale.
The plant availability risk can only be resolved in a demonstration
plant such as the Solar TRES now being designed. In the end,
this risk could lead to additional costs not previously considered.
Published data from Refs. 27,28 and SENER studies lead to
the figures shown in Table 1.
Solar TRES Project Description
A schematic flow diagram of the plant is shown in Fig. 3.
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Technology
The Solar TRES project will take advantage of several advancements
in the molten-salt technology since Solar TWO was designed
and built. These include the following:
A larger plant with 2480 heliostat field, approximately three
times the size of Solar TWO 120 m2 large-area glass-metal
heliostats developed by SENER based on economic criteria.
Use of a large-area heliostat in the collector field
greatly reduces plant costs, mainly because fewer drive
mechanisms are necessary for the same mirror area.
A 120 MWth high-thermal-efficiency cylindrical receiver
system, able to work at high flux and lower heat losses. The
receiver has been designed to minimize thermal stress and to
resist intergranular stress corrosion cracking. High nickel
alloy materials and an innovative integral header and nozzle
design developed by SENER, achieving the objectives of
high thermal efficiency, improved reliability, and reduced
cost, will be used.
Table 1 Technology assessment for 50 MW e plants
Parabolic
trough+oil
CRS+
steam
CRS+molten
salts
Mean gross efficiency as percentage of direct
radiation, without parasitics
15.4 14.2 18.1
Mean net efficiency 14 13.6 14
Specific power generation kw h/m 2 yr 308 258 375
Capacity factor % 23–50 24 Up to 75
Unitary investment €/kw h yr 1.54 1.43 1.29
Operation and maintenance c€/kW h 3.2 4.1 3.7
Levelized electricity cost €/kW he 0.16–0.19 0.17–0.23 0.14–0.17
Fig. 3 Solar TRES flow schematic
An improved physical plant layout with a molten-salt flow
loop Fig. 4 that reduces the number of valves, eliminates
“dead legs,” and allows fail-safe draining that keeps salt
from freezing.
A larger thermal storage system 15 h, 647 MW h, 6250 t
salts with insulated tank immersion heaters. This highcapacity
liquid nitrate-salt storage system is efficient and
low risk, and high-temperature liquid salt at 565°C in stationary
storage drops only by 1–2°C/day. The cold salt is
stored at 45°C above its melting point 240°C, providing a
substantial margin for design.
Advanced pump designs that will pump salt directly from
the storage tanks, eliminating the need for pump sumps, and
high temperature multistage vertical turbine pumps to be
mounted on top of the thermal storage tanks, using a longshafted
pump with salt-lubricated bearings. This pump ar-
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Fig. 4 Solar TRES 3D view „SENSOL output…
rangement eliminates the sump, level control valve, and potential
overflow of the pump sump vessels.
A 43 MW steam generator system that will have a forced
recirculation steam drum. This innovative design places
components in the receiver tower structure at a height above
the salt storage tanks that allows the molten-salt system to
drain back into the tanks, providing a passive fail-safe design.
This simplified design improves plant availability and
reduces operation and maintenance costs. The new design
will use a forced recirculation evaporator configuration to
move molten salt through the shell side of all heat exchangers,
reducing risk of nitrate-salt freezing.
A more efficient 39.4% at design point and 38% annual
average, higher-pressure reheat turbine and very high steam
pressure and temperature conditions for relatively low size
compared to conventional power plants. A can be started up
and stopped daily, and responds well to load changes, assuring
a 30 yr lifetime with good efficiency.
Improved instrumentation and control systems for heliostat
field and high temperature nitrate-salt process.
Improved electric heat tracing system for protection against
freezing of salt circuits, storage tanks, pumps, valves, etc.
These advancements improve the peak and annual conversion
efficiency over the Solar TWO design. Although the turbine will
be only slightly larger than Solar TWO’s, the larger heliostat field
and thermal storage system will enable the plant to operate
24 h/day during the summer and have an annual solar capacity
factor of approximately 64% up to 71%, including 15% production
from fossil backup.
An example of Solar TRES’ dispatchability is illustrated in Fig.
5, which shows the load-dispatch capacity from the 14th to the
Fig. 5 Solar TRES power dispatch capacity
18th of August. The figure shows the solar intensity power on
receiver, energy stored in the hot tank, and power output as a
function of the time of day.
Solar TRES Sensitivity Analysis
Several plant configuration studies 29 taking into consideration
economic profitability and plant investment cost were performed
using the SENSOL code, developed by SENER for solar
plant optimization 30.
The following factors were analyzed:
Number of heliostats: different heliostat field configurations,
ranging from 1800 to 3500.
Optimum heliostat mirror-surface, reflectivity, and cleaningfactor
performance.
Tower height: from 90 m to 150 m.
Receiver dimensions: diameter 8–10 m, height 9–11 m,
number of panels.
Storage size: from 10 h to 20 h.
Turbine power: from 10 MWe to 20 MWe. Annual use of natural gas, ranging from 10% to 15%, with
different applications for maintaining the hot-salt temperature.
Storage during electricity generation and nongeneration,
supporting solar energy during startup.
For each of these factors, several plant configurations have been
evaluated with SENSOL, predicting the global investment and the
economic profitability of each particular design. Global plant production
and consumption were calculated, as well as other operating
costs maintenance, cleaning, etc. for each configuration.
As an example of the different plant configurations studied, Fig.
6 shows the SENSOL output for the number of heliostats, turbine
power, and cost per kW h produced.
The analysis concluded that, based on RD 436/2004 and RD
2531/2004, the best combination of profitability and minimum
investment leads to the basic Solar TRES plant configuration defined
in Table 2.
Present Status of Central Receiver System Molten-Salt
Technology
The Solar TRES project is now in the last stages of technical
verification testing of receiver modules, heliostats, molten-salt
pilot plant, and control system and sitting final definition, licensing
and permitting, and final cost estimation.
Regarding the technical development, testing at PSA on a prototype
receiver module, now under development, will allow
SENER to determine the safety limits and the life of the receiver
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Fig. 6 Solar TRES sensitivity analysis „heliostat/turbine
power/energy cost…
under critical conditions, as well as to confirm relevant parameters
e.g., receiver efficiency to minimize risks and to increase operational
experience with molten-salt system.
Project schedule is also pending on the administrative issues of
the project, already mentioned. Construction and assembling is
expected to last for 24 months after having all those issues solved
and properly defined.
The Solar TRES project represents the demonstration step for
CRS molten-salt technology, since this technology has not yet
shown its real potential in a long term and continuous operation.
For that reason, this project involves some technical risk, regarding
mainly the operation, on real conditions of a large molten-salt
system, including receiver, pumps, valves, long pipes, and tanks.
Further development of the technology should led to bigger
plants, in the 50–100 MW range, that must reduce technology
costs. Feasibility studies being performed by SENER for some
utilities show the cost reduction potential for a 100 MW e moltensalt
central receiver solar power plant under different configurations.
Conclusions
The CRS technology and molten-salt storage proven experimentally
in Solar TWO offers the following advantages over other
solar technologies: high-capacity thermal storage, good availability
for dispatchable power, and least-cost kW h produced. These
advantages, along with the benefits of Spanish legislation on solar
energy, were the reasons that SENER decided to promote the construction
of a 17 MWe solar plant, named Solar TRES. It will be
the first commercial CRS solar power plant with molten-salt storage
and will help consolidate this technology for future plants
with higher power.
Table 2 Solar TRES key figures
Number of heliostats 2480
Surface covered by heliostats 285,200 m 2
Surface covered by heliostats 142.31 ha
Tower height 120 m
Receiver power 120 MW th
Turbine power 17 MW e
Storage size 15 h
Natural gas boiler capacity 16 MW th
Annual electric production min. 96,400 MW he
CO 2 mitigation best available technology 23,000 tons/yr
CO 2 mitigation coal power plant 85,000 tons/yr
Acknowledgment
The engineering and testing activities of the Solar TRES power
plant are being partly funded by the European Commission EC
Contract No. NNE5-2001-369.
Nomenclature
Acronyms
CHP combined heat and power
CIEMAT center for Energy, Environment and Technological
Research Spain
CRS central receiver system
CSP concentrating solar thermal power
DNI direct normal insolation
EC European Commission E.U.
DOE Department of Energy
NREL National Renewable Energy Laboratory U.S.
SENER Engineering, Consulting and Integration Company
Spain
SNL Sandía National Laboratory U.S.
STP solar thermal power
RD Royal Decree
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