Characterization of a microchannel solar thermal receiver for a supercritical carbon dioxide (sCO2) is presented. The receiver design is based on conjugate computational fluid dynamics and heat transfer simulations as well as thermo-mechanical stress analysis. Two receivers are fabricated and experimentally characterized — a parallel microchannel design and a microscale pin fin array design. Lab-scale experiments have been used to demonstrate the receiver integrity at the design pressure of 125 bar at 750°C surface temperature. A concentrated solar simulator was designed and assembled to characterize the thermal performance of the lab scale receiver test articles. Results indicate that, for a fixed exit fluid temperature of 650°C, increase in incident heat flux results in an increase in receiver and thermal efficiency. At a fixed heat flux, efficiency decreased with an increase in receiver surface temperature. The ability to absorb flux of up to 100 W/cm2 at thermal efficiency in excess of 90 percent and exit fluid temperature of 650°C using the microchannel receiver is demonstrated. Pressure drop for the pin array at the maximum flow rate for heat transfer experiments is less than 0.64 percent of line pressure.

This computational study investigates design of microchannel based solar receiver for use in concentrated solar power. A design consisting of a planar array of channels with solar flux incident on one side and using supercritical carbon dioxide as the working fluid is sought. Use of microchannels is investigated as they offer enhanced heat transfer in solar receivers and have the potential to dramatically reduce the size and increase the performance. Designs are investigated for an incident heat flux of 1 MW/m2, up to 3.3 times that of current solar receivers [1], resulting in significant reduction of size and cost. The goal is to design a microchannel receiver with inlet and outlet temperatures of the working fluid of 500°C and 650°C, operating pressure of 100 bar, pressure drop less than 0.35 bar and surface efficiency greater than 90% defined by radiation and convection losses to the environment. Three micro-channel designs are considered: rectangular cross section with high and low aspect ratio (designs A and B) and rectangular cross section with an array of micro pin-fins of various shape spanning the height of the channel (design C). Numerical simulations are performed on individual channels and on a unit cell of the pin-fin design. Structural analysis is performed to ensure that the design can withstand the operating pressure and thermal stresses. The effects of flow maldistribution and header system in an array of channels are also investigated. Preliminary results show that all three designs are capable of meeting the requirements, with the pin-fin design having the lowest pressure drop and highest efficiency.

This paper discuses the design of several micro-channel solar receiver devices. Due to enhanced heat transfer in micro-channels, these devices can achieve a higher surface efficiency than current receiver technology, leading to an increase in overall plant efficiency. The goal is to design an efficient solar receiver based on use of super-critical carbon-dioxide and molten salt as heat-transfer fluids. The super-critical Brayton cycle has shown potential for a higher efficiency than current power cycles used in CSP. Molten salt has been used in CSP applications in the past. The required inlet and outlet temperatures of the fluid are 773.15 K and 923.15 K for carbon-dioxide and 573.15 K and 873.15 K for molten salt. These temperature values are determined by the power cycles the devices are designed to operate in. The required maximum pressure drop is 0.35 bar for carbon-dioxide and 1 bar for molten salt. These pressure values are intended to be a practical goal for maximum pressure drop. The super-critical carbon-dioxide power cycle requires an operating pressure of is 120 bar. Finally, each device must withstand any mechanical and thermal stresses that may exist. Devices presented range in size from 1 cm2 to 4 cm2 and in heat transfer rates from 200 W to 400 W. The size of the device is based on the output capacity of the solar simulator which will be used for testing. For carbon-dioxide, three designs were developed with varying manufacturability. The low risk design features machined and welded parts and straight parallel channels. The medium risk design features machined and diffusion bonded parts and straight parallel channels. The high risk design features a circular micro-pin-fin array created using EDM and is constructed using diffusion bonding. The absence of high operating pressure for molten salt made structural design much easier than for carbon-dioxide. Conjugate heat-transfer simulations of each design were used to evaluate pressure drop, receiver efficiency, and flow distribution. Two and three dimensional structural analyses were used to ensure that the devices would withstand the mechanical and thermal stresses. Based on the numerical analyses, a receiver efficiency of 89.7% with a pressure drop of 0.2 bar were achieved for carbon-dioxide. The design was found to have a structural safety factor of 1.3 based maximum mechanical stress occurring in the headers. For molten salt, an efficiency of 92.1% was achieved with a pressure drop of 0.5 bar.