In the ferronickel production process, mineral calcination is one of the most energy-intensive stages. In a typical rotary kiln calciner, particulate solids and combustions gases move counter currently, while solids undergo drying, pre-reduction, and partial reduction reactions. The combustion of natural gas provides the thermal energy for drying and reduction reactions. About 80 to 85% of the incoming laterite ore leaves the reactor as calcined ore, while the flue gases entrain part of the solids as dust. This work presents a theoretical analysis contrasted with experimental results to evaluate the partial reduction of laterite ores in two rotary kilns of 185 m and 135 m length. The study focused on the water formed in the process, including a comparative analysis of water consumption by two different solids recovery technologies, a gas scrubber and an electrostatic precipitator. Simulations allowed evaluating the water and greenhouse gas formation in the main streams of the process. Among the tested operation conditions, the moisture content in the pellets, consisting of agglomerated dust, strongly influenced the amount of water released in the process and the energy consumption. Furnace RK-2 needs approximately 56% more energy to evaporate the moisture content in the feedstock. Furthermore, furnace RK-2 released 55.4 m 3 h −1 of water into the atmosphere, which represented two times the amount released by furnace RK-1. Gas scrubber analysis showed that as the liquid water increased, more H 2 O in the gases was condensed; however, the destroyed exergy also increased. Electrostatic precipitators appear as an adequate technology for reducing water and energy consumption in the ferronickel industry.

Camera-based imaging methods were evaluated to quantify both particle and convective heat losses from the aperture of a high-temperature particle receiver. A bench-scale model of a field-tested on-sun particle receiver was built, and particle velocities and temperatures were recorded using the small-scale model. Particles heated to over 700 °C in a furnace were released from a slot aperture and allowed to fall through a region that was imaged by the cameras. Particle-image, particle-tracking, and image-correlation velocimetry methods were compared against one another to determine the best method to obtain particle velocities. A high-speed infrared camera was used to evaluate particle temperatures, and a model was developed to determine particle and convective heat losses. In addition, particle sampling instruments were deployed during on-sun field tests of the particle receiver to determine if small particles were being generated that can pose an inhalation hazard. Results showed that while there were some recordable emissions during the tests, the measured particle concentrations were much lower than the acceptable health standard of 15 mg/m 3 . Additional bench-scale tests were performed to quantify the formation of particles during continuous shaking and dropping of the particles. Continuous formation of small particles in two size ranges (< ∼1 microns and between ∼8–10 microns) were observed due to de-agglomeration and mechanical fracturing, respectively, during particle collisions.

The global energy demand has increased at a very large rate, and in parallel, the Municipal Solid Waste (MSW) has also increased, both posing enormous technological challenges to world sustainable growth. Therefore, in order to contribute with concrete alternatives to face such quest for sustainability, this work presents an analysis of an integrated power plant fired by municipal solid waste that uses a biological filter for the combustion emissions fixation. The facility located in the Sustainable Energy Research & Development Center (NPDEAS) at Federal University of Parana is taken as a case study to analyze the process of technical and economic viability. For that, an exergoeconomic optimization model of the waste-to-energy power plant that generates electricity and produces microalgae biomass is utilized. An incineration furnace, which has a 50 kg/h capacity, heats the flue gas above 900°C and provides energy for a 15 kW water-vapor Rankine cycle. A set of heat exchangers preheats the intake air for combustion and provides warm utility water to other processes in the plant, which assures that the CO 2 rich flue gas can be airlifted to the microalgae cultivation photobioreactors (PBR) at a low temperature, using a 9 m high mass transfer emissions fixation column. Five 12 m 3 tubular photobioreactors are capable of supplying up to 30,000 kg/year of microalgae biomass with southern Brazil solar conditions of 1732 kWh/m 2 per year. The results show that considering the incineration services, the integrated power plant could have a payback period as short as 1.35 years. In conclusion, the system provides a viable way to obtain clean energy by thermally treating MSW, together with microalgae biomass production that could be transformed in a large variety of valuable bioproducts (e.g., nutraceuticals, pharmaceuticals, animal feed, and food supplements).

Direct solar power receivers consist of tubular arrays, or panels, which are typically tubes arranged side by side and connected to an inlet and outlet manifold. The tubes absorb the heat incident on the surface and transfer it to the fluid contained inside them. To increase the solar absorptance, high temperature black paint or a solar selective coating is applied to the surface of the tubes. However, current solar selective coatings degrade over the lifetime of the receiver and must be reapplied, which reduces the receiver thermal efficiency and increases the maintenance costs. This work presents an evaluation of several novel receiver shapes which have been denominated as fractal like geometries (FLGs). The FLGs are geometries that create a light-trapping effect, thus, increasing the effective solar absorptance and potentially increasing the thermal efficiency of the receiver. Five FLG prototypes were fabricated out of Inconel 718 and tested in Sandia’s solar furnace at two irradiance levels of ∼15 and 30 W/cm 2 and two fluid flow rates. Photographic methods were used to capture the irradiance distribution on the receiver surfaces and compared to results from ray-tracing models. This methods provided the irradiance distribution and the thermal input on the FLGs. Air at nearly atmospheric pressure was used as heat transfer fluid. The air inlet and outlet temperatures were recorded, using a data acquisition system, until steady state was achieved. Computational fluid dynamics (CFD) models, using the Discrete Ordinates (DO) radiation and the k-ω Shear Stress Transport (SST) equations, were developed and calibrated, using the test data, to predict the performance of the five FLGs at different air flow rates and irradiance levels. The results showed that relative to a flat plate (base case), the new FLGs exhibited an increase in the effective solar absorptance from 0.86 to 0.92 for an intrinsic material absorptance of 0.86. Peak surface temperatures of ∼1000°C and maximum air temperature increases of ∼200°C were observed. Compared to the base case, the new FLGs showed a clear air outlet temperature increase. Thermal efficiency increases of ∼15%, with respect to the base case, were observed. Several tests, in different days, were performed to assess the repeatability of the results. The results obtained, so far, are very encouraging and display a very strong potential for incorporation in future solar power receivers.

Highly-specular reflective surfaces that can withstand elevated-temperatures are desirable for many applications including reflective heat shielding in solar receivers and secondary reflectors, which can be used between primary concentrators and heat collectors. A high-efficiency, high-temperature solar receiver design based on arrays of cavities needs a highly-specular reflective surface on its front section to help sunlight penetrate into the absorber tubes for effective flux spreading. Since this application is for high-temperature solar receivers, this surface needs to be durable and to maintain its optical properties through the usable life. Degradation mechanisms associated with elevated temperatures and thermal cycling, which include cracking, delamination, corrosion/oxidation, and environmental effects, could cause the optical properties of surfaces to degrade rapidly in these conditions. Protected mirror surfaces for these applications have been tested by depositing a thin layer of SiO 2 on top of electrodeposited silver by means of the sol-gel method. To obtain an effective thin film structure, this sol-gel procedure has been investigated extensively by varying process parameters that affect film porosity and thickness. Endurance tests have been performed in a furnace at 150°C for thousands of hours. This paper presents the sol-gel process for intermediate-temperature specular reflective coatings and provides the long-term reliability test results of sol-gel protected silver-coated surfaces.

Within the European research project SOL2HY2, key components for a solar hybrid sulfur cycle are being developed and demonstrated at pilot scale in a real environment. Regarding the thermal portion, a plant for solar sulfuric acid decomposition is set up and initially operated at the research platform of the DLR Solar Tower in Jüulich, Germany. One major component is the directly irradiated volumetric receiver, superheating steam and SO 3 coming from a tube-type evaporator to above 1000 °C. At the design flow rate of sulfuric acid (50%-wt.) of 1 l/min, a nominal solar power of 57 kW is required at the receiver. With a flat ceramic absorber made from SiC and a flat quartz glass window, the design is based on lab scale reactors successfully demonstrated at the solar furnace of the German Aerospace Centre (DLR) in Cologne, Germany. A flexible lumped thermodynamic tool representing the receiver, compiled to assess different configurations, is presented in detail. An additional raytracing model has been established to provide the irradiation boundaries and support the design of a conical secondary concentrator with an aperture diameter of 0.6 m. A comparison with first experimental data (up to 65% nominal power), obtained during initial operation, indicates the models to be viable tools for design and operational forecast of such systems. With a provisional method to account for the efficiency of the secondary concentrator, measured fluid outlet temperatures (up to 1000 °C) are predicted with deviations of ±60 °C. Respective absorber front temperatures (up to 1200 °C) are under-predicted by 100–200 °C, with lower deviations at higher mass flows. The measured window temperature (up to 700 °C) mainly depends on the absorber front temperature level, which is well predicted by the model.

Efforts at Sandia National Laboratories are addressing more efficient solar selective coatings for tower applications, based on oxide materials deposited by a variety of methods. Over the course of this investigation, several compositions with optical properties competitive to Pyromark have been identified. These promising coatings were deposited on Inconel 625 and Haynes 230 Ni alloys and isothermally aged in air at temperatures between 600–800 °C for up to 480 hours, concurrently with Pyromark ® , which was used as a reference standard. At various heating times, the samples were removed from the furnace and their optical properties (solar-weighted absorptance and emittance) were measured. In addition, x-ray diffraction and scanning electron microscopy were utilized to investigate any structural or morphological changes that occurred over time with heating, in an attempt to correlate with changes in optical properties. At 600 and 700 °C, several of the coatings maintained an absorptivity > 90%. While the chemical makeup of the coating material greatly influences its optical properties, the morphology of the surface also plays in important part. A thermal sprayed coating modified using a novel laser treatment showed improved properties versus the untreated coating, on par with Pyromark™ at 600 °C, with little degradation after 480 hours. The results of aging on the optical, structural, and morphological properties of these novel coatings will be discussed.

Accurate measurement of heat flux and temperature can significantly affect the energy usage in several industrial applications, including furnace operation, metal processing, fire safety tests and more. Directional Flame Thermometers, or DFTs, offer the ability to use both temperature and heat flux measurements for furnace control. Currently, analysis of dynamic temperature data from the DFTs to compute heat flux information must be performed off-line at the conclusion of data-gathering by using software tools such as IHCP1D. Availability of a near real-time algorithm for accurate reduction of the data will allow for continual monitoring of the furnace during operation. This will result in better control over the process and significant savings in energy and cost. In this paper, a filter form of the inverse heat conduction algorithm is developed for utilization in DFTs. The algorithm is based on linearized solutions of the direct heat equation, and non-linear effects introduced by temperature dependent thermal properties are accounted for by interpolating of the resulting filter coefficients. The developed method is tested through several numerical experiments and also ANSYS model. A graphical user interface is developed in LabVIEW to provide a friendly interface for the end user. The temperature data measured by thermocouples on the DFT are transmitted to the computer through data acquisition card and the developed tool in LabView display the heat flux in a near real time fashion.

Pyrolysis of biomass (wood) was studied at the focus of a 1.5 kW vertical axis solar furnace. The sweeping gas feeding system was designed based on the CFD simulation results. The effects of temperature on the product yields and compositions of gas were investigated by experiments performed at heating rate of 50°C/s up to 600, 800, 1000, and 1200°C. The role of heating rates influencing the product yields and gas composition was studied by experiments carried out at different heating rates of 5, 100, 25 °C/s to 1200°C. The results show that the increase of gas product from 27.7% to 47.8% with increasing temperature and heating rate comes from the tar decomposition. In the solar reactor, heating rate plays a more important role for the product yields than temperature does, which is different with respect to conventional reactors.

A new experimental set-up has been introduced at San Diego State University’s Combustion and Solar Energy Lab to study the thermal oxidation characteristics of in-situ generated carbon particles in air at high pressure. The study is part of a project developing a Small Particle Heat Exchange Receiver (SPHER) utilizing concentrated solar power to run a Brayton cycle. The oxidation data obtained will further be used in different existing and planned computer models in order to accurately predict reactor temperatures and flow behavior in the SPHER. The carbon black particles were produced by thermal decomposition of natural gas at 1250 °C and a pressure of 5.65 bar (82 psi). Particles were analyzed using a Diesel Particle Scatterometer (DPS) and scanning electron microscopy (SEM) and found to have a 310 nm average diameter. The size distribution and the complex index of refraction were measured and the data were used to calculate the specific extinction cross section γ of the spherical particles. The oxidation rate was determined using 2 extinction tubes and a tube furnace and the values were compared to literature. The activation energy of the carbon particles was determined to be 295.02 kJ/mole which is higher than in comparable studies. However, the oxidation of carbon particles bigger than 100 nm is hardly studied and almost no previous data is available at these conditions.

The optical design and engineering features of a 10 kW solar furnace now operational at Valparaiso University are described. The solar furnace is anticipated to achieve a mean concentration ratio of 3000 suns over a 6 cm diameter focus. It will support high-temperature solar chemistry research and undergraduate engineering pedagogy. Many of the components of the solar furnace were designed and constructed by undergraduate engineering students. Some of these students cite their participation in the solar furnace project as the motivating factor for continuing to work in the area of energy science in industry or graduate school.

A sulfur based thermochemical energy storage cycle for baseload power generation is being developed under the support of US DOE Sunshot program. Solar heat is stored in elemental sulfur via thermal decomposition of sulfuric acid and disproportionation of sulfur dioxide into elemental sulfur and sulfuric acid. Heat energy is recovered upon sulfur combustion. On-sun decomposition of sulfuric acid in a solar furnace has been demonstrated between 650 and 850°C. Near equilibrium conversion was obtained at high temperature but conversion was reduced due to catalyst poisoning at the lower temperatures. Sulfur dioxide disproportionation modeling showed the reaction driving force is maximized at the high system pressure and low system temperature. The effect of system pressure was validated experimentally. However, the disproportionation rate was found to increase with system temperature as a result of increased reaction kinetics. Homogenous iodide catalysts were used to further enhance the degree of disproportionation and the reaction rate. The process steps required to recover the catalyst for reuse have been verified.

The ambitious DOE SunShot cost target ($0.06/kWh) for concentrated solar power (CSP) requires innovative concepts in the collector, receiver, and power cycle subsystems, as well as in thermal energy storage (TES). For the TES, one innovative approach is to recycle waste from metallurgic industry, called slags, as low-cost high-temperature thermal energy storage material. The slags are all the non-metallic parts of cast iron which naturally rises up by lower density at the surface of the fusion in the furnace. Once cooled down some ceramic can be obtained mainly composed of oxides of calcium, silicon, iron, and aluminum. These ceramics are widely available in USA, about 120 sites in 32 States and are sold at a very low average price of $5.37/ton. The US production of iron and steel slag was estimated at 19.7 million tons in 2003 which guarantees a huge availability of material. In this paper, electric arc furnace (EAF) slags from steelmaking industry, also called “black slags”, were characterized in the range of temperatures of concentrated solar power. The raw material is thermo-chemically stable up to 1100 °C and presents a low cost per unit thermal energy stored ($0.21/kWh t for ΔT = 100 °C ) and a suitable heat capacity per unit volume of material (63 kWh t /m 3 for ΔT = 100°C ). These properties should enable the development of new TES systems that could achieve the TES targets of the SunShot (temperature above 600 °C, installed cost below $15/kWh t , and heat capacity ≥25 kWh t /m 3 ). The detailed experimental results are presented in the paper. After its characterization, the material has been shaped in form of plates and thermally cycled in a TES system using hot-air as heat transfer fluid. Several cycles of charge and discharged were performed successfully and the concept was validated at laboratory scale. Apart from availability, low-cost, and promising thermal properties, the use of slag promotes the conservation of natural resources and is a noble solution to decrease the cost and to develop sustainable TES systems.

This paper introduces a new analytical “stretch” function that accurately predicts the flux distribution from on-axis point-focus collectors. Different dish sizes and slope errors can be assessed using this analytical function with a ratio of the focal length to collector diameter fixed at 0.6 to yield the maximum concentration ratio. Results are compared to data, and the stretch function is shown to provide more accurate flux distributions than other analytical methods employing cone optics.

Reforming performances for the double-walled reactor tubes with Na 2 CO 3 /MgO composite thermal storage was examined by an intermittent heating. The intermittent heating of the reactor tubes is composed of the heat-discharge (or cooling) mode and the subsequent heating mode. The heat-discharging mode simulates a fluctuating insolation for cloud passages. The heating mode simulates a heating of reactor due to concentrated solar radiation by using an electric furnace. The internal tube of the reactor was packed with the 2wt%Ru/Al 2 O 3 catalyst balls while the thermal storage materials were filled in the annular region of the reactor tubes. The reactor was heated up to 920°C in the cylindrical electric furnace and the CH 4 /CO 2 mixture was fed into the internal catalyst tube at gas hourly space velocity (GHSV) of 12500 h −1 . Through the cooling mode and the subsequent heating mode, temperature variations of reactor tubes, catalyst and composite material, H 2 /CO ratio variations of effluent gas from the reactor, higher heating value (HHV) power of reformed gas were respectively examined for the double-walled reactor tubes and a single-wall reactor tube without the thermal storage.

A 4.2 kW solar furnace heliostat was interfaced with a closed-loop control system to manipulate the azimuth and elevation rotational degrees of freedom to continuously align a solar concentrator with the sun. A QP50-6SD2 quadrant photodiode laser beam positioning device, developed by Pacific Silicon and Sensor, was modified to sense the orientation of the sun. The quadrant photodiode was mounted inside a dark box with a pinhole aperture and mounted so that when the heliostat reflects light along the desired axis, the quadrant photodiode relays balanced error signals. These error signals were interpreted with a Basic Stamp 2p40 microcontroller developed by Parallax Inc. LM741 operational amplifiers and ADC0831 analog to digital converters were used for signal conditioning. The 2p40 microcontroller interprets and checks the error signals every 500ms and uses a ULN2803 Darlington Transistor array to activate the heliostat drive motor’s solid-state relays to maintain solar alignment. The closed-loop heliostat control system can track with 1.6 degrees of accuracy. This is closer than the original prediction of 3 degrees. The control system requires user-inputs for initial alignment. Alignment can initiate with the heliostat out of alignment by at least 6 degrees. The versatility of the 2p40 allows subroutines to be programmed in that can handle hysteresis in the slewing of the heliostat, continue tracking as the heliostat begins to wobble from wind gusts, or continue tracking during intermittent shadowing from clouds.

Sandia National Laboratories (SNL) is investigating thermochemical approaches for reenergizing CO 2 and H 2 O feed stocks for input to synthetic liquid hydrocarbon fuels production. Key to the approach is the Counter-Rotating-Ring Receiver/Reactor/Recuperator (CR5), a novel solar-driven thermochemical heat engine concept for high-temperature carbon dioxide and water splitting based on two-step, nonvolatile metal oxide thermochemical cycles. The CR5 integrates two reactors, recuperators, and solar receiver and intrinsically separates the product gases. The CR5 thermochemical heat engine concept and the underlying thermodynamics and kinetics have many uncertainties. While results from laboratory scale material tests are promising, they are different than what occurs in a CR5. To evaluate the potential of the CR5 we have designed and built a CR5 prototype. The overall objective of the SNL Sunshine to Petrol (S2P) project is to show a solar thermochemical pathway for the efficient production of liquid fuels from CO 2 and H 2 O feed stocks. To achieve the overall long-term goal of 10% efficient conversion of sunlight to petroleum, the thermochemical solar conversion of sunlight to CO needs to be 20% efficient. The short-term goal for the CR5 prototype is to demonstrate a solar to chemical conversion efficiency of at least 2%. In this paper, we present initial test results for the CR5 prototype in the 16 kW t National Solar Thermal Test Facility (NSTTF) solar furnace in Albuquerque, NM. Lessons learned from the initial tests and approaches for improving performance to achieve our goals are also presented.

CO 2 capture and storage (CCS) systems are technologies that can be used to reduce CO 2 emissions by different industries where combustion is part of the process. A major problem of CCS system utilization in electricity generation industry is their high efficiency penalty in power plants. For different types of power plants fueled by oil, natural gas and coal, there are three main techniques that can be applied: • CO 2 capture after combustion (post-combustion); • CO 2 capture after concentration of flue gas by using pure oxygen in boilers and furnaces (oxy-fuel power plant); • CO 2 capture before combustion (pre-combustion). More than 90% of electricity generation in Iran is based on fossil fuel power plants. Worldwide, electricity generation is responsible for 54% of GHG emissions. Thus, it is vital to reduce CO 2 emission in fossil fuel-fired power plants. In this paper, it is shown that, by applying CO 2 capture systems in power generation industry, very low CO 2 emission intensity is possible but the energy and economic penalties are substantial. The analyses showed that for different technologies efficiency penalty could be as high as 25% and cost of electricity might increase by more than 65%. Two scenarios for Iranian electricity generation sector were investigated in this paper: installing CCS in the existing power plants with current technologies and replacing existing power plants by natural gas combined cycle plants equipped with CO 2 capture system. The results revealed that the GHG intensity can be reduced from 610 to 79 gCO 2 eq/kWh in the first scenario and to 54 gCO 2 eq/kWh in the second scenario.

This paper summarizes the results of a detailed energy analysis carried out for a typical Colorado residence using three different HVAC systems for 10 distinct locations in Colorado. The HVAC systems considered in the analysis include: • 78% efficient furnace with a 13 SEER air conditioner; • Vertical well ground source heat pump with a heating COP of 3.5 and a cooling EER of 17.1; • Slinky ground source heat pump with a heating COP of 3.5 and a cooling EER of 17.1. The results of the analysis indicate that relative to the conventional systems, ground source heat pumps (GSHPs) offer several benefits including lower annual energy costs, electrical peak demand, and carbon emissions. However, GSHPs use more electrical energy use. Specifically, it was found that relative to a 78 AFUE furnace / 13 SEER AC system, in all locations both GSHPs, vertical well and slinky, show on average a 41.2% increase in electricity use, a 10% decrease in energy cost, a 4.5% decrease in CO 2 emissions, and a 16.8% average decrease in peak summer electric demand.

A free and open source Monte Carlo ray-tracing program for concentrating solar energy research and development is presented. The program uses non energy partitioning Monte Carlo methods to model radiative exchange between arbitrarily arranged surfaces. Surface models include concentrating geometries, such as spherical, parabolic, and elliptical concentrators as well as compound parabolic concentrators. The program’s modular design allows implementation of additional surface and source models. The program has been thoroughly tested and experimentally validated. It has been used to model several concentrating devices including PSI’s high flux solar furnace and ETH’s high flux solar simulator. Furthermore, it has been used to design PSI’s high flux solar simulator and UFL’s high flux solar simulator. The code is particularly suited to provide radiative boundary conditions for numerical models of high temperature solar receivers and solar thermochemical reactors.