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This work presents a basic forecast tool for predicting direct normal irradiance (DNI) in hourly resolution, which the Solar-Institut Jülich (SIJ) is developing within a research project. The DNI forecast data shall be used for a parabolic trough collector (PTC) system with a concrete thermal energy storage (C-TES) located at the company KEAN Soft Drinks Ltd in Limassol, Cyprus. On a daily basis, 24-hour DNI prediction data in hourly resolution shall be automatically produced using free or very low-cost weather forecast data as input. The purpose of the DNI forecast tool is to automatically transfer the DNI forecast data on a daily basis to a main control unit (MCU). The MCU automatically makes a smart decision on the operation mode of the PTC system such as steam production mode and/or C-TES charging mode. The DNI forecast tool was evaluated using historical data of measured DNI from an on-site weather station, which was compared to the DNI forecast data. The DNI forecast tool was tested using data from 56 days between January and March 2022, which included days with a strong variation in DNI due to cloud passages. For the evaluation of the DNI forecast reliability, three categories were created and the forecast data was sorted accordingly. The result was that the DNI forecast tool has a reliability of 71.4 % based on the tested days. The result fulfils SIJ’s aim to achieve a reliability of around 70 %, but SIJ aims to still improve the DNI forecast quality.
In this work, three patent pending calibration methods for heliostat fields of central receiver systems (CRS) developed by the Solar-Institut Jülich (SIJ) of the FH Aachen University of Applied Sciences are presented. The calibration methods can either operate in a combined mode or in stand-alone mode. The first calibration method, method A, foresees that a camera matrix is placed into the receiver plane where it is subjected to concentrated solar irradiance during a measurement process. The second calibration method, method B, uses an unmanned aerial vehicle (UAV) such as a quadrocopter to automatically fly into the reflected solar irradiance cross-section of one or more heliostats (two variants of method B were tested). The third calibration method, method C, foresees a stereo central camera or multiple stereo cameras installed e.g. on the solar tower whereby the orientations of the heliostats are calculated from the location detection of spherical red markers attached to the heliostats. The most accurate method is method A which has a mean accuracy of 0.17 mrad. The mean accuracy of method B variant 1 is 1.36 mrad and of variant 2 is 1.73 mrad. Method C has a mean accuracy of 15.07 mrad. For method B there is great potential regarding improving the measurement accuracy. For method C the collected data was not sufficient for determining whether or not there is potential for improving the accuracy.
Elektromagnetischer Aktuator zur Betätigung eines Stellgliedes (2), mit wenigstens einem Elektromagneten (4) und einem mit dem Stellglied (2) verbundenen Anker (3), der gegen die Kraft einer Rückstellfeder (6) aus seiner Ruhelage in Richtung auf den Elektromagneten (4) bewegbar ist, mit einer Rückstellfeder (6), die eine nicht lineare, bezogen auf die Ruhelage des Ankers (3) progressiv ansteigende Kennlinie aufweist.
In addition to electromobility and alternative drive systems, a focus is set on electrically driven compressors (EDC), with a high potential for increasing the efficiency of internal combustion engines (ICE) and fuel cells [01]. The primary objective is to increase the ICE torque, provided independently of the ICE speed by compressing the intake air and consequently the ICE filling level supported by the compressor. For operation independent from the ICE speed, the EDC compressor is decoupled from the turbine by using an electric compressor motor (CM) instead of the turbine. ICE performances can be increased by the use of EDC where individual compressor parameters are adapted to the respective application area [02] [03]. This task contains great challenges, increased by demands with regard to pollutant reduction while maintaining constant performance and reduced fuel consumption. The FH-Aachen is equipped with an EDC test bench which enables EDC-investigations in various configurations and operating modes. Characteristic properties of different compressors can be determined, which build the basis for a comparison methodology. Subject of this project is the development of a comparison methodology for EDC with an associated evaluation method and a defined overall evaluation method. For the application of this comparison methodology, corresponding series of measurements are carried out on the EDC test bench using an appropriate test device.
In this work, the effect of low air relative humidity on the operation of a polymer electrolyte membrane fuel cell is investigated. An innovative method through performing in situ electrochemical impedance spectroscopy is utilised to quantify the effect of inlet air relative humidity at the cathode side on internal ionic resistances and output voltage of the fuel cell. In addition, algorithms are developed to analyse the electrochemical characteristics of the fuel cell. For the specific fuel cell stack used in this study, the membrane resistance drops by over 39 % and the cathode side charge transfer resistance decreases by 23 % after increasing the humidity from 30 % to 85 %, while the results of static operation also show an increase of ∼2.2 % in the voltage output after increasing the relative humidity from 30 % to 85 %. In dynamic operation, visible drying effects occur at < 50 % relative humidity, whereby the increase of the air side stoichiometry increases the drying effects. Furthermore, other parameters, such as hydrogen humidification, internal stack structure, and operating parameters like stoichiometry, pressure, and temperature affect the overall water balance. Therefore, the optimal humidification range must be determined by considering all these parameters to maximise the fuel cell performance and durability. The results of this study are used to develop a health management system to ensure sufficient humidification by continuously monitoring the fuel cell polarisation data and electrochemical impedance spectroscopy indicators.
Quantitative evaluation of health management designs for fuel cell systems in transport vehicles
(2022)
Focusing on transport vehicles, mainly with regard to aviation applications, this paper presents compilation and subsequent quantitative evaluation of methods aimed at building an optimum integrated health management solution for fuel cell systems. The methods are divided into two different main types and compiled in a related scheme. Furthermore, different methods are analysed and evaluated based on parameters specific to the aviation context of this study. Finally, the most suitable method for use in fuel cell health management systems is identified and its performance and suitability is quantified.
Cybersecurity of Industrial Control Systems (ICS) is an important issue, as ICS incidents may have a direct impact on safety of people or the environment. At the same time the awareness and knowledge about cybersecurity, particularly in the context of ICS, is alarmingly low. Industrial honeypots offer a cheap and easy to implement way to raise cybersecurity awareness and to educate ICS staff about typical attack patterns. When integrated in a productive network, industrial honeypots may not only reveal attackers early but may also distract them from the actual important systems of the network. Implementing multiple honeypots as a honeynet, the systems can be used to emulate or simulate a whole Industrial Control System. This paper describes a network of honeypots emulating HTTP, SNMP, S7communication and the Modbus protocol using Conpot, IMUNES and SNAP7. The nodes mimic SIMATIC S7 programmable logic controllers (PLCs) which are widely used across the globe. The deployed honeypots' features will be compared with the features of real SIMATIC S7 PLCs. Furthermore, the honeynet has been made publicly available for ten days and occurring cyberattacks have been analyzed
A promising approach to reduce the system costs of molten salt solar receivers is to enable the irradiation of the absorber tubes on both sides. The star design is an innovative receiver design, pursuing this approach. The unconventional design leads to new challenges in controlling the system. This paper presents a control concept for a molten salt receiver system in star design. The control parameters are optimized in a defined test cycle by minimizing a cost function. The control concept is tested in realistic cloud passage scenarios based on real weather data. During these tests, the control system showed no sign of unstable behavior, but to perform sufficiently in every scenario further research and development like integrating Model Predictive Controls (MPCs) need to be done. The presented concept is a starting point to do so.
The integration of high temperature thermal energy storages into existing conventional power plants can help to reduce the CO2 emissions of those plants and lead to lower capital expenditures for building energy storage systems, due to the use of synergy effects [1]. One possibility to implement that, is a molten salt storage system with a powerful power-to-heat unit. This paper presents two possible control concepts for the startup of the charging system of such a facility. The procedures are implemented in a detailed dynamic process model. The performance and safety regarding the film temperatures at heat transmitting surfaces are investigated in the process simulations. To improve the accuracy in predicting the film temperatures, CFD simulations of the electrical heater are carried out and the results are merged with the dynamic model. The results show that both investigated control concepts are safe regarding the temperature limits. The gradient controlled startup performed better than the temperature-controlled startup. Nevertheless, there are several uncertainties that need to be investigated further.
To fulfil the CO2 emission reduction targets of the European Union (EU), heavy-duty (HD) trucks need to operate 15% more efficiently by 2025 and 30% by 2030. Their electrification is necessary as conventional HD trucks are already optimized for the long-haul application. The resulting hybrid electric vehicle (HEV) truck gains most of the fuel saving potential by the recuperation of potential energy and its consecutive utilization. The key to utilizing the full potential of HEV-HD trucks is to maximize the amount of recuperated energy and ensure its intelligent usage while keeping the operating point of the internal combustion engine as efficient as possible. To achieve this goal, an intelligent energy management strategy (EMS) based on ECMS is developed for a parallel HEV-HD truck which uses predictive discharge of the battery and adaptive operating strategy regarding the height profile and the vehicle mass. The presented EMS can reproduce the global optimal operating strategy over long phases and lead to a fuel saving potential of up to 2% compared with a heuristic strategy. Furthermore, the fuel saving potential is correlated with the investigated boundary conditions to deepen the understanding of the impact of intelligent EMS for HEV-HD trucks.
Concerning current efforts to improve operational efficiency and to lower overall costs of concentrating solar power (CSP) plants with prediction-based algorithms, this study investigates the quality and uncertainty of nowcasting data regarding the implications for process predictions. DNI (direct normal irradiation) maps from an all-sky imager-based nowcasting system are applied to a dynamic prediction model coupled with ray tracing. The results underline the need for high-resolution DNI maps in order to predict net yield and receiver outlet temperature realistically. Furthermore, based on a statistical uncertainty analysis, a correlation is developed, which allows for predicting the uncertainty of the net power prediction based on the corresponding DNI forecast uncertainty. However, the study reveals significant prediction errors and the demand for further improvement in the accuracy at which local shadings are forecasted.
Despite the challenges of pioneering molten salt towers (MST), it remains the leading technology in central receiver power plants today, thanks to cost effective storage integration and high cost reduction potential. The limited controllability in volatile solar conditions can cause significant losses, which are difficult to estimate without comprehensive modeling [1]. This paper presents a Methodology to generate predictions of the dynamic behavior of the receiver system as part of an operating assistance system (OAS). Based on this, it delivers proposals if and when to drain and refill the receiver during a cloudy period in order maximize the net yield and quantifies the amount of net electricity gained by this. After prior analysis with a detailed dynamic two-phase model of the entire receiver system, two different reduced modeling approaches where developed and implemented in the OAS. A tailored decision algorithm utilizes both models to deliver the desired predictions efficiently and with appropriate accuracy.
In order to realistically predict and optimize the actual performance of a concentrating solar power (CSP) plant sophisticated simulation models and methods are required. This paper presents a detailed dynamic simulation model for a Molten Salt Solar Tower (MST) system, which is capable of simulating transient operation including detailed startup and shutdown procedures including drainage and refill. For appropriate representation of the transient behavior of the receiver as well as replication of local bulk and surface temperatures a discretized receiver model based on a novel homogeneous two-phase (2P) flow modelling approach is implemented in Modelica Dymola®. This allows for reasonable representation of the very different hydraulic and thermal properties of molten salt versus air as well as the transition between both. This dynamic 2P receiver model is embedded in a comprehensive one-dimensional model of a commercial scale MST system and coupled with a transient receiver flux density distribution from raytracing based heliostat field simulation. This enables for detailed process prediction with reasonable computational effort, while providing data such as local salt film and wall temperatures, realistic control behavior as well as net performance of the overall system. Besides a model description, this paper presents some results of a validation as well as the simulation of a complete startup procedure. Finally, a study on numerical simulation performance and grid dependencies is presented and discussed.
Rocket engine test facilities and launch pads are typically equipped with a guide tube. Its purpose is to ensure the controlled and safe routing of the hot exhaust gases. In addition, the guide tube induces a suction that effects the nozzle flow, namely the flow separation during transient start-up and shut-down of the engine. A cold flow subscale nozzle in combination with a set of guide tubes was studied experimentally
to determine the main influencing parameters.