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Technical assessment of Brayton cycle heat pumps for the integration in hybrid PV-CSP power plants
(2022)
The hybridization of Concentrated Solar Power (CSP) and Photovoltaics (PV) systems is a promising approach to reduce costs of solar power plants, while increasing dispatchability and flexibility of power generation. High temperature heat pumps (HT HP) can be utilized to boost the salt temperature in the thermal energy storage (TES) of a Parabolic Trough Collector (PTC) system from 385 °C up to 565 °C. A PV field can supply the power for the HT HP, thus effectively storing the PV power as thermal energy. Besides cost-efficiently storing energy from the PV field, the power block efficiency of the overall system is improved due to the higher steam parameters. This paper presents a technical assessment of Brayton cycle heat pumps to be integrated in hybrid PV-CSP power plants. As a first step, a theoretical analysis was carried out to find the most suitable working fluid. The analysis included the fluids Air, Argon (Ar), Nitrogen (N2) and Carbon dioxide (CO2). N2 has been chosen as the optimal working fluid for the system. After the selection of the ideal working medium, different concepts for the arrangement of a HT HP in a PV-CSP hybrid power plant were developed and simulated in EBSILON®Professional. The concepts were evaluated technically by comparing the number of components required, pressure losses and coefficient of performance (COP).
In the past, CSP and PV have been seen as competing technologies. Despite massive reductions in the electricity generation costs of CSP plants, PV power generation is - at least during sunshine hours - significantly cheaper. If electricity is required not only during the daytime, but around the clock, CSP with its inherent thermal energy storage gets an advantage in terms of LEC. There are a few examples of projects in which CSP plants and PV plants have been co-located, meaning that they feed into the same grid connection point and ideally optimize their operation strategy to yield an overall benefit. In the past eight years, TSK Flagsol has developed a plant concept, which merges both solar technologies into one highly Integrated CSP-PV-Hybrid (ICPH) power plant. Here, unlike in simply co-located concepts, as analyzed e.g. in [1] – [4], excess PV power that would have to be dumped is used in electric molten salt heaters to increase the storage temperature, improving storage and conversion efficiency. The authors demonstrate the electricity cost sensitivity to subsystem sizing for various market scenarios, and compare the resulting optimized ICPH plants with co-located hybrid plants. Independent of the three feed-in tariffs that have been assumed, the ICPH plant shows an electricity cost advantage of almost 20% while maintaining a high degree of flexibility in power dispatch as it is characteristic for CSP power plants. As all components of such an innovative concept are well proven, the system is ready for commercial market implementation. A first project is already contracted and in early engineering execution.
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.
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.
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.
Digital twins are seen as one of the key technologies of Industry 4.0. Although many research groups focus on digital twins and create meaningful outputs, the technology has not yet reached a broad application in the industry. The main reasons for this imbalance are the complexity of the topic, the lack of specialists, and the unawareness of the twin opportunities. The project "Digital Twin Academy" aims to overcome these barriers by focusing on three actions: Building a digital twin community for discussion and exchange, offering multi-stage training for various knowledge levels, and implementing realworld use cases for deeper insights and guidance. In this work, we focus on creating a flexible learning platform that allows the user to select a training path adjusted to personal knowledge and needs. Therefore, a mix of basic and advanced modules is created and expanded by individual feedback options. The usage of personas supports the selection of the appropriate modules.
The development of protype applications with sensors and actuators in the automation industry requires tools that are independent of manufacturer, and are flexible enough to be modified or extended for any specific requirements. Currently, developing prototypes with industrial sensors and actuators is not straightforward. First of all, the exchange of information depends on the industrial protocol that these devices have. Second, a specific configuration and installation is done based on the hardware that is used, such as automation controllers or industrial gateways. This means that the development for a specific industrial protocol, highly depends on the hardware and the software that vendors provide. In this work we propose a rapid-prototyping framework based on Arduino to solve this problem. For this project we have focused to work with the IO-Link protocol. The framework consists of an Arduino shield that acts as the physical layer, and a software that implements the IO-Link Master protocol. The main advantage of such framework is that an application with industrial devices can be rapid-prototyped with ease as its vendor independent, open-source and can be ported easily to other Arduino compatible boards. In comparison, a typical approach requires proprietary hardware, is not easy to port to another system and is closed-source.
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.
Having well-defined control strategies for fuel cells, that can efficiently detect errors and take corrective action is critically important for safety in all applications, and especially so in aviation. The algorithms not only ensure operator safety by monitoring the fuel cell and connected components, but also contribute to extending the health of the fuel cell, its durability and safe operation over its lifetime. While sensors are used to provide peripheral data surrounding the fuel cell, the internal states of the fuel cell cannot be directly measured. To overcome this restriction, Kalman Filter has been implemented as an internal state observer.
Other safety conditions are evaluated using real-time data from every connected sensor and corrective actions automatically take place to ensure safety. The algorithms discussed in this paper have been validated thorough Model-in-the-Loop (MiL) tests as well as practical validation at a dedicated test bench.
The industrial revolution IR4.0 era have driven many states of the art technologies to be introduced especially in the automotive industry. The rapid development of automotive industries in Europe have created wide industry gap between European Union (EU) and developing countries such as in South-East Asia (SEA). Indulging this situation, FH Joanneum, Austria together with European partners from FH Aachen, Germany and Politecnico Di Torino, Italy is taking initiative to close the gap utilizing the Erasmus+ United grant from EU. A consortium was founded to engage with automotive technology transfer using the European ramework to Malaysian, Indonesian and Thailand Higher Education Institutions (HEI) as well as automotive industries. This could be achieved by establishing Engineering Knowledge Transfer Unit (EKTU) in respective SEA institutions guided by the industry partners in their respective countries. This EKTU could offer updated, innovative, and high-quality training courses to increase graduate’s employability in higher education institutions and strengthen relations between HEI and the wider economic and social environment by addressing Universityindustry cooperation which is the regional priority for Asia. It is expected that, the Capacity Building Initiative would improve the quality of higher education and enhancing its relevance for the labor market and society in the SEA partners. The outcome of this project would greatly benefit the partners in strong and complementary partnership targeting the automotive industry and enhanced larger scale international cooperation between the European and SEA partners. It would also prepare the SEA HEI in sustainable partnership with Automotive industry in the region as a mean of income generation in the future.
Using optimization to design a renewable energy system has become a computationally demanding task as the high temporal fluctuations of demand and supply arise within the considered time series. The aggregation of typical operation periods has become a popular method to reduce effort. These operation periods are modelled independently and cannot interact in most cases. Consequently, seasonal storage is not reproducible. This inability can lead to a significant error, especially for energy systems with a high share of fluctuating renewable energy. The previous paper, “Time series aggregation for energy system design: Modeling seasonal storage”, has developed a seasonal storage model to address this issue. Simultaneously, the paper “Optimal design of multi-energy systems with seasonal storage” has developed a different approach. This paper aims to review these models and extend the first model. The extension is a mathematical reformulation to decrease the number of variables and constraints. Furthermore, it aims to reduce the calculation time while achieving the same results.
Useful market simulations are key to the evaluation of diferent market designs existing of multiple market mechanisms or rules. Yet a simulation framework which has a comparison of diferent market mechanisms in mind was not found. The need to create an objective view on different sets of market rules while investigating meaningful agent strategies concludes that such a simulation framework is needed to advance the research on this subject. An overview of diferent existing market simulation models is given which also shows the research gap and the missing capabilities of those systems. Finally, a methodology is outlined how a novel market simulation which can answer the research questions can be developed.
Direct methods comprising limit and shakedown analysis is a branch of computational mechanics. It plays a significant role in mechanical and civil engineering design. The concept of direct method aims to determinate the ultimate load bearing capacity of structures beyond the elastic range. For practical problems, the direct methods lead to nonlinear convex optimization problems with a large number of variables and onstraints. If strength and loading are random quantities, the problem of shakedown analysis is considered as stochastic programming. This paper presents a method so called chance constrained programming, an effective method of stochastic programming, to solve shakedown analysis problem under random condition of strength. In this our investigation, the loading is deterministic, the strength is distributed as normal or lognormal variables.
Kawasaki Heavy Industries, Ltd. (KHI), Aachen University of Applied Sciences, and B&B-AGEMA GmbH have investigated the potential of low NOx micro-mix (MMX) hydrogen combustion and its application to an industrial gas turbine combustor. Engine demonstration tests of a MMX combustor for the M1A-17 gas turbine with a co-generation system were conducted in the hydrogen-fueled power generation plant in Kobe City, Japan.
This paper presents the results of the commissioning test and the combined heat and power (CHP) supply demonstration. In the commissioning test, grid interconnection, loading tests and load cut-off tests were successfully conducted. All measurement results satisfied the Japanese environmental regulation values. Dust and soot as well as SOx were not detected. The NOx emissions were below 84 ppmv at 15 % O2. The noise level at the site boundary was below 60 dB. The vibration at the site boundary was below 45 dB.
During the combined heat and power supply demonstration, heat and power were supplied to neighboring public facilities with the MMX combustion technology and 100 % hydrogen fuel. The electric power output reached 1800 kW at which the NOx emissions were 72 ppmv at 15 % O2, and 60 %RH. Combustion instabilities were not observed. The gas turbine efficiency was improved by about 1 % compared to a non-premixed type combustor with water injection as NOx reduction method. During a total equivalent operation time of 1040 hours, all combustor parts, the M1A-17 gas turbine as such, and the co-generation system were without any issues.
A capacitive electrolyte-insulator-semiconductor (EISCAP) biosensor modified with Tobacco mosaic virus (TMV) particles for the detection of acetoin is presented. The enzyme acetoin reductase (AR) was immobilized on the surface of the EISCAP using TMV particles as nanoscaffolds. The study focused on the optimization of the TMV-assisted AR immobilization on the Ta 2 O 5 -gate EISCAP surface. The TMV-assisted acetoin EISCAPs were electrochemically characterized by means of leakage-current, capacitance-voltage, and constant-capacitance measurements. The TMV-modified transducer surface was studied via scanning electron microscopy.
An interdisciplinary view on humane interfaces for digital shadows in the internet of production
(2022)
Digital shadows play a central role for the next generation industrial internet, also known as Internet of Production (IoP). However, prior research has not considered systematically how human actors interact with digital shadows, shaping their potential for success. To address this research gap, we assembled an interdisciplinary team of authors from diverse areas of human-centered research to propose and discuss design and research recommendations for the implementation of industrial user interfaces for digital shadows, as they are currently conceptualized for the IoP. Based on the four use cases of decision support systems, knowledge sharing in global production networks, human-robot collaboration, and monitoring employee workload, we derive recommendations for interface design and enhancing workers’ capabilities. This analysis is extended by introducing requirements from the higher-level perspectives of governance and organization.
The seismic performance and safety of major European industrial facilities has a global interest for Europe, its citizens and economy. A potential major disaster at an industrial site could affect several countries, probably far beyond the country where it is located. However, the seismic design and safety assessment of these facilities is practically based on national, often outdated seismic hazard assessment studies, due to many reasons, including the absence of a reliable, commonly developed seismic hazard model for whole Europe. This important gap is no more existing, as the 2020 European Seismic Hazard Model ESHM20 was released in December 2021. In this paper we investigate the expected impact of the adoption of ESHM20 on the seismic demand for industrial facilities, through the comparison of the ESHM20 probabilistic hazard at the sites where industrial facilities are located with the respective national and European regulations. The goal of this preliminary work in the framework of Working Group 13 of the European Association for Earthquake Engineering (EAEE), is to identify potential inadequacies in the design and safety control of existing industrial facilities and to highlight the expected impact of the adoption of the new European Seismic Hazard Model on the design of new industrial facilities and the safety assessment of existing ones.
Masonry infill walls are the most traditional enclosure system that is still widely used in RC frame buildings all over the world, particularly in seismic active regions. Although infill walls are usually neglected in seismic design, during an earthquake event they are subjected to in-plane and out-of-plane forces that can act separately or simultaneously. Since observations of damage to buildings after recent earthquakes showed detrimental effects of in-plane and out-of-plane load interaction on infill walls, the number of studies that focus on influence of in-plane damage on out-of-plane response has significantly increased. However, most of the xperimental campaigns have considered only solid infills and there is a lack of combined in-plane and out-of-plane experimental tests on masonry infills with openings, although windows and doors strongly affect seismic performance. In this paper, two types of experimental tests on infills with window openings are presented. The first is a pure out-of-plane test and the second one is a sequential in-plane and out-of-plane test aimed at investigating the effects of existing in-plane damage on outof-plane response. Additionally, findings from two tests with similar load procedure that were carried out on fully infilled RC frames in the scope of the same project are used for comparison. Test results clearly show that window opening increased vulnerability of infills to combined seismic actions and that prevention of damage in infills with openings is of the utmost importance for seismic safety.
Recent earthquakes showed that low-rise URM buildings following codecompliant seismic design and details behaved in general very well without substantial damages. Although advances in simulation tools make nonlinear calculation methods more readily accessible to designers, linear analyses will still be the standard design method for years to come. The present paper aims to improve the linear seismic design method by providing a proper definition of the q-factor of URM buildings. Values of q-factors are derived for low-rise URM buildings with rigid diaphragms, with reference to modern structural configurations realized in low to moderate seismic areas of Italy and Germany. The behaviour factor components for deformation and energy dissipation capacity and for overstrength due to the redistribution of forces are derived by means of pushover analyses. As a result of the investigations, rationally based values of the behaviour factor q to be used in linear analyses in the range of 2.0 to 3.0 are proposed.