A heliostat is a motorized mirror used in a Solar Power Tower plant. The technology has been around since the 1970’s, and involves hundreds or thousands of heliostats reflecting the sun’s rays to the top of a high tower, where the incident solar energy is converted to heat energy, which in turn is used to drive steam turbines and produce electricity. Demonstration plants have been built in the U.S.A. and Spain, and a number of new facilities have been added since 2005. To achieve a commercial breakthrough, the technology must be made more efficient so that electricity can be produced at prices comparable with other options such as wind, photovoltaic, nuclear and coal. A critical component in the economics of the Solar Power Tower plant is the cost of the heliostat, which is estimated to account for approximately 50 % of the investment cost of the total plant. This report deals with the heliostat from a multifaceted perspective. Different design approaches are explained. First, mirror geometries, with manufacturing dimensions, for a rotation-symmetric paraboloid-shaped mirror-assembly are obtained for mirrors with different sizes with a Matlab code. Investigating wind loads are among the most important tasks in a heliostat development project, as large wind loads radically complicates the design work. A wind load calculation-method based on previous work by Sandia National Laboratories and finite element method (FEM) is used in this work to design heliostats to withstand expected wind loading. The design of the geometry and the structure to withstand wind loading is illustrated with two azimuth elevation heliostats (25 m 2 and 49 m2). Finally, a number of innovative technical solutions are suggested. These are a new mirror facet mounting technique, sliding bearings, elevation drive, and a very unique azimuth motor module, which uses steel wires as belts with an integrated brake. It is hoped that the results and designs presented in this thesis will be a good foundation for further research in the heliostat structures and heliostat controls at the Robotics lab in IISc and elsewhere. Keywords: Solar Power, Heliostat, Thermal solar power, Solar Power Tower, Central Receiver System / En heliostat är en motordriven spegel som används i tornsolkraftverk, kända som Solar Power Tower, även kallade Central Receiver system. Tekniken har funnits sedan 1970-talet och går ut på att hundratals eller tusentals heliostater speglar solstrålarna till toppen av ett högt torn, där stålningsenergin omvandlas till värmeenergi, som t.ex. kan användas till att driva ångturbiner och producera elektricitet. Demonstrationsanläggningar har byggts i bland annat USA och Spanien, och ett flertal nya installationer har tillkommit sedan år 2005. För att verkligen nå ett kommersiellt genombrott måste tekniken göras billigare så att solelen kan produceras till minst lika bra pris som andra alternativ, så som t.ex. solceller, kärnkraft och kolkraft. En kritisk komponent för tornsolkraftverkens ekonomi är kostnaden för heliostaterna, som beräknas stå för ungefär 50 % av anläggningens totala investeringskostnad. Den här rapporten avhandlar heliostaten ur ett mångfacetterat perspektiv där olika konstruktionsspår förklaras. Vidare behandlar rapporten spegelgeometrier, och en Matlab-kod som genererar tillverkningsmått för en rotationssymmetrisk paraboloidformad spegelyta finns bifogad. Att undersöka vindlaster är bland det viktigaste i ett heliostatutvecklingsprojekt, eftersom dessa är de dimensionerande lasterna för designarbetet. Här används en vindlastberäkningsmetod utgiven av Sandia National Laboratories, som kortfattat går ut på att man multiplicerar det dynamiska vindtrycket med en korrigeringsfaktor som baserats på emiriska studier av heliostatmodeller i vindtunnel. En dimensioneringsprocess för heliostater föreslås och utvecklingsgången för två Azimut-Elevation heliostater i storlek 25 m 2 resp. 49 m2 demonstreras. FEM-mjukvara nyttjas som det främsta verktyget för att dimensionera heliostatkonstruktioner som kan stå emot vindlasterna. Slutligen ges förslag på innovativa tekniska lösningar för spegelmontering, glidlager, montering av elevation-motorerna, och en unik azimut-motormodul, vilken använder stålvajrar som remmar och har en integrerad broms. Med all denna information bör Robotics Lab på IISc ha en god grund att stå på inför vidare forskning inom konstruktion och styrning av heliostater. Nyckelord: Solenergi, Heliostat, Termisk solenergi, Solar Power Tower, Tornsolkraftverk

In concentrated solar power (CSP) stations, large arrays of mirrors which are capable of changing its orientation are used to reflect the incident solar energy to a stationary receiver kept at a distance. Such mirrors are often called as heliostats. The receiver contains a heat absorbing medium like molten salt. By absorbing the thermal energy reflected from thousands of heliostats, the temperature would reach around 6000C and the heat can be used in thermal power plants to generate steam and thus run a turbine to produce electricity. One of the biggest advantages of CSP over conventional energy harvesting from Sun is that it can generate electricity during night for long hours of time from the thermal energy stored during daytime. This eliminates the usage of batteries or any other energy storing methods. The conversion efficiency is also high in CSP due to the high temperature achieved. With prior knowledge of the station coordinates, viz., the latitude and longitude, the day of the year and time, the direction or the path of sun can be fully determined. Typically, the sun's motion is tracked by the azimuth-elevation (Az-El) or the target-aligned configuration heliostats. In both these approaches, the mirror needs to be moved about two axes independently using two actuators in series with the mirror effectively mounted at a single point at the centre. This arrangement causes the mirror to deform in presence of gusty winds in a solar field which results in loss of pointing accuracy. Typically a beam error of less than 2-3 mrad is desirable in a large solar field and this value also includes other sources of loss of pointing accuracy like gravity and wind loading. In order to prevent this, a rigid support frame is required for each of the heliostats. In this work, two three degree-of-freedom parallel manipulators, viz., the 3-UPU wrist and 3-RPS, have been proposed to track the sun in central receiver systems. The main reasons for choosing a parallel manipulator as heliostat are its desirable characteristics like large load carrying capacity, high accuracy in positioning the mirror and easy to obtain the inverse kinematics and convenient for real time control. The proposed parallel manipulators support the load of the mirror, structure and wind loading at three points resulting in less deflection and thus a much larger mirror can be moved with the required tracking accuracy and without increasing the weight of the support structure. The algorithm for sun tracking is developed, extensive simulation study with respect to actuations required, variation of joint angles, spillage loss and leg intersection has been carried out. Using FEA, it is shown that for same sized mirror, wind loading of 22 m/s and maximum deflection requirement (2 mrad), the weight of the support structure is between 15% and 60% less with the parallel manipulators when compared to azimuth-elevation or the target-aligned configurations. A comprehensive study on stroke minimization of prismatic joints is carried out. It is found that a stroke of 700 mm is required for a 2 m x 2 m heliostat at Bangalore when the farthest heliostat is at a distance of 300 m from the tower. Although, there is an extra motor required to track the sun, the 3-RPS manipulator is better than the conventional methods if the mirror area per actuator criteria is taken into consideration. Prototypes of the Az-El and 3-RPS heliostats were made with a mirror size of 1 m x 1 m. A PID controller implemented using MATLAB-Simulink and a low cost, custom made motor driver circuit is used to control the motion of the 3-RPS heliostat. The algorithm developed is tested on the prototype by tracking a point marked on the wall of the lab space and is found to have a tracking error of only 7.1 mrad. Finally, the actual sun tracking is carried out on the roof of a building reflecting the sun-light to a wall situated 6.72 m above and a distance of 15.87 m from the heliostats. The images are captured at various instances of time from 11:30 a.m. to 3:30 p.m. on October 15th and November 10th, 2016, tracking errors are quantified and it is demonstrated that the proposed 3-RPS parallel manipulator can indeed work as a heliostat in concentrated solar power plants.

Depuis les années quarante, la consommation énergétique mondiale n'a cessé d'augmenter. Cette énergie étant majoritairement d'origine fossile, il en résulte une augmentation globale de température terrestre. De ce fait, il est devenu urgent de réduire les émissions de gaz à effet de serre pour stopper le changement climatique. Dans ce contexte, le développement de la production d'électricité à partir d'énergie solaire concentrée par voie thermodynamique est une solution prometteuse. Les efforts de recherche visent à rendre cette technologie plus efficace et plus compétitive économiquement. Dans ce but, ce manuscrit présente une méthode de conception optimale pour les centrales solaires à récepteur central. Elle tire parti des méthodes développées depuis de nombreuses années par le groupe de recherche StaRWest, regroupant notamment des chercheurs des laboratoires RAPSODEE (Albi), LAPLACE (Toulouse) et PROMES (Odeillo). Couplant des algorithmes de Monte Carlo à hautes performances et des algorithmes stochastiques d'optimisation, le code de calcul implémentant cette méthode permet la conception et l'optimisation d'installations solaires. Il est utilisé pour mettre en évidence les potentialités d'un type de centrales à récepteur central peu répandu : les centrales à réflecteur secondaire, également appelées centrales de type "beam down". / Since the early 40's, world energy consumption has grown steadly. While this energy mainly came from fossil fuel, its use has included an increase in temperatures. It has become urgent to reduce greenhouse gas emissions to halt climate change. In this context, the development of concentrated solar power (CSP) is a promising solution. The scientific community related to this topic has to focus on efficiency enhancement and economic competitiveness of CSP technologies. To this end, this thesis aims at providing an optimal design method applied to central receiver power plants. It takes advantage of methods developed over many years by the research group StaRWest. Both RAPSODEE (Albi), LAPLACE (Toulouse) and PROMES (Odeillo) researchers take an active part in this group. Coupling high performance Monte Carlo algorithms and stochastic optimization methods, the code we developed allows an optimal design of concentrated solar systems. This code is used to highlight the potential of an uncommon type of central receiver plants: reflective towers, also called "beam down" central receiver systems.

The objective of this thesis was to investigate the potential for introducing a concentrating solar thermal (CST) central receiver plant system based on flexible heliostats - HelioPods - to provide high-temperature process heat in industrial applications. A CST plant system was designed in MATLAB, optically simulated for three design days in the ray-tracing software Tonatiuh and further analyzed in MATLAB by interpolating the results for each hour of the year. A case study was made on introducing a CST plant system based on HelioPods in a South African manganese sinter plant. The study included an investigation of the profitability of up- and downsizing the heliostat field annually with fluctuating heat demand. A circular heliostat field was modelled for the chosen location. The final field had a radius of 53 meters with the receiver located 60% from the field centre. The storage size was 16 demand hours and 17 plants were required. The results showed that 88% of the annual heat demand could be covered by solar heat in the design year. The marketing approach used for the following years was that the heat demand covered by solar heat should never be below the share at the first year, despite the predicted fluctuations in demand. Thus, a minimum solar share of 88% was used as a strategy for annual up- and downsizing of the fields throughout the investigated period of 25 years. That resulted in a field radius differing between 52 and 55 meters. The payback period of the final system was 4.35 years, the NPV was 54.33 MUSD over a period of 25 years and the LCOH was 35.39 USD/MWht. However, it was found that the profitability of the system was sensitive to the different scenarios for predicted future diesel prices, this since the pricing of the solar heat was set to 90% of the diesel price. The results in this thesis show that a CST plant system based on HelioPods is a suitable solution to supply high-temperature process heat to industrial applications. It also shows that the HelioPods can unlock potential for flexibility with changing production patterns in the industry of implementation. The results from the study can be used also for other industries with similar temperature range and heat demand. Thus, it could be argued that the implementation of a HelioPod based CST plant system also can be suitable for other industries located in high-DNI areas with dependency on conventional fuels and steady production throughout the whole day. / Syftet med denna uppsats var att undersöka potentialen för implementering av koncentrerad termisk solvärme (CST) från ett soltorn med ett heliostatfält baserat på flexibla heliostater - HelioPods – för att generera högtempererad processvärme för industriell tillämpning. Ett CST-system designades i MATLAB, simulerades för tre designdagar i det optiska ray-tracingprogrammet Tonatiuh och analyserades sedan åter i MATLAB genom att interpolera de genererade resultaten för årets alla timmar. En fallstudie av ett CST-system baserat på HelioPods i ett sydafrikanskt sinterverk för mangan genomfördes därefter. Studien innehöll en undersökning av lönsamheten av årlig ökning och minskning av heliostatfältet vid fluktuerande värmebehov. Ett cirkulärt heliostatfält modellerades för den valda platsen. Det slutgiltiga fältet hade en radie om 53 meter med mottagaren placerad 60% från fältets mittpunkt. Storleken på lagringsfaciliteten var 16 timmar av full tillförsel och antalet verk uppgick till 17. Resultaten visade att 88% av det årliga värmebehovet kunde förses med solvärme under designåret. Marknadsstrategin för de resterande åren var att den procentuella andelen solvärme aldrig skulle vara lägre än under designåret, oberoende av fluktuationer i värmebehovet på grund av ändrad produktion. Således sattes 88% solvärme som ett minimikrav och utgjorde strategin för den årliga ökningen och minskningen av fältet för den undersökta perioden av 25 år. Det resulterade i en fältradie mellan 52 och 55 meter. Återbetalningstiden för det slutgiltiga fältet var 4.35 år, nuvärdesberäkningen av det framtida kassaflödet var 54.22 miljoner USD över en 25-årsperiod och produktionskostnaden för värme (LCOH) var 35.39 USD/MWht. Dock var systemets lönsamhet känslig för de olika prognoser av framtida dieselpriser som undersöktes, detta eftersom priset för solvärme sattes till 90% av dieselpriset. Resultaten i denna uppsats visar att ett CST-system baserat på HelioPods är en lämplig lösning för att generera högtempererad processvärme för industriell tillämpning. De visar även att HelioPods kan öka potentialen för flexibilitet vid förändringar i produktionsmönstret i vederbörande industri. Resultaten kan även användas i andra industrier med likartade temperaturer och värmebehov. Hävdas kan således att implementation av ett CST-system kan vara lämpligt även för andra industrier belägna i områden med högt DNI som är beroende på konventionella energikällor och har jämn produktion dygnet runt.