Micro-laminated pin array solar receivers for high flux heating of supercritical carbon dioxide part 1: Design and fabrication methods

Development of gas-based solar receivers that can withstand the extreme temperatures (>700 °C) and high pressures required in next generation concentrating solar plants remains a significant challenge. This study presents an investigation of the design and fabrication methods of a prototype modular, micro-pin solar receiver for directly heating supercritical carbon dioxide from temperatures of 550 °C to 720 °C at a pressure of 20 MPa and an incident flux > 100 W cm⁻². The receiver is fabricated from high nickel content Haynes 230 alloy. Multiple failure modes related to design and fabrication methods were identified in a first-generation prototype. Here, these failure modes are mitigated by the introduction of improved diffusion bonding, brazing, design of the receiver header and micro-pin array. The efficacy of each improvement was evaluated separately using a combination of simulations and lab-scale experiments. The design improvements were then integrated into sub-scale (5 cm × 5 cm) and prototype scale (15 cm × 15 cm) test devices. The study resulted in the successful fabrication and proof and cyclic pressure testing of a prototype receiver that was tested in a concentrating solar dish. The results of this study can guide the development process of other high temperature receiver technologies that must operate at extreme pressures and incident fluxes.