Spectral reflectance properties of black chrome for use as a solar selective coating

The NASA-Lewis Research Center has determined that a widely available, commercially electroplated decorative finish known as black chrome has desirable solar selective properties. Black chrome electroplated coating has high absorbence in the solar spectrum and low emissivity in the 250°F blackbody thermal spectrum.The discovery of the solar selective properties of black chrome adds another high-efficiency coating to the older, previously known coatings. Additionally, the black chrome is significant as a solar selective coating because the current extensive use of black chrome in the electroplating industry as a durable, decorative finish makes black chrome widely available and potentially lower cost as a solar selective coating.The spectral reflectance properties of a commercially prepared black chrome on steel have been measured. Values are presented for reflectance of the black chrome. These are compared with the reflectance of black paint (Nextel) and with two available samples of black nickel which had been prepared for solar selective properties.The reflectance of black chrome, the two black nickels, and black paint integrated over the solar spectrum for air mass 2 were 0·132, 0·123, 0·133 and 0·033, respectively.The reflectance of the black chrome, two black nickels, and black paint integrated over the blackbody spectrum for 250°F from 3 to 15 μm are 0·912, 0·934, 0·891 and 0·033, respectively. These reflectance measurements indicate absorptivity-to-emissivity ( ) values of 9·8, 13·8, 8·0 and 1·00, respectively.     

Thermal application of composites of iron and magnesium in thermosyphon solar water heating system

A novel and low-cost mixture of iron and magnesium have been synthesized and used as selective coatings for flat plate absorber in solar water heating system. The commercial black paint is fabricated with the mixture of composition Fe₃(PO₄)₂·0.1Mg₂P₂O₇·1.9 MgSO₄(FPM3A). The composition of the coating mixture has been characterized by various analytical techniques. Thermal studies of these mixtures were accomplished using differential scanning calorimetry and thermo-gravimetric analysis. From the thermal analysis, it has been observed that the mixtures can be used as thermal heat storage materials. The FPM3A-modified black paint has been tested in a thermosyphon solar water heater prototype. The average water temperature and efficiency of the flat plate absorber with FPM3A-modified black paint have increased by an average of 7.5° and around 12%, respectively, in comparison with that with commercial unprocessed black paint.     

Selective paint coatings for coloured solar absorbers: Polyurethane thickness insensitive spectrally selective (TISS) paints (Part II)

Red, green and blue paints were prepared for use as thickness insensitive spectrally selective (TISS) paint coatings for solar façade absorbers. The paints were composed of a polyurethane resin binder in which various pigments were incorporated in such a way that they formed stable paint dispersions, satisfying stability criteria for façade coatings. A low emittance of the paints was achieved by using low-emittance aluminium flake pigments combined with iron oxide (red coloured paints). Black pigment was added to adjust solar absorptance. Blue and green paints were made by the addition of coloured aluminium flake pigment and the solar absorptance was also adjusted by the addition of black pigment. Efficiency for photo-thermal conversion of solar radiation was assessed by evaluation of the corresponding performance criteria, which enabled the selection of paints whose performance criteria values were higher than 0 (spectrally non-selective black coating). The results confirmed that blue and green paints and to minor extent red ones, combined selectivity with colour. The morphology of the paints was assessed, revealing that the colours originated from the deposition of finely dispersed colour and/or black pigment on the surface of the aluminium flakes during paint preparation.     

Effect of heat treatment and chemical composition on the corrosion behavior of Ni–Al intermetallics in molten (Li + K) carbonate

The corrosion performance of several Ni–Al alloys in 62 mol% Li₂CO₃–38 mol% K₂CO₃ at 650 °C has been studied using the weight loss technique. Alloys included 50Ni–50Al at.% (NiAl) and 75Ni–25Al at.% (Ni₃Al) alloys with additions of 1, 3 and 5 at.% Li each one, with or without a heat treatment at 400 °C during 144 h. For comparison, AISI-316L type stainless steel was also studied. The tests were complemented by X-ray diffraction, scanning electronic microscopy and micro-analyses. Results showed that NiAl-base alloy without heat treatment presented the lowest corrosion rate even lower than Ni₃Al alloy but still higher than conventional 316L-type stainless steel. In general terms, by either by heat treating these base alloys or by adding Li, the mass loss was increased. This effect was produced because by adding Li the adhesion of the external protective layer was decreased by inducing a higher number of discontinuities inside the grain boundaries. When the alloys were thermally annealed, these irregularities in the grain boundaries disappeared, decreasing the number of paths for the outwards diffusion of Al from the alloy to form the external, protective Al₂O₃ layer.     

Ni–P and Ni–Co–P coated aluminum alloy 5251 substrates as metallic bipolar plates for PEM fuel cell applications

This study is aimed to replace graphite bipolar plates in PEM fuel cells with surface modified aluminum alloy. To improve the surface characteristics of aluminum alloy 5251 (AA5251) substrate, Ni–P and Ni–Co–P coatings were deposited using electroless and electroplating deposition techniques [power supply and chronoamperometry]. Surface morphology and chemical composition of prepared coatings have been investigated using scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) techniques. The corrosion behaviour of Ni–P and Ni–Co–P coated AA5251 was studied in (0.5 M H₂SO₄ + 2 ppm HF) solution by potentiodynamic polarization technique. Lower corrosion current densities and more positive corrosion potentials were gained after coating AA5251 with Ni–P and Ni–Co–P deposits. Much better corrosion resistance was shown by coatings containing cobalt. Potentiostatic tests were carried out at +160 mV (MMS) in air-saturated solution to simulate cathode environment in PEM fuel cells. The current density of Ni–Co–P (1:1)/AA5251 was stabilized at a value lowered by 4 times relative to that at bare AA5251 substrate. Interfacial contact resistance values between coated substrates and carbon paper were measured. Ni–P and Ni–Co–P coatings prepared by electroless method showed ICR values, twice that at ones prepared by electroplating power supply technique.     

Antireflection treatment of Thickness Sensitive Spectrally Selective (TSSS) paints for thermal solar absorbers

There are several methods to produce solar absorbers, and one cheap alternative is painted absorbers, preferably painted with a spectrally selective paint. The optical properties of Thickness Sensitive Spectrally Selective (TSSS) paints are, however, limited by the thickness of the paint layer. In this study it is shown that the solar absorptance of two commercial TSSS paints can be increased between 0.01 and 0.02 units with an antireflection treatment using a silicon dioxide layer deposited from silica-gel. It was found that the thermal emittance (100 °C) did not change significantly after the treatment.     

A solar fryer

The design and operation of a large-area frying pan heated by solar radiation is described. A mirror below the pan directs the radiation to the pan bottom, which is coated with a low-emissivity black absorber. The mirror uses flat, hexagonal panels of aluminized-Mylar to provide uniform illumination across most of the pan bottom. The mirror mount allows 8 h/day operation with a single mirror-angle adjustment, plus a seasonal mounting adjustment for full-year use. A 0.46 m (18″) diameter pan and ∼1.2 m (48″) diameter mirror are used in the prototype, which is designed for cooking 0.42 m diameter slices of injera bread in East Africa. The prototype provides ∼640 W of heating power (60% efficiency compared to the full mirror area), and loses ∼100 W while cooking the bread. This allows for cooking ∼4 kg of bread per hour. The pan preheats to the 180 °C cooking temperature in 15-20 min. Materials and design are chosen for low-cost, and the prototype US-retail materials cost is ∼100 US$. The design is scalable to any desired pan size, with cost proportional to pan area. Most of the construction requires only hand tools, encouraging production in the country of use.     

Scratch-resistant zeolite anti-reflective coating on glass for solar applications

Sol-gel SiO₂ anti-reflection (AR) coating on solar glass is known to increase the current output by a few percent, but its mechanical durability is of concern. To improve its strength, the amorphous SiO₂ may be replaced by zeolite, which is a microporous aluminosilicate crystalline material. Scratch-resistant AR coating has been prepared by the dip coating of a composition which contains aggregated zeolite nanoparticles as the structure provider and zeolite precursors as the reactive binder. AR coating with better than 5H pencil hardness can be made with a composition containing BEA zeolite. Nanoindenter measurements show that this BEA zeolite films have 1.5 GPa indent hardness and 35 GPa elastic modulus. Furthermore, the freshly prepared AR coating shows a self-cleaning effect with a water contact angle (WCA) close to zero. It can be made super-hydrophobic with larger than 130° WCA after modifying with hexamethyl-disilazane (HMDS), upon which the pencil hardness further increases to 6H.     

Thermal performance of linear Fresnel reflecting solar concentrator with trapezoidal cavity absorbers

Thermal performance of the four identical trapezoidal cavity absorbers for linear Fresnel reflecting solar device were studied and compared. The absorbers were designed for operating in conjunction with a prototype Fresnel solar reflector. Rectangular and round pipe sections were used as absorber by placing in the trapezoidal cavity. The absorber pipes were coated with ordinary dull black board paint and black nickel selective surface. The bottom of the cavity was provided with plane glass to allow the solar radiation to be reflected from the Fresnel reflector. The other three sides of the cavity absorber were insulated to reduce heat loss. Thermal performance of the Fresnel reflecting concentrator with each trapezoidal cavity absorber was studied experimentally at different concentration ratio of the reflector. The study revealed that the thermal efficiency was influenced by the concentration ratio and selective surface coating on the absorber. The thermal efficiency decreased with the increase in the concentration ratio of the Fresnel reflecting collector. The selective surface coated absorber had a significant advantage in terms of superior thermal performance as compared to ordinary black painted absorber. The round pipe (multi-tube) receiver had higher surface area to absorb solar energy as compared to rectangular pipe receiver. Thermal efficiency of the solar device with round pipe absorber was found higher (up to 8%) as compared to rectangular pipe absorber.     

Modelling and performances of a deep-freezing process using low-grade solar heat

A solar deep-freezing process has been designed. It aims at cooling down a cold box to about −20 °C, using simple flat plate solar collectors operating at 70 °C. This original process involves two cascaded thermochemical systems based on the BaCl₂/ammonia reaction. Its working mode is discontinuous as it alternates between a regeneration mode during daytime and a cold production mode during nighttime. A global dynamic model involving the various system components allows the simulation of the process; it predicts the evolution of the components temperatures and the rates of chemical reactions of the system. It also allows the dimensioning of the system components to maintain a 500 l cold box at −20 °C during the 6 sunniest months of the year under typical Mediterranean weather conditions and provide over 80% of the total yearly cooling needs of this box. This requires a solar collector area of 5.8 m² and 39 kg of reactive salt. The predicted coefficient of performance (COP) is about 0.1 over the year, and the net solar COP, taking into account the collector efficiencies, is 0.05.     

Performance of unglazed solar ventilation air pre-heaters for broiler barns

Solar radiation is an interesting heat source for applications requiring a limited amount of energy, such as pre-heating cold fresh air used in venting livestock barns. The objective of this study was to evaluate the energy recovery efficiency of a solar air pre-heater consisting of an unglazed perforated black corrugated siding where the incoming fresh ventilation air picks up heat from its face and back. Installed on the southeast wall of two broiler barns located 40 km east of Montreal, Canada, the performance of solar air pre-heaters was monitored over 2 years. Sensors inside the barns monitored the temperature of the ambient air, that pre-heated by the solar collector and that exhausted by one of the three operating fans. An on-site weather station measured ambient air temperature, wind direction and velocity and radiation energy absorbed on a vertical plane parallel to the unglazed solar air pre-heaters. The measured vertical solar radiation value was used to evaluate the heat recovery efficiency of the unglazed solar air pre-heaters. Using data from the Varennes Environment Canada weather station located 30 km northwest, the solar sensors were found to measure the absorbed solar radiation with a maximum error of 7%, including differences in exterior air moisture. Unglazed, the efficiency of the solar air pre-heaters reached 65% for wind velocities under 2 m/s, but dropped below 25% for wind velocities exceeding 7 m/s. Nevertheless, the unglazed solar air pre-heaters were able to reduce the heating load especially in March of both years. Over a period starting in November and ending in March, the solar air heaters recovered an energy value equivalent to an annual return on investment of 4.7%.     

Improvement in long-term stability of dye-sensitized solar cell for outdoor use

To improve the intrinsic stability of the component of dye-sensitized solar cells (DSCs), we have fabricated the unit cell using solvent-free ionic liquid electrolyte. The degradation in the continuous 1 sun light soaking test at 60 °C over 15,000 h was effectively suppressed, compared with the cell using γ-butyrolactone electrolyte. The lifetime for outdoor use was estimated over 15 years from acceleration factor based on the outdoor exposure test. To confirm the stability of the DSC under practical outdoor use, we fabricated the solar light using the DSC modules, rechargeable batteries and bright light emitting diode (LED). The solar lights have been emitting a bright white light at night using the electricity from batteries charged by the DSC modules during the daytime in any weather condition for a half year.     

Low-cost black Cu–Ni alloy coatings for solar selective applications

The development of the Cu–Ni alloy coating as a selective surface for solar energy use is reported. The coatings were deposited by electrodeposition using Hull cell. Effects of electrolyte concentration and operating parameters on the appearance and optical properties of the coating were studied. Deposition parameters were optimized to achieve high solar absorptance alpha α=0.94 and low emittance epsilon ε=0.08. The elemental composition and morphology were evaluated by SEM and energy dispersive X-ray diffraction analysis (EDAX). The coating may be promising for solar collector panels used in domestic water heaters.     

A numerical thermal approach to study the accelerated aging of a solar absorber material

Solar power tower receivers are exposed to highly-concentrated solar flux. The strong flux variations that they are exposed to during their service life enhance the physical–chemical aging mechanisms and cause the decrease of the material’s thermal performance. A material that is commonly used for these applications was selected for our study. It is used for the absorber tubes of a solar power tower receiver. This material is made of an alloy (Inconel 625) that is coated with a silicone-based paint coating (Pyromark 2500 black) to increase the solar radiation absorption capacity.With the aim of determining the optimal conditions to accelerate the aging of this two-layer material (metal + paint coating), an axisymmetric 2-D model reproducing its thermal behavior was developed. Several thermal indicators (temperature, thermal gradients, temporal gradient), which are representative of the thermal aging factors and the material’s thermal performance, are analyzed in different configurations of boundary conditions. One configuration was defined according to the normal working conditions of a particular solar power plant application; the others are associated with various boundary conditions with the potential to increase or modify the thermal stress factors to accelerate the aging mechanisms. Other aging factors such as humidity, pollutants, and dust are not investigated in this paper. Several simulations were run in permanent and variable regimes. The most influencing boundary conditions and material properties were highlighted by a sensitivity study. To design relevant aging tests, particular attention should be paid to the incident solar power and the cooling characteristics of the material. The surface total absorptance, the thermal conductivities and the thermal contact resistance between the paint and the metal layers are the parameters that most affect the material’s thermal behavior. The evolution of those material properties characterizes the aging and should be monitored. Irradiance cycles were simulated for their potential to increase the thermal fatigue. Depending on the average, the amplitude and the period of the cycle, the evolution of the thermal indicators were analyzed. They were compared to select the most appropriate aging tests that are to be performed. From there, two aging strategies were determined. To put them in practice, an experimental Solar Accelerated Aging Facility (SAAF) was built and is described in this paper. It enables to perform accelerated aging experiments with a 2-m-diameter parabola concentrating the sun radiation up to 16,000 times. A preliminary experiment to validate the model confirmed that the simulation results are in good agreement with the experimental.     

Nickel-black solar absorber coatings

A new electrolyte has been proposed for the deposition of nickel-black selective coatings for use in flat-plate solar collectors. The authors have studied the influence of various ingredients and operating parameters on the appearance of the black coatings so obtained with special reference to their optical values (, ε). The coating exhibits better corrsion resistance than the well known black-nickel coatings (which contains nickel, zinc and sulphur) apart from having thermal stability upto 380°C. With no zinc in the deposit, this can be used in place of black nickel coatings with less corrosion problems.     

Polymer solar cell modules prepared using roll-to-roll methods: Knife-over-edge coating, slot-die coating and screen printing

A complete polymer solar cell module prepared in the ambient atmosphere using all-solution processing with no vacuum steps and full roll-to-roll (R2R) processing is presented. The modules comprise five layers that were prepared on a 175-μm flexible polyethyleneterephthalate (PET) substrate with an 80-nm layer of transparent conducting indium-tin oxide (ITO). The ITO layer was first patterned by screen printing an etch resist followed by etching. The second layer was applied by either knife-over-edge (KOE) coating or slot-die coating a solution of zinc oxide nanoparticles (ZnO-nps) followed by curing. The second layer comprised a mixture of the thermocleavable poly-(3-(2-methylhexan-2-yl)-oxy-carbonyldithiophene) (P3MHOCT) and ZnO-nps and was applied by a modified slot-die coating procedure, enabling slow coating speeds with low viscosity and low surface tension ink solutions. The third layer was patterned into stripes and juxtaposed with the ITO layer. The fourth layer comprised screen-printed or slot-die-coated PEDOT:PSS and the fifth and the final layer comprised a screen-printed or slot-die-coated silver electrode. The final module dimensions were 28 cm×32 cm and presented four individual solar cell modules: a single-stripe cell, a two-stripe serially connected module, a three-stripe serially connected module and finally an eight-stripe serially connected module. The length of the individual stripes was 25 cm and the width was 0.9 cm. With overlaps of the individual layers this gave a width of the active layer of 0.6 cm and an active area for each stripe of 15 cm². The performance was increased ten fold compared to mass-produced modules employing screen printing for all five layers of the device. The processing speeds employed for the R2R processed layers were in the range of 40-50 m h⁻¹. Finally a comparison is made with the state of the art represented by P3HT-PCBM as the active layer and full R2R solution processing using slot-die coating.     

The stability of NiCoZn electrocatalyst for hydrogen evolution activity in alkaline solution during long-term electrolysis

The long-term stability of NiCoZn coating for hydrogen evolution reaction (HER) was investigated in 1 M KOH solution under 100 mA cm⁻² current density at room temperature. The effect of electrolysis on the corrosion behavior of NiCoZn coating was also studied. The alloy prepared on a copper electrode (Cu/NiCoZn) was etched in a concentrated alkaline solution (30% NaOH) to produce a porous and electrocatalytic surface suitable for use in the HER. The bulk and surface compositions of coating before and after alkaline leaching were determined by atomic absorption spectroscopy (AAS) and energy dispersive X-ray (EDX) analysis. The surface morphologies of freshly prepared and aged electrodes were investigated by scanning electron microscopy (SEM). Their catalytic activity towards the HER was assessed by recording cathodic current–potential curves and electrochemical impedance spectroscopy (EIS) techniques. It was found that the NiCoZn coating has a compact and porous structure. The long-term operation at 100 mA cm⁻² current density showed that the electrochemical activity of Cu/NiCoZn electrode increased slightly with increasing electrolysis time. The activation of electrode related to the removal of any existing corrosion products and accumulations from the pores and formation of cracks during hydrogen gas evolution. The corrosion tests showed that the corrosion resistance of Cu/NiCoZn electrode changed after electrolysis.     

A new lead alloy current-collector manufactured by a powder rolling process and its corrosion behavior under lead-acid battery conditions

A new powder rolling process for manufacturing current-collector sheets for lead-acid batteries has been developed. Gas-atomized lead–tin and lead–tin–calcium alloy powders obtained by a rapid solidification process in air were employed as raw materials for the powder rolling process. The corrosion behavior of powder-rolled lead–tin alloys with various compositions of tin has been investigated. A dipping corrosion test of square plain sheets of the alloys was performed in H₂SO₄ at 75 °C. The test was repeated up to 20 cycles with each cycle consisting of a controlled 10 mA cm⁻² oxidation current for 6 h and a rest under open circuit voltage for 6 h. The extent of corrosion–elongation and the appearance of the corroded surface of the tested specimens were the main observations. The corrosion–elongation of the corroded sheet of a powder-rolled lead alloy containing 1.5 wt% tin with ca. 200 μm initial thickness was less than 5%, whereas that of the corroded sheet of the cast-rolled lead alloy containing 1.5 wt% tin with the same initial thickness was 25–30% under the same corrosion test conditions. The corroded powder-rolled sheet of the 1.5 wt% tin lead alloy has uniform corrosion, but the cast-rolled sheet of lead alloy containing 1.5 wt% tin was much distorted and was perforated by the corrosion. Intergranular corrosion of the powder-rolled lead–tin alloys was much suppressed as compared with that of the cast-rolled lead–tin alloys.     

Potential benefits of solar reflective car shells: Cooler cabins,fuel savings and emission reductions

Vehicle thermal loads and air conditioning ancillary loads are strongly influenced by the absorption of solar energy. The adoption of solar reflective coatings for opaque surfaces of the vehicle shell can decrease the “soak” temperature of the air in the cabin of a vehicle parked in the sun, potentially reducing the vehicle’s ancillary load and improving its fuel economy by permitting the use of a smaller air conditioner. An experimental comparison of otherwise identical black and silver compact sedans indicated that increasing the solar reflectance (ρ) of the car’s shell by about 0.5 lowered the soak temperature of breath-level air by about 5–6 °C. Thermal analysis predicts that the air conditioning capacity required to cool the cabin air in the silver car to 25 °C within 30 min is 13% less than that required in the black car. Assuming that potential reductions in AC capacity and engine ancillary load scale linearly with increase in shell solar reflectance, ADVISOR simulations of the SC03 driving cycle indicate that substituting a typical cool-colored shell (ρ = 0.35) for a black shell (ρ = 0.05) would reduce fuel consumption by 0.12 L per 100 km (1.1%), increasing fuel economy by 0.10 km L⁻¹ [0.24 mpg] (1.1%). It would also decrease carbon dioxide (CO₂) emissions by 2.7 g km⁻¹ (1.1%), nitrogen oxide (NO_x) emissions by 5.4 mg km⁻¹ (0.44%), carbon monoxide (CO) emissions by 17 mg km⁻¹ (0.43%), and hydrocarbon (HC) emissions by 4.1 mg km⁻¹ (0.37%). Selecting a typical white or silver shell (ρ = 0.60) instead of a black shell would lower fuel consumption by 0.21 L per 100 km (1.9%), raising fuel economy by 0.19 km L⁻¹ [0.44 mpg] (2.0%). It would also decrease CO₂ emissions by 4.9 g km⁻¹ (1.9%), NO_x emissions by 9.9 mg km⁻¹ (0.80%), CO emissions by 31 mg km⁻¹ (0.79%), and HC emissions by 7.4 mg km⁻¹ (0.67%). Our simulations may underestimate emission reductions because emissions in standardized driving cycles are typically lower than those in real-world driving.     

Analysis and feasibility of implementing solar chimney power plants in the Mediterranean region

This paper analyzes the feasibility of solar chimney power plants as an environmentally acceptable energy source for small settlements and islands of countries in the Mediterranean region. For the purpose of these analyses, two characteristic geographic locations (Split and Dubrovnik) in Croatia were chosen and simplified model for calculation of produced electric power output is also developed. These locations possess typical characteristics of the Mediterranean climate. The solar characteristics of the chosen geographic locations are shown along with characteristic meteorological data. A solar chimney (SC) power plant with a chimney height of 550 m and a collector roof diameter of 1250 m would produce 2.8–6.2 MW of power. The average annual electric power production of this SC power plant would range between 4.9 and 8.9 GWh/year, but in reality from 5.0 to 6.0 GWh/year in average. An approximate costs analysis, which included a total investment estimate, was performed. The levelized electricity cost was also calculated. It is found that the price of produced electric energy by solar chimney power plant in Mediterranean region is considerably higher compared to the other power sources.