Development of integrated reformer systems for syngas production

Precision Combustion, Inc. (PCI) has developed autothermal reformer (ATR) units based on its patented Microlith^® technology and demonstrated stable, coke-free operation using JP-8 consisting of up to 70 ppm_w sulfur for 1100 h with complete fuel conversion and reforming efficiency of ∼85%. The feasibility of operating ATR reformers with distillate fuels containing higher sulfur (up to 400 ppm_w) has also been demonstrated for 55 h, while producing syngas (i.e., H₂ and CO) at >80% reforming efficiency and at complete fuel conversion. Reformer test results, demonstrating water neutral operation, catalyst sulfur tolerance, removal of sulfur to <1 ppm_v, and maintenance of higher hydrocarbons to levels acceptable for fuel cell stacks, provide a measure of the ATR performance that can be expected under realistic conditions with readily available fuels. The results also give valuable insights to the system design and operation strategy for integrated power generation systems.     

Microcrystalline silicon solar cell using p-a-Si:H window layer deposited by photo-CVD method

A p-a-Si:H layer, deposited by a photo-assisted chemical vapor deposition (photo-CVD) method, was adopted as the window layer of a hydrogenated microcrystalline silicon (μc-Si:H) solar cell instead of the conventional p-μc-Si:H layer. We verified the usefulness of p-a-Si:H for the p-layer of the μc-Si:H solar cell by applying it to SnO₂-coated glass substrate. It was found that the quantum efficiency (QE) characteristics and solar cell performance strongly depend on the p-a-Si:H layer thicknesses. We applied boron-doped nanocrystalline silion (nc-Si:H) p/i buffer layers to μc-Si:H solar cells and investigated the correlation of the p/i buffer layer B₂H₆ flow rate and solar cell performance. When the B₂H₆ flow rate was 0.2 sccm, there was a little improvement in fill factor (FF), but the other parameters became poor as the B₂H₆ flow rate increased. This is because the conductivity of the buffer layer decreases as the B₂H₆ flow rate increases above appropriate values. A μc-Si:H single-junction solar cell with ZnO/Ag back reflector with an efficiency of 7.76% has been prepared.     

Experimental study for natural ventilation on a solar chimney

Thermal performance of a solar chimney for natural ventilation was experimentally investigated. The experimental model was implemented on full scale and real meteorological conditions, so that experimental results will be compared with the simulation results. The results show that for a maximum irradiance of 604 W/m², occurring around 13:00 h on September 15th, 2007, a maximum air temperature increment of 7 °C was obtained through the solar chimney. Also, a volumetric air flow rate ranging from 50 to 374 m³/h was measured on that day. Thus, an average air flow rate of 177 m³/h was achieved from 0:00 h to 24:00 h. The experimental solar chimney discharge coefficient, C_d, was 0.52. This coefficient is useful to determine the mass flow rate in the solar chimney design. It was observed that the air flow rate through the solar chimney is influenced by a pressure difference between input and output, caused by thermal gradients and wind velocity, mainly.     

Solar-driven steam-based gasification of sugarcane bagasse in a combined drop-tube and fixed-bed reactor – Thermodynamic,kinetic, and experimental analyses

Syngas production via steam-based thermochemical gasification of Brazilian sugarcane bagasse, using concentrated solar energy for process heat, was thermodynamically and experimentally investigated. Energy and exergy analyses revealed the potential benefits of solar-driven over conventional autothermal gasification that included superior quality of syngas composition and higher yield per unit of feedstock. Reaction rates for the gasification of fast pyrolyzed bagasse char were measured by thermogravimetric analysis and a rate law based on the oxygen exchange mechanism was formulated. In order to provide residence times long enough for adequate char conversion, a laboratory-scale entrained flow reactor that combines drop-tube and fixed-bed concepts was developed. Testing was performed in an electric furnace with the final aim to supply heat by concentrated solar radiation. Experimental runs at reactor temperatures of 1073–1573 K and a biomass feed rate of 0.48 g/min yielded high-quality syngas of molar ratios H₂/CO = 1.6 and CO₂/CO = 0.31, and with heating values of 15.3–16.9 MJ/kg, resulting in an upgrade factor (ratio of heating value of syngas produced over that of the feedstock) of 112%. Theoretical upgrade factors of up to 126%, along with the treatment of wet feedstock and elimination of the air separation unit, support the potential benefits of solar-driven over autothermal gasification.     

Analysis of multicrystalline silicon solar cells by modified 3-diode equivalent circuit model taking leakage current through periphery into consideration

We proposed a modified 3-diode equivalent circuit model for analysis of multicrystalline silicon (Mc-Si) solar cells. By using this equivalent circuit model, we can precisely evaluate the characteristics of Mc-Si solar cells taking the influence of grain boundaries and large leakage current through the peripheries into consideration and extract electrical properties. The calculated value of current-voltage characteristics for small size (3 mm×3 mm) Mc-Si solar cells using this model completely agreed with the measured value at various cell temperatures. Moreover, the calculated open-circuit voltage (V_oc) obtained by extracted parameters and measured V_oc agreed well.     

Design of direct solar PV driven air conditioner

Solar air conditioning system directly driven by stand-alone solar PV is studied. The air conditioning system will suffer from loss of power if the solar PV power generation is not high enough. It requires a proper system design to match the power consumption of air conditioning system with a proper PV size. Six solar air conditioners with different sizes of PV panel and air conditioners were built and tested outdoors to experimentally investigate the running probabilities of air conditioning at various solar irradiations. It is shown that the instantaneous operation probability (OPB) and the runtime fraction (R_F) of the air conditioner are mainly affected by the design parameter r_pL (ratio of maximum PV power to load power). The measured OPB is found to be greater than 0.98 at instantaneous solar irradiation I_T > 600 W m⁻² if r_pL > 1.71. R_F approaches 1.0 (the air conditioner is run in 100% with solar power) at daily-total solar radiation higher than 13 MJ m⁻² day⁻¹, if r_pL > 3.     

Formation of a low reflective surface on crystalline silicon solar cells by chemical treatment using Ag electrodes as the catalyst

A new method was developed for making a porous silicon layer as an anti-reflective coating on the top of crystalline silicon solar cells. The porous silicon layer was formed in a mixed solution of H₂O₂ and HF by using screen-printed Ag front electrodes as the catalyst. With the help of the catalytic effect, porous silicon layers were formed by treatment in a solution chemically milder than conventional solutions. The multi-crystalline silicon solar cell covered with the porous silicon layer showed a surface reflectance below 15% in a wavelength region of 400–800 nm.     

Experimental investigation of forced convection and desiccant integrated solar dryer

An indirect forced convection and desiccant integrated solar dryer is designed and fabricated to investigate its performance under the hot and humid climatic conditions of Chennai, India. The system consists of a flat plate solar air collector, drying chamber and a desiccant unit. The desiccant unit is designed to hold 75 kg of CaCl₂-based solid desiccant consisting of 60% bentonite, 10% calcium chloride, 20% vermiculite and 10% cement. Drying experiments have been performed for green peas at different air flow rate. The equilibrium moisture content M_e is reached in 14 h at an air flow rate of 0.03 kg/m² s. The system pickup efficiency, specific moisture extraction rate, dimensionless mass loss, mass shrinkage ratio and drying rate are discussed in this paper.     

Solar chemical reactor technology for industrial production of lime

We developed the solar chemical reactor technology to effect the endothermic calcination reaction CaCO₃(s) → CaO(s) + CO₂(g) at 1200–1400 K. The indirect heating 10 kW_th multi-tube rotary kiln prototype processed 1–5 mm limestone particles, producing high purity lime that is not contaminated with combustion by-products. The quality of the solar produced quicklime meets highest industrial standards in terms of reactivity (low, medium, and high) and degree of calcination (exceeding 98%). The reactor’s efficiency, defined as the enthalpy of the calcination reaction at ambient temperature (3184 kJ kg⁻¹) divided by the solar energy input, reached 30–35% for quicklime production rates up to 4 kg h⁻¹. The solar lime reactor prototype operated reliably for more than 100 h at solar flux inputs of about 2000 kW m⁻², withstanding the thermal shocks that occur in solar high temperature applications. By substituting concentrated solar energy for fossil fuels as the source of process heat, one can reduce by 20% the CO₂ emissions in a state-of-the-art lime plant and by 40% in a conventional cement plant. The cost of solar lime produced in a 20 MW_th industrial solar calcination plant is estimated in the range 131–158 $/t, i.e. about 2–3 times the current selling price of conventional lime.     

Formation of porous silicon for large-area silicon solar cells: A new method

Luminescent porous silicon (PS) was prepared for the first time using a spraying set-up, which can diffuse in a homogeneous manner HF solutions, on textured or untextured (1 0 0) oriented monocrystalline silicon substrate. This new method allows us to apply PS onto the front-side surface of silicon solar cells, by supplying very fine HF drops. The front side of N⁺/P monocrystalline silicon solar cells may be treated for long periods without altering the front grid metallic contact. The monocrystalline silicon solar cells (N⁺/P, 78.5 cm²) which has undergone the HF-spraying were made with a very simple and low-cost method, allowing front-side Al contamination. A poor but expected 7.5% conversion efficiency was obtained under AM1 illumination. It was shown that under optimised HF concentration, HF-spraying time and flow HF-spraying rate, Al contamination favours the formation of a thin and homogeneous hydrogen-rich PS layer. It was found that under optimised HF-spraying conditions, the hydrogen-rich PS layer decreases the surface reflectivity up to 3% (i.e., increase light absorption), improves the short circuit current (I_sc), and the fill factor (FF) (i.e., decreases the series resistance), allowing to reach a 12.5% conversion efficiency. The dramatic improvement of the latter is discussed throughout the influence of HF concentration and spraying time on the I–V characteristics and on solar cells parameters. Despite the fact that the thin surfae PS layer acts as a good anti-reflection coating (ARC), it improves the spectral response of the cells, especially in the blue-side of the solar spectrum, where absorption becomes greater, owing to surface band gap widening and conversion of a part of UV and blue light into longer wavelengths (that are more suitable for conversion in a Si cell) throughout quantum confinement into the PS layer.     

Effect of gas flow rates on PECVD-deposited nanocrystalline silicon thin film and solar cell properties

Nanocrystalline silicon films have been deposited at a plasma excitation frequency of 54.24 MHz by varying the flow rates of SiH₄+H₂ mixture in the reaction chamber. It has been found that with increase in gas flow rate from 100 to 300 sccm the defect density, microstructural defect fraction and the crystalline volume fraction in the film decrease. Films deposited at optimum total gas flow rate of 200 sccm with comparable crystalline volume fraction have shown better structural and optoelectronic properties compared to the films deposited at 100 sccm total gas flow rate for application in solar cell. Solar cells have been fabricated using these layers as absorber layers and the maximum cell efficiency obtained is 6.2% (AM1.5, 28 °C) at 200 sccm total gas flow rate. It has been found that material prepared using higher total gas flow rate of 200 sccm together with higher hydrogen dilution is better suited for solar cell application.     

Modeling of a direct solar receiver reactor for decomposition of sulfuric acid in thermochemical hydrogen production cycles

Hydrogen production thermochemical cycles, based on the recirculation of sulfur-based compounds, are among the best suited processes to produce hydrogen using concentrated solar power. The sulfuric acid decomposition section is common to each sulfur-based cycle and represents one of the fundamental steps. A novel direct solar receiver-reactor concept is conceived, conceptually designed and simulated. A detailed transport phenomena model, including mass, energy and momentum balance expressions as well as suitable decomposition kinetics, is described adopting a finite volume approach. A single unit reactor is simulated with an inlet flow rate of 0.28 kg/s (corresponding to a production of approximately 11 kg_H2/h in a Hybrid Sulfur process) and a direct solar irradiation at a constant power of 143 kW/m². Results, obtained for the high temperature catalytic decomposition of SO₃ into SO₂ and O₂, demonstrate the effectiveness of the proposed concept, operating at pressures of 14 bar. A maximum temperature of 879 °C is achieved in the reactor body, with a corresponding average SO₂ mass fraction of 27.8%. The overall pressure drop value is 1.7 bar. The reactor allows the SO₃ decomposition into SO₂ and O₂ to be realized effectively, requiring an external high temperature solar power input of 123.6 kJ/molSO2 (i.e. 123.6 kJ/mol_H2).     

Texturing of large area multi-crystalline silicon wafers through different chemical approaches for solar cell fabrication

Surface texturing of silicon can reduce the reflectance of incident light and hence increase the conversion efficiency of solar cells. Comparatively lesser concentrated (10%) standard alkaline (NaOH/KOH) solution does not give good textured multi-crystalline silicon (mc-Si) surface, which could give satisfactory open-circuit voltage. This is due to grain-boundary delineation with steps formed between successive grains of different orientations. In this work an attempt has been made to obtain a well-textured mc-Si surface through three different approaches. The first two are with two different types of acid solutions and the third with concentrated alkaline NaOH. Solutions of HF–HNO₃–CH₃COOH/H₂O system with different concentrations of HF and HNO₃ were used for texturing. The results on the effect of texturing of these three solutions on the surface morphology of very large area (125 mm×125 mm) mc-Si wafer as well as on the performance parameters of solar cell are presented in this paper. Attempts have been made to study extensively the surface morphologies of mc-Si wafers in two effective regions of the isoetch curves of the HF:HNO₃:diluent's system. Also we studied the reflectance, uniformity, spectral response, short-circuit current, open-circuit voltage, fill factor and dark current–voltage of the cells fabricated using wafers textured with the three different methods. Short-circuit current of the solar cells fabricated using acid-textured wafers were measured to be in the range of 4.93 A. This value is 0.37 and 0.14 A higher than the short-circuit current values measured in the cells fabricated with isotextured and alkaline-textured wafers, respectively.     

Electrodeposition zinc-oxide inverse opal and its application in hybrid photovoltaics

This article reports the preparation of three-dimensional (3D) mesoporous zinc oxide (ZnO) films and their application in solar cells. The films were obtained through electrochemical deposition in DMSO solutions by using PS colloidal crystal as templates. The ZnO films with inverse opal (IO) structure were obtained after removing the templates by thermolysis. The ordered porous ZnO films were used to prepare hybrid solar cells by infiltrating the films with poly(3-hexylthiophene) (P3HT) or P3HT:ZnO nanocomposite. Results showed that the interpenetrating network of both ZnO(IO) and P3HT can form continuous pathways for electron and hole transport. By infiltrating a P3HT:ZnO nanocomposite into the porous ZnO films, the photocurrent of the solar cell can be dramatically improved. The cell shows the V_oc and I_sc of 462 mV and 444.3 μA/cm², respectively. By using a 420 nm cutoff filter, the cell retains about 80% and 50% of its original V_oc and I_sc after continuous white-light illumination (100 mW/cm²) for 10 h. Stability of the device under above conditions was estimated to be 51 h.     

A simple process to remove boron from metallurgical grade silicon

It is necessary to develop solar grade (SoG) silicon for the photovoltaic industry. A desirable approach is to upgrade metallurgical grade (MG) silicon. The most problematic impurities to remove from MG silicon are B and P. A simple process to remove B from MG silicon has been developed by refining MG silicon in the molten state followed by directional solidification. With this approach, B has been reduced to 0.3 ppma, P to <10 ppma and all other impurities to <0.1 ppma using commercially available, as-received MG silicon. It remains to develop a similar P reduction process so that SoG silicon production from MG silicon can be commercialized. The B-removal process was applied to B overdoped electronic grade silicon, and the resulting material was used for crystal growth. Test solar cells of 12.5–13.4% (1 cm²) efficiency were produced.     

Study of electrical properties of oxidized porous silicon for back surface passivation of silicon solar cells

Back surface passivation becomes a key issue for the silicon solar cells made with thin wafers. The high surface recombination due to the metal contacts can be lowered by reducing the back contact area and forming local back surface field (LBSF) in conjunction with the passivation with dielectric layer. About 3×10^-7 m thick porous silicon (PS) layer with pore diameter mostly of 1×10^-8–5×10^-8 m was formed by chemical etching of silicon using the acidic solution containing hydrofluoric acid (HF), nitric acid (HNO₃) and De-ionized water in the volume ratio 1:3:5 at 298 K for which etching time was kept constant for 360 s. Electrical properties of oxidized PS was studied through the current–voltage (I–V) and capacitance–voltage (C–V) characteristics of the metal–insulator–semiconductor (MIS) device in which the oxidized PS was used as an insulating layer and the results were further analyzed. The C–V curves of all the studies MIS devices showed the negative flatband voltage varying from -2 to , confirming that the oxidized layer of PS has fixed positive charge.     

Solar thermal cracking of methane in a particle-flow reactor for the co-production of hydrogen and carbon

An experimental investigation on the thermal decomposition of CH₄ into C and H₂ was carried out using a 5 kW particle-flow solar chemical reactor tested in a solar furnace in the 1300–1600 K range. The reactor features a continuous flow of CH₄ laden with μm-sized carbon black particles, confined to a cavity receiver and directly exposed to concentrated solar irradiation of up to 1720 suns. The reactor performance was examined for varying operational parameters, namely the solar power input, seed particle volume fraction, gas volume flow rate, and CH₄ molar concentration. Methane conversion and hydrogen yield exceeding 95% were obtained at residence times of less than 2.0 s. A solar-to-chemical energy conversion efficiency of 16% was experimentally reached, and a maximum value of 31% was numerically predicted for a pure methane flow. SEM images revealed the formation filamentous agglomerations on the surface of the seed particles, reducing their active specific surface area.     

Multicrystalline silicon wafers prepared from upgraded metallurgical feedstock

A solution to the problem of the shortage of silicon feedstock used to grow multicrystalline ingots can be the production of a feedstock obtained by the direct purification of upgraded metallurgical silicon by means of a plasma torch. It is found that the dopant concentrations in the material manufactured following this metallurgical route are in the 10¹⁷ cm⁻³ range. Minority carrier diffusion lengths L_n are close to 35 μm in the raw wafers and increases up to 120 μm after the wafers go through the standard processing steps needed to make solar cells: phosphorus diffusion, aluminium–silicon alloying and hydrogenation by deposition of a hydrogen-rich silicon nitride layer followed by an annealing. L_n values are limited by the presence of residual metallic impurities, mainly slow diffusers like aluminium, and also by the high doping level.     

Exergy analysis of a passive solar still

This paper presents a steady-state and transient theoretical exergy analysis of a solar still, focused on the exergy destruction in the components of the still: collector plate, brine and glass cover. The analytical approach states an energy balance for each component resulting in three coupled equations where three parameters—solar irradiance, ambient temperature and insulation thickness—are studied. The energy balances are solved to find temperatures of each component; these temperatures are used to compute energy and exergy flows. Results in the steady-state regime show that the irreversibilities produced in the collector account for the largest exergy destruction, up to 615 W/m² for a 935 W/m² solar exergy input, whereas irreversibility rates in the brine and in the glass cover can be neglected. For the same exergy input a collector, brine and solar still exergy efficiency of 12.9%, 6% and 5% are obtained, respectively. The most influential parameter is solar irradiance. During the transient regime, irreversibility rates and still temperatures find a maximum 6 h after dawn when solar irradiance has a maximum value. However, maximum exergy brine efficiency, close to 93%, is found once T_col<T_w (dusk) and the heat capacity of the brine plays an important role in the modeling of collector–brine interaction. Nocturnal distillation is characterized by very low irreversibility rates due to reduced temperature difference between collector and an increase in exergy efficiency towards dawn due to ambient temperature decrease.     

Stability of thin film solar cells having less-hydrogenated amorphous silicon i-layers

In this study, highly stabilized hydrogenated amorphous silicon films and their solar cells were developed. The films were fabricated using the triode deposition system, where a mesh was installed between the cathode and the anode (substrate) in a plasma-enhanced chemical vapor deposition system. At a substrate temperature of 250 °C, the hydrogen concentration of the resulting film (Si–H=4.0 at%, Si–H₂<1×10²⁰ cm⁻³) was significantly less than that of conventionally prepared films. The films were used to develop the i-layers of solar cells that exhibited a significantly low degradation ratio of 7.96%.