Digital design and 3D printing of innovative SiC architectures for high temperature volumetric solar receivers

Abstract

In order to demonstrate that digital material engineering methodology is able to address the design and optimisation of architectured ceramic materials, solar volumetric receivers employed in Solar Thermal Power Plants (STPP) have been studied. A digital design approach for obtaining new receivers, at the macroscopic structural scale, is proposed. This approach couples virtual structure generation, ray tracing and thermal simulations at the scale of the base structural components (microscopic scale). Then, a recently developed process for manufacturing silicon carbide (SiC) parts by binder jetting is used to elaborate three optimised structures which are tested on-sun at high temperature in a solar concentrator reproducing the STPP operation conditions. The results obtained with these structures, having original shapes, are promising: the average experimental outlet air temperature reaches a maximum of 1133 K, energy yields can reach 0.49 despite high experimental heat losses, and all the SiC structures, made with a new material based on 3D printing, withstood the high temperatures reached, up to 1500 K. Comparison between digital and experimental results shows that the approach presented in this paper paves the way to a new digital material engineering approach.