College of Engineering

Department of Mechanical Engineering

Spring 2018-2019

Senior Design Project Report

Project Title: Concentrated Solar Power Plant

In partial fulfillment of the requirements for the

Degree of Bachelor of Science in Mechanical Engineering

Team Members

Student Name Student ID

1 Mohammed Alarfaj 201500818
2 Nasser Alsuhaibani 201401066
3 Abdullah Almubayedh 201500011
4 Mohammed Alafaleq 201403938
5 Abdulrhman Althawaiqib 201202089

Project Advisors: Dr. Aymen Jendoubi

Abstract

This project is not only beneficial in terms of its reduced cost. Solar system energy uses an

energy source (the sun) that is consistently available especially in a region like Saudi Arabia.

It will be a clean source of energy and will not do damage to the environment and to the nature.

Furthermore, it will not harm our earth, and since it uses renewable energy, it will last forever.

The movement for energy independence coupled with aggressive renewable energy goals

and government investment incentives (2030 vision) has led the power industry to develop

efficient and reliable sources of renewable power. In a power tower system, a central Solar

Receiver Steam Generator is surrounded by a field of mirrors that focus and concentrate

sunlight onto the receiver tubes. The energy from the sunlight is used to generate and superheat

steam for electric production.

2
Acknowledgement

We would like to thank our advisor Dr. Aymen Jendoubi for his support and continuous help

in our prototype and report, also we like to thank Dr. Bouchaib for his support and guidance

that helped us achieve our senior project, also we would like to thank and express our sincere

gratitude to the dean of the collage of engineering Dr. Jamal Nyfeh and the dean of the

mechanical engineering department Dr. Faramarz Djavanroodi for their support and providing

us with the best working and studying environment.

3
List of Acronyms (Symbols) used in the report

CSP Concentrated Solar Power

CAD Computer Aided Design
Qemit Radiation emitted the surface Surface
𝐴𝑠 Surface Area
𝜎 The Stefan-Boltzmann Constant
𝑇𝑠 Surface Temperature
𝜂 Efficiency
𝑤𝑡 Work of the turbine
𝑤𝑝 Work of the pump
𝑞𝑖𝑛 Heat entering the system

(𝑤𝑡 )𝑠 Work of the turbine shifted

ℎ Enthalpy
ℎ𝑠 Enthalpy Shifted
(𝑤𝑃 )𝑠 Work of the pump shifted
𝑚 Mass flow rate

𝐴 Area of the pipe

𝑉 Velocity
ρ Density
F focal length measured by hand

Dap Diameter of plate of parabolic

θ Angle of the parabolic dish

A Focal Point
P Pressure
Z Hieght
ℎ𝐿 Head Loss
ℎ𝐿𝑡 Head Loss of Turbine
ℎ𝐿𝑝 Head Loss of Pump

4
 List of Figures
Figure 1: Example of CSP plant ............................................................................................... 9
Figure 2: Hydroelectric Power plant ........................................................................................ 14
Figure 3: Wind Turbine ........................................................................................................... 14
Figure 4: Wind Turbine Arial View......................................................................................... 15
Figure 5: Coal Laid-off Plants ................................................................................................. 16
Figure 6: Ivanpah CSP Plant .................................................................................................... 18
Figure 7: Trough System ......................................................................................................... 18
Figure 8: Power Tower System................................................................................................ 19
Figure 9: Dish System .............................................................................................................. 19
Figure 10: 1968, by professor Giovanni Francia the concentrated solar power plant. ............ 21
Figure 11: Schematic of the 1 MW the solar power tower system .......................................... 22
Figure 12:Comparison of thermal energy density in different media ...................................... 23
Figure 16: CAD Drawings ....................................................................................................... 31
Figure 17: Dish Figure 18: Wrapping the Dish............................................................ 32
Figure 19: Trying the dish reflection ....................................................................................... 32
Figure 20: Boiler ...................................................................................................................... 33
Figure 21: Steam Turbine ........................................................................................................ 34
Figure 22: Condenser ............................................................................................................... 34
Figure 23: Water pump impeller .............................................................................................. 35
Figure 24: Water pump ............................................................................................................ 35
Figure 25: Infrared Gun ........................................................................................................... 38
Figure 26 Pressure Gauge ........................................................................................................ 39

5
 List of Tables
Table 1: ASTM Standards ....................................................................................................... 27
Table 2: Thermal Conductivity ................................................................................................ 28
Table 3: Thermal Diffusivity ................................................................................................... 28
Table 4: Parts ........................................................................................................................... 39
Table 5: Data of the results ...................................................................................................... 39
Table 6: Project Plan ................................................................................................................ 42
Table 7: Tasks Assigned to team members.............................................................................. 44
Table 8: Dates and Activates of Events ................................................................................... 45
Table 9: Bill of Materials ......................................................................................................... 47

6
 Table of Contents
Chapter 1: Introduction ….........................................................................................................8
1.1 Project Definition ............................................................................................................... 9
1.2 Project Objectives ............................................................................................................. 10
1.3 Project Specifications ........................................................................................................10
1.4 Project Applications ..........................................................................................................11
Chapter 2: Literature Review ................................................................................................. 12
2.1 Project Background .......................................................................................................... 13
2.2 Previous Work .................................................................................................................. 20
2.3 Comparative Work ........................................................................................................... 21
Chapter 3: System Design ...................................................................................................... 25
3.1 Design Constraints and Design Methodology .................................................................. 26
3.2 Engineering Design Standards ......................................................................................... 27
3.3 Theory and Theoretical Calculations ............................................................................... 29
3.4 Product Subsystems and selection of Components .......................................................... 31
Chapter 4: System Testing and Analysis ................................................................................ 36
4.1 Experimental Setup, Sensors and data acquisition system ............................................... 37
4.2 Results, Analysis and Discussion ..................................................................................... 39
Chapter 5: Project Management ............................................................................................. 40
5.1 Project Plan ....................................................................................................................... 41
5.2 Contribution of Team Members ....................................................................................... 42
5.3 Project Execution Monitoring .......................................................................................... 45
5.4 Challenges and Decision Making ..................................................................................... 46
5.5 Project Bill of Materials & Budget ................................................................................... 47
Chapter 6: Project Analysis .................................................................................................... 48
6.1 Life-Long Learning .......................................................................................................... 49
6.2 Impact of Engineering Solutions ...................................................................................... 50
6.3 Contemporary Issues Addressed ...................................................................................... 51
Chapter 7: Conclusion & Future Recommendations .............................................................. 52
7.1 Conclusion ........................................................................................................................ 53
7.2 Future Recommendations ................................................................................................. 53
8. References ......................................................................................................................... 54
Appendix A: Progress Reports ............................................................................................... 57
Appendix B: Engineering Standards ...................................................................................... 63
Appendix C: CAD Drawings and Bill of Materials ............................................................... 65
Appendix D: Prototype Pictures ............................................................................................. 67
Appendix E: Operation Manual .............................................................................................. 68

7
Chapter 1: Introduction

1.1 Project Definition

1.2 Project Objectives

1.3 Project Specification

1.4 Application

8
 1.1. Project Definition
In 19th century, revolution of industries has started, these industries require a huge amount of

energy. Based on the need of energy, there was shortage in the resources that were easily

acquired such as coal. This caused many conflicts and wars which made people search for

another source of energy. At that time, oil was discovered and considered one of the main

sources of power. As time passes, innovation and knowledge had improved and discovered that

these sources of energy had bad environment effect and they are limited energy sources.

After a period of time a new renewable clean energy sources are innovated such as dams and

wind and solar energy. Solar energy uses solar panels which can’t withstand high temperatures

because it reduces its efficiency, so they innovate a new method that can withstand high

temperatures which is concentrated solar power (CSP)

Figure 1: Example of CSP plant

CSP uses concentrated sunlight to generate energy. The CSP plant consists of 5 main parts

which are, boiler, condenser, turbine, reflecting mirrors and an electric generator. The

reflecting mirrors concentrate direct sunlight to the boiler where the liquid is heated and turned

into steam due to high temperatures, the steam then goes to the turbine where it rotates it and

9
the turbine rotates the electric generator shaft thus producing energy. Once the energy is

produced, the steam that leaves the turbine goes to the condenser where it is turned back into

liquid and the process starts again. This power plant is considered one of the cleanest and

renewable power sources.

1.2. Project Objectives

CSP technology has been into many development and upgrades throughout the time. The

following are the objectives of the project:

• To create an initial prototype of the CSP system with a roughly design which can be

used for initial tests.

• To make the energy generated from the system renewable.

• To ensure that the system can withstand high temperatures.

1.3. Project Specification

• Prototype of CSP system will take place in 1.5m length and 1.5m width.

• CSP system contain of reflectors, boiling tower, turbine, cooling system and electrical
generator.

• CSP system reflects the sun light by the reflectors to a boiler on a tower and use the
heat reflected to generate electricity by turbine and electrical generator.

• Hot weather means higher temperature which make CSP system produce higher amount

of energy

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 1.4. Application

Concentrated solar power system has one main usage, which is converting the heat

gained from sunlight to electricity. Its best application is the large desert areas where the

temperatures is very high. The larger the area, the and faster electricity will be produced

due to the large number of mirrors.

11
Chapter 2: Literature Review

2.1 Project Background

2.2 Previous Work

2.3 Comparative Study

12
 2.1. Project Background

A power station, additionally alluded to as a power plant, is an industrial facility to

generate electric power. Most power stations contain one or more generators and a rotating

machine that converts mechanical energy into electrical energy. The relative motion between

a magnetic field and a conductor creates an electrical flow that creates current. The power

source hardness to turn the generator differs widely. Most power stations on the planet use

fossil fuels to burn them such as coal, oil, and natural gas to generate power. Others use nuclear

energy, yet there is an expanding utilization of cleaner renewable sources such

as solar, wind and hydroelectric.

The innovation behind hydroelectric energy is genuinely simple, however restraining

the intensity of water is a challenge. Hydro control plants are costly to fabricate, however it is

not complicated to operate. The hydroelectric energy is considered one of the most useful,

renewable and largest energy sources in the world with a 17.5% of the world’s electricity. [1]

Dams produce reservoirs that allow for a larger heights of fall and conjointly serve to manage

energy withdrawal. Water is held and used once the demand for electricity is the greatest. The

water is directed from the reservoir which is on a higher level to a lower level through tunnels,

going through a turbine on the way. The turbine used depends on the size of the hydroelectric

power plant, distance of fall and other alternatives. Francis and Kaplan turbines are the most

common types being used in the hydroelectric power plants with average heights of fall. Hydro

power plants with longer distances of fall, mostly use a Pelton turbine. A generator then

converts the mechanical energy which is generated by rotating the turbine shaft into electrical

energy, a transformer will increase the voltage and also increase the electricity that is

transmitted to the grid. [2]

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 Figure 2: Hydroelectric Power plant

The hydroelectric power plant has advantages and disadvantages. Some of these

advantages are that the hydroelectric power plant is renewable, cause no pollution, reliable,

flexible and safe. On the other hand, the disadvantages of the hydroelectric power plant are that

it can cause environmental issues, expensive, it wouldn’t work when there is drought and it has

limited reservoirs. [3]

Wind power could be a clean energy supply that may be relied on for the upcoming

future. A turbine creates reliable, efficient, pollution free energy. it's cheap, clean and property.

One turbine is sufficient to get energy for a house. as a result of wind could be a supply of

energy that is renewable, wind turbines produce power while not exploitation fossil fuels, while

not manufacturing greenhouse gases or radioactive or waste material. [4]

Figure 3: Wind Turbine

14
 Although alternative energy plants have comparatively very little impact on the setting

compared to fuel power plants, there's some concern over the noise created by the rotor blades,

aesthetic impacts, and birds and buggy having been killed by flying into the rotors. Most of

those issues are resolved or greatly reduced through technological development or by properly

siting wind plants. [5]

Figure 4: Wind Turbine Arial View

This aerial demonstration of a turbine plant shows how a bunch of wind turbines will

build electricity for the utility grid. The electricity is distributed through transmission and

distribution lines to homes, businesses, schools, and so on. read the turbine animation to

determine however a turbine works or take a glance within. [6]

Coal is one of the most important sources used to generate electricity in the world.

Nowadays coal it is used to generate around 40% of electricity in the world. Coal fired power

plants are a kind of power plant that create use of the combustion of coal so as to produce

electricity. Countries like South Africa use coal for 94% of their electricity and China

and India use coal for 70-75% of their electricity desires. the utilization of coal provides access

to electricity to people who antecedently did not have it, that helps to extend quality of life

and scale back financial condition in those regions, but it produces giant quantities of

various pollutants that reduces air quality and contributes to global climate change.

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 Coal laid-off power plants follow the temperature unit cycle so as to

finish this method. Since they need many water to be circulated during this cycle, coal power

plants must be set close to a body of water. The method of coal laid-off plants is seen below in

the Figure

Figure 5: Coal Laid-off Plants

The disadvantages of the coal laid off plants are that it causes Environmental Impacts,

Air pollution and Water Use/Pollution. [7]

Oil and gas are the world’s primary sources of energy for many years. they need enabled

advances all told sectors of the economy, from residential lighting and heating to transportation

and industrial producing. the utilization of those fuels is additionally the most supply of

greenhouse gases. In last decades the uses of the gas to provide electricity for private and

business are increased to twenty-three percent worldwide. [8][9]

Natural gas power plants generate electricity by burning natural gases. There are many

varieties of fossil fuel power plants that all generate electricity however serve totally different

functions. All-natural gas plants use a gas turbine, together with a stream of air, that combusts

and expands through this rotary engine inflicting a generator to spin a magnet, creating

electricity. there's waste heat that comes from this method, thanks to the second law of physics.

Some fossil fuel plants use this waste heat in addition. [10][11]

16
 Natural gas power plants are low-cost and fast to make. They even have high

thermodynamically efficiencies compared to different power plants. matter than coal and oil

on the opposite hand, fossil fuel plants have considerably higher emissions than a nuclear

energy plant. this suggests that air quality tends to boost. once change to fossil fuel plants from

coal plants—but nuclear energy will even a lot of to boost air quality. [10][11]

As with all other sources of power it has advantages and disadvantages, the advantages

are that does not pollute the bottom od the ocean and it is widely available. On the other hand,

the disadvantages are that it is not renewable and it is toxic and flammable. [12]

Solar photovoltaic (PV) is a system that absorbs the heat from the sunlight and convert

it to electricity. The larger the area the more electricity will be produced. What benefits from

that is reducing the need for fossil fuel generation, in other words, the reliance on the renewable

energy. In the past, it was not clear how PV systems combine with greenhouse gases

(production wise). With the development of science, combining these two saved within 0.7 to

2 years of use of grid-connected operation, depending on the amount of sunlight. [13][14]

The Concentrated Solar Power (CSP) is a technology that uses mirrors to focus the

sunlight energy and converts it into heat that creates steam to rotate a turbine that is connected

to an electrical generator via a shaft therefore it starts to generate electricity. [15]

CSP technology consists of a combination of two parts, one that collects solar energy

and coverts it to heat and another one is to convert the heat energy absorbed into electrical

energy. This renewable source of energy is used in countries that are exposed to a large amount

of sunlight. The United States it self produces from 11-21 GW of electricity using the CSP,

they use it to reduce the use of fossil fuels plant since the CSP is cleaner, renewable and reduces

carbon emissions. [15] [17]

Unlike PV systems that are shown in television commercials or seen on the rooftops of

houses, the CSP technology needs a large area of land and uninterrupted amount of sunlight.

17
Therefore, the mostly common users of the CSP systems are industries or governments with

access to large areas of desert land. [16]

Figure 6: Ivanpah CSP Plant

The CSP systems has three main types of systems which are, trough systems, power

tower systems and dish/engine systems. [15]

Trough systems are large parabolic (U-Shaped) reflectors that have oil filled pipes

called receivers that are located at the center of the reflector. As shown in figure (7). The

reflectors are located toward the sun and the focused sunlight hits the receivers therefore

heating the oil inside up to 400 degrees Celsius. The heated oil then is used to heat up the water

which generate steam that drives the turbine that is connected to the electrical generator

therefore generating electricity. [15]

Figure 7: Trough System

Power Tower Systems (PTS), also known is central receivers uses a large amount of

flat heliostats (mirrors) reflectors to focus the sunlight onto the receiver. As shown in figure

18
(8). The receiver is located on top of a tall tower in order to heat up the fluid inside, where

temperatures can reach up to 565 degrees Celsius. The hot fluid inside the receiver can be used

immediately to generate electricity by driving the turbine to drive the electric generator or it

can be stores for later use. [15]

Figure 8: Power Tower System

Dish systems use mirror dishes that are large in size to concentrate the sunlight onto a

receiver. As shown in figure (9). The receiver is located at the focus point of the dish. To get

the maximum benefit from the sun, the dish has a controller that controls it motion depending

on where the most amount of sunlight is. The engine which is the receiver contains gas which

runs through the tubes that run along the engine’s piston cylinders. As the sunlight hits the

receiver, the gas inside the tubes heats up and expands in which it moves the pistons which are

connected to the electric generator though a crankshaft, therefore generating electricity. [15]

Figure 9: Dish System

The CSP systems has pros and cons, some of the pros are that it is easy to focus the

sunlight in a specific point and generate heat, large areas of desert or land are all over the world,

19
mirrors are cheap and it decreases the mechanical failure since it doesn’t need a mechanism to

run it through the day. On the other hand, there are some cons about the CSP which are it is

costly to start a CSP plant, the plant requires a large areas of land, CSP plants runs on water

and they are mostly located in the deserts where water supply is limited and it needs

uninterrupted amount of sunlight. [16]

2.2. Previous Work

The concentrated solar power was first mentioned in Greece 214-212 BC by

Archimedes, but it was for a very different purpose. He used it as a defensive tactic, from a

bronze shield to concentrate the sunlight onto invaders ships. Even though it was a myth, the

Greek Scientist Dr. Loannis Sakkas proved the myth by lining up 60 Greek sailors, holding

oblong bronzed coated mirrors tipped to reflect the sunlight and directing them at a ship

approximately 200 feet away, which within minutes caught fire. [18]

he first documented use of concentrated solar power technology was in 1866 where

Auguste Mouchout used parabolic troughs to heat water and produce steam to run the first solar

steam engine. Later on, solar power plant was first established in 1913 at Al Meadi which lies

south of Cairo on the Nile River and figure () shows the plant. This plant was used to operate

a 100 HP solar engine; it was initially intended for producing electric power but instead it was

used for pumping water from the river. [18]

The first operation was in Italy 1968, by professor Giovanni Francia when he built the

concentrated solar power plant with its central receiver surrounded by a field of solar collectors.

In 1982 the U.S. Department of energy, along with several industries began operating Solar

One, a 10MW central receiver demonstration project, which lead to the establishment of the

feasibility of power tower systems. Few years later, the world’s largest solar thermal facility,

located in Kramer Junction, California, was commissioned. The solar field contained rows of

20
mirrors that reflected the sunlight onto a system of pipes that surrounds the heat transfer fluid.

This fluid is used to produce high pressure vapor, which powered a conventional turbine to

produce electricity. In 1996 the U.S. Department of energy, alongside a group of industries

began operating Solar Two (an upgrade of its Solar One tower). Until 1999, Solar Two

demonstrated how solar energy can be stored efficiency and economically so that power can

be produced even when there is no sunlight. Which later on, the interest of power towers has

been increased. [18]

Figure 10: 1968, by professor Giovanni Francia the concentrated solar power plant.

2.3. Comparative Study

SunBorne Energy company has collaborated with three universities which are

university of south Florida, iMdea and ETH led by Dr. Nitin Goel in order to build a solar

power tower. In 2012, the team’s objective was to make a 1 MW watt central receiver prototype

plant. With encouragement and support of the Indian Government, the team has planned and

designed to build the central power plant. After doing various researches, they got to choose

which materials are suitable for their project. The plant consists of four main parts which are

21
suitable for their project. The plant consists of four main parts which are receiver, heliostat,

thermal storage and solar field control. [19]

Figure 11: Schematic of the 1 MW the solar power tower system

Receiver:

The team made an open volumetric receiver utilizing ambient air as the heat transfer

fluid is presently under development. The concentrated solar radiation from the heliostats was

made incident on a volumetric receiver where it is absorbed inside the porous structure volume

of the receiver. The team has worked to transfer the thermal energy to the heat transfer fluid

flowing through the porous structure. Also, the team have incorporated a novel design feature

for reducing the energy spillage across the absorber. [19]

Heliostat:

The team has adapted PV dualaxis tracking technology to develop a non-pedestal

heliostat system having a size of 150m2. The team’s current cost projections show that the

1MWth solar field can be manufactured at less than 150 USD/m2 as compared to SANDIA’s

reference of 200 USD/m2 for a 50MWe plant. [19]

22
Solar Field Controls:

The team has proposed a control architecture where the heliostat aiming strategy is

driven by a central control system. In such control methodology, the local heliostat control is

required to achieve the desired azimuth and elevation positions as directed by the central

control system.

Thermal Storage:

The team has been evaluating few indigenous rocks as thermal storage media readily

available in India. The cost of such material is about 3-4 INR/kg. The team made a thermal

storage system packed with rocks as the sensible storage medium. They evaluated various rocks

locally available in India. The selected thermal storage media properties are compared with

different thermal storage materials in Table 1. It shows that the new material has much higher

energy density in comparison to molten salt. In addition, the packed bed configuration will

eliminate the cost associated with molten salt. systems due toits corrosive and molten state

requirements. [19]

Figure 12:Comparison of thermal energy density in different media

23
Team project objectives:

• The system must have Higher temperature (higher efficiency)

• The system must be suitable for air cooled systems (conserve water)

• The system must be flexibility in the use of heat transfer fluid (Oil, Water, Air,

Molten Salt)

• The system must be flexibility in the solar field expansion

• The system must be suitable for high temperature process heat application

• Flat mirrors are required (lower cost)

• Dual axis solar tracking is required (higher efficiency)

• The system must have Lower receiver losses (higher efficiency)

24
 Chapter 3: System Design

3.1 Design Constraints and Methodology

3.2 Engineering design standard

3.3 Theoretical Calculations

3.4 Product Subsystems and selection of Components

25
3.1. Design Constraints and Methodology
The concentrated solar system that can be used in desert area. In order to achieve successful

result of the concentrated solar system, you will need a good quality design. Using a CAD such

as SOLIDWORKS will definitely assist in achieving the target. Therefore, there are multiple

constraints need to be overcome during designing:

• Unclear weather.

• Air flow reduces the heat transferred to the boiler.

• Reflecting material.

• Concavity of the reflector.

• Impurities on the reflector’s surface.

• Boiler’s material.

• Leakage between boiler and turbine.

In order to get the most efficient results out of this system, these major constraints should be

avoided. First of all, the weather must be clear enough to proceed in this system. in addition,

the air flow work as a cooler on the boiler, so this system will not provide enough efficiency in

some areas where the speed of air is high. For example, on mountains and high hills. After that,

the material chosen to be used should be well-reflective to sunlight, well-concaved as well,

which will produce more accurate focus point. Moving forward, the reflector have to be

polished very well to get the efficiency needed. Based on the research done, the most absorbed

material found was stainless steel. The pipe used to connect the main system parts must be

designed for complete connection, so that leaks will be avoided by fitting the inlets with outlets.

26
3.2. Engineering design standard

Table 1: ASTM Standards

27
Material Thermal Conductivity (W/K m)

Copper 399

Gold 317

Aluminum 237

Iron 80.2

Carbon Steel 43

Stainless Steel 15.1

Glass 0.81

Table 2: Thermal Conductivity

Material Thermal Diffusivity (m2/s)

Silver 149 × 10−6

Gold 127 × 10−6

Copper 113 × 10−6

Aluminum 97.5 × 10−6

Iron 22.8 × 10−6

Mercury 4.7 × 10−6

Stainless Steel 4.2 × 10−6

Table 3: Thermal Diffusivity

28
3.3. Theoretical Calculation
➢ Radiation Heat Transfer:

❖ Qemit = 𝜀𝜎𝐴𝑠 𝑇𝑠 4 Radiation emitted by real Surface (Equation 3.1)

q = heat transfer per unit time (W)

σ = 5.6703 *108 (W/m2K4) - The Stefan-Boltzmann Constant

T = absolute temperature in kelvins (K)

A = area of the emitting body (m2)

➢ Thermal Efficiency:

𝑤𝑡 − 𝑤𝑝
𝜂=
𝑞𝑖𝑛

Wt = work of turbine

Wp = work of pump

Qin = heat entering the system

➢ Turbine Efficiency:

(𝑤𝑡 ) ℎ1 − ℎ2
𝜂𝑡 = =
(𝑤𝑡 )𝑠 ℎ1 − ℎ2𝑠
Wt = work turbine

(Wt)s = work turbine shifted

➢ Pump Efficiency:

(𝑤𝑝 )𝑠 ℎ4𝑠 − ℎ3
𝜂𝑝 = =
(𝑤𝑝 ) ℎ4 − ℎ3
Wp = work pump

(Wp)s = work pump shifted

29
 ➢ Mass flow rate:

𝑚 = ρ𝑉𝐴

V = velocity

A = area

ρ = Density

➢ Angle of Parabolic: (Equation 3.4)

3.2
= tan−1 ( ) = 64°
1.56

F = focal length measured by hand

Dap = Diameter of plate of parabolic

➢ Bernoulli Equation:
𝑃1 𝑉 2 𝑃2 𝑉2
+ + 𝑍1 + ℎ𝐿𝑝 = + + 𝑍2 + ℎ𝐿𝑡 + ℎ𝐿
ρg 2 ρg 2
➢ Head Loss:
𝑓𝐿 𝑉2
ℎ𝐿 = [{ + {𝐾𝐿 ]
D 2g
➢ Focal Point:
X2 = 4 *a * y

X2 = is width squared (150)

A = focal point

Y = height (28cm)
150
Focal Point A = 112 = 1.339𝑐𝑚

30
3.4. Product Subsystems and selection of Components

System Design Drawing:

Figure 13: CAD Drawings

Solar Reflectors:

Solar reflector is one of the main parts in the system. Without the solar reflector, there is no

way one can re-orient the sunlight to transfer its solar energy. Unlike other parts, solar reflector

requires a bit more cautions when choosing the right material for it. The reason behind that is

the fact that every material has its own reflection ratio. For this system, satellite dishes were

used and wrapped it with a reflective film.

31
 Figure 14: Dish Figure 15: Wrapping the Dish

The satellite dishes were chosen because it has a concave shape that has a significant role in in

concentrating the sunlight. As a team, the biggest challenge was to choose the right material

and reflector film for this system. Another challenge was the machining work to remove the

impurities from the dish before wrapping it to get the maximum light needed for the process.

Figure 16: Trying the dish reflection

32
Boiler:

This part considered one of the main parts in this system. As it gains the heat reflected from

the sunlight through the reflector. It is important to choose the proper material to get the

maximum efficiency of the system, which is in this case the material chosen is stainless steel.

When the heat is transferred to the boiler, the water gets boiled and produces steam. After it

turns into steam, it gets out through the pressure valve to the steam turbine. Which is the goal

of this part.

Figure 17: Boiler

Turbine:

A Steam Turbine is a mechanical device that produce thermal energy from pressurized steam

and convert it into work. Since the turbine produces rotary motion, it is especially fit to driving

electrical generators – about 90% of all electricity generation in the United States (1996) is by

use of steam turbines. As the name infers, a steam turbine is fueled by steam. As hot, vaporous

steam flows past the turbine' spinning blades, steam extends and cools, emitting most of the

energy it contains. This steam turns the blades constantly. The blades in this manner convert

33
most of the steam's potential energy into kinetic energy. The turbine is then used to run a

generator, producing electricity.

Figure 18: Steam Turbine

Condenser:

The condenser is a device used in many systems especially in the refrigeration systems.

Condensers play a large role in many closed systems due to their importance. The main use a

condenser is to convert the gas coming into the condenser into liquid form. This process

happens when the gas enters the condenser which is a cold reservoir at a high temperature and

the meets the cold surroundings of the condenser, at this point the gas releases energy which is

heat and condensation happens where the gas is turned into liquid.

Figure 19: Condenser

34
Pump:

A pump it’s a device that moves fluid (liquid, gasses), by mechanical action. Pumps divided

into three different methods to move fluid: direct lift, displacement, and gravity pumps. Every

type of a pump consume energy to preform mechanical work to move fluid into any system.

Mechanical pumps serve in wide range of application like: car industry, home use, energy

industry, cooling towers. Pumps uses impeller or double impeller to move the fluid in the

system in high pressure. in this system the pump has important role which is circulating water

in the system from the conducer to the boiler to complete the cycle.

Figure 23: Water pump impeller Figure 24: Water pump

35
 Chapter 4: System Testing and Analysis

4.1 Experimental Setup, Sensors and data acquisition

system

4.2 Results, Analysis and Discussion

36
4.1 Experimental Setup, Sensors and data acquisition system

4.1.1: Infrared gun

At this part, we need to use a type of thermometer to measure the temperature of the boiler.

Since that the boiler surface will be hot, we had to use such a tool to measure the temperature

from a distance. We used an Infrared gun to measure the surface temperature of the boiler.

Specifications:

• Infrared IR thermometer with red laser pointer

• Temperature Range: -25 to 716 °F (-32 to 380 °C)

• Large LCD display: 4 digits & multiple functions, white backlight

• Quick response time: 0.5 seconds

• Data Hold and auto shut-off Battery: 9V

• Brand: Nicety(R)

• Model: FBA_ST380+

• Item Weight: 0.198 kg

• Product Dimensions: 15 x 10 x 2.5 cm

• Item model number: ST380A

• Manufacturer Part Number: FBA_ST380+

• Voltage: 9 volts

37
 Figure 20: Infrared Gun

4.1.2: Pressure Gauge

A pressure gauge is used to measure the pressure of the steam inside the boiler when the valve

is closed, also to measure the steam pressure when we open the valve. The gage will give an

indication of the best pressure value that is needed to rotate the turbine.

Specifications:

• Basic Gauge Case Material Plastic

• Basic Gauge Wetted Parts Brass / Bronze

• Gauge Connection Size1/4"

• Gauge Connection Location Center Back

• Gauge Primary Range Units psi

• Gauge Primary Range Values 0 to 160

• Gauge Secondary Range Units kPa

• Gauge Secondary Range Values 0 to 1100

38
 • Gauge Accuracy+/-3-2-3%

Figure 21: Pressure Gauge

Testing Parameters Objective

Infrared Gun To measure the temperature of the boiler

Pressure Gauge To measure the pressure of the steam

Table 4: Parts
4.2 Results, Analysis and Discussion

Ambient temperature ( C ) Pressure kpa Boiler temperature (C)

27 53 119
29 76 148
30 98 181
Table 5: Data of the results

In this section, there are relation between the temperature and the pressure in c,
kpa. as noticed the increasing of temperature the pressure increase.

39
Chapter 5: Project Management

5.1 Project Plan

5.2 Contribution of team members

5.3 Project Execution Monitoring

5.4 Challenges and Decision Making

5.5 Project Bill of Materials and Budget

40
In this project, there are many tasks included. Each task is assigned to one or more members.

Here is the all information about the tasks, team members, and the duration of each task to be

completed. See table 5.1 for project plan and table 5.2 for the assigned members and their

contribution.

5.1 Project Plan

Days to Members
Start Date complete
Task 1 Plan
Identifying Project 1/6/2019 3 Mohammed Y
Determine objectives 1/9/2019 5 Nasser
Subdividing small tasks to
1/17/2019 7
collect information All
Search and write small report
1/23/2019 6
about useful instruments All
Task 2 Report
Workout a software shows
1/24/2019 1
collected data Abdulrhman
Analyze data collected 1/24/2019 1 All
Writing chapter 1 Mohammed M,
1/25/2019 3
Introduction Nasser
Mohammed Y,
Writing chapter 2 Literature 1/31/2019 6 Abdulrhman,
Review Abdullah
Mention same projects 2/4/2019 2 Mohammed Y
Prepare for midterm 2/8/2019 20 All
Task 3 SOLIDWORKS
Mohammed M,
2/12/2019 2
Parts Abdullah
Mohammed M,
2/14/2019 2
Assembly Abdullah
Task 4 System Design
Design the prototype 2/7/2019 5 All
calculations 2/7/2019 10 Mohammed Y
Type of material 2/7/2019 3 Nasser
Taking calculation of turbine 2/7/2019 10 Nasser
Length of the tower and the
5
degree of the reflector 2/7/2019 Abdullah
Prototype assembly 2/18/2019 15 All
Task 5 Testing
Testing the prototype 3/5/2019 5 All
Testing the efficiency of the
2
turbine 3/5/2019 Nasser
Testing required sunlight and
2
temperature 3/5/2019 Abdulrhman
Task 6 Finalizing Project
Mohammed M,
10
Conclude the report 3/10/2019 Abdullah

41
 Presentation 3/17/2019 7 All
Prepare for Final 3/25/2019 20 All
Table 6: Project Plan

5.2 Contribution of Team Members

# Tasks Assigned Cont. %
1 Chapter 1: Introduction All 100%

Abdulla 33%
Project Background Abdulrhman 33%
Mohammed 34%
M
Chapter 2: Literature Mohammed 34%
2 Y
Review Previous Work
Nasser 33%
Mohammed 33%
M
Mohammed 33%
Y
Comparative Study
Nasser 34%
Abdulrhman 33%
Mohammed 30%
Y
Design Constraints and
Abdulla 30%
Design Methodology
Nasser 30%
Abdulrhman 10%
Engineering Design Mohammed 50%
M
standards
Abdulrhman 50%
3 Chapter 3: System Design Nasser 50%
Theory and Theoretical
Abdulla 30%
Calculations
Mohammed 20%
M
Mohammed 30%
Product Subsystems and M
selection of Components Mohammed 40%
Y
Abdulrhman 30%
Manufacturing and Abdulla 50%
assembly Mohammed 50%
M

42
 Chapter 4: System Testing Experimental Setup,
4
Sensors and data All 100%
&Analysis
Results, Analysis and
Discussion
Project Plan

Contribution of Team
members
Chapter 5: Project
Project Execution All
5 Management 100%
Monitoring
Challenges & Decision
Making

Project Bill of Material &

Budget

Life Long Learning

Impact of Engineering
6 Chapter 6: Project Analysis Solution All 100%
Contemporary Issues
Addressed
Conclusion
Chapter 7: Conclusion &
7
Recommendation
Future Recommendation 100%
All

Boiler and tubes Abdulrhman 100%

Mohammad Y
8 Mohammad
M
Design of Prototype Reflectors and bases Abdulrhman
Mohammad Y
Mohammad
M
Tower and base Mohammad 100%
M

Pressure gauge and Mohammad 100%

extension valve M
Pressure gauge Abdullah
Nasser

43
 Steam turbine 100%
Parts Purchase All
9
Boiler and tower
100%
10 Dish reflctore All
Manufacturing
Bases and the conctione
between the parts

11 Testing All the parts All 100%

Table 7: Tasks Assigned to team members

44
5.3 Project Execution Monitoring

Time/Date Activities/Events

Once a week Assessment class

Weekly Meeting with group members

Biweekly Meeting with the advisor

19 March, 2019 Finishing first prototype

21, March 2019 Midterm presentation

9, April 2019 First test of the system

13, April 2019 Finishing final prototype

14, April 2019 Test the system

2, May 2019 Final Submission of the report

2, May, 2019 Final presentation

Table 8: Dates and Activates of Events

45
5.4 Challenges and Decision Making

During the project phases, we faced some challenges that effect the progress of the project.

Following challenges are the main challenges we have faced:

• Selection of materials

• Weather constraints

• Pipes

First, we selected stainless steel to be the boiler’s material and found that the thermal

conductivity was poor comparing to copper and aluminum. The boiler has been changed to

aluminum since copper is too expensive to manufacture.

The major constraint was the weather, because we cannot control it. Unfortunately, the last

couple of weeks the weather was cloudy and rainy, so we struggled with the testing.

The connection between the boiler and turbine was challenging a bit. Since the inlet of the

turbine was too small to fit the pipe, which caused losses of steam.

46
5.5 Project Bill of Materials and Budget

Materials Cost (SR)

Two Reflectors 180

Tower 150

Boiler 280

Bases of Reflectors 80

Steam Turbine 510

Foils 100

Pipes 50

Pressure Gauge 60
Valves 50

Total 1460

Table 9: Bill of Materials

47
Chapter 6: Project Analysis

6.1 Life-long Learning

6.2 Impact of Engineering Solutions

6.3 Contemporary Issues Addressed

48
6.1 Life-long Learning
Working on this project have improved us and broaden our knowledge in various aspects. As

a group, we have started with an idea that can be improved and be applied in real world

applications, through brainstorming, develop and discussing the alternatives. Through our

meetings, we have divided the tasks among us in equal manner and succeed within the pre-

scheduled time. During assembling the project, we used some new hardware devices and

software tools, that helped us to complete the project build up.

• Hardware devices

For the hardware devices, we used an infrared gun to measure the temperature of the

boiler when it is reflected from the dishes. In addition to that, pressure gauge was used

to measure the steam pressure needed to rotate the turbine and generates electricity.

• Software tools

For this part, the main program that we used is SOLIDWORKS to design our system.

Part drawing and proper dimensions, manufacturing, and finding the factor of safety.

In addition, Microsoft word and excel are used to make the project report and to manage

the tasks in Gannt chart form.

• Time management skills

Having several meetings have developed our time management skills. Moreover,

following the deadlines given by the department lead us to manage our time. Dividing

the tasks and subtasks on the group members to deliver the goal.

49
6.2 Impact of Engineering Solutions
In brief words, our project is inspired by the Kingdom’s vision 2030 where there

establishing new renewable energy systems. Part of these projects will be solar

concentrated power plants.

6.2.1: society

The impact of this project on society is creating job opportunities, enhancing the

behavior of life in the Kingdom to a better future. Achieving the 2030 vision of reduce

the needs of finite sources with renewable energy sources. Moreover, building this

project in remote areas will freshen these particular areas.

6.2.2: Economy

The main purpose of this project is to improve our country’s economy, by reducing the

use of the other gas power plants. Increase job opportunity, take advantage of un used

land.

6.2.3: Environment

This project will decrease the use of fossil fuels which have bad effects on the

environment. The renewable energy is to use the steam generated by solar, which is

considered clean and continues source.

50
6.3 Contemporary Issues Addressed
As discussed earlier, the goal of the Kingdom’s vision 2030 is to minimize the use of

fossil fuels as much as possible. In last decades, the high depends on fossil fuels caused

environmental issues, such as air pollution that are produced from emissions of

refineries which may come as an acidic rain. The workers in these refineries are more

susceptible to diseases such as cancer and skin diseases. The fossil fuel is a “finite”

source which means that it may drain one day. That is an eternal issue presented since

the discovery of these sources.

51
Chapter 7: Conclusions and Future Recommendations

7.1 Conclusion

7.2 Recommendations

52
7.1. Conclusion

All in all, as a team we started designing and manufacturing a Concentrated Solar Power Plant

System. It is a system which can convert the solar energy to electrical energy by using the

concepts of mechanical engineering. It starts by locating the focal point of the moving dish that

is covered by aluminum foil to reflect the sunrays into the boiler. Then the boiler starts to heat

the liquid stored inside it which is water in our case, and begin to generate the steam. The steam

is pressurized to a certain value that gives us the pressure needed to rotate the turbine. Finally,

the turbine starts to generate electricity.

Throughout building this system, we got to develop our own skills such as time management,

divide the tasks equally and accomplish them in a timely manner. A better understanding for

choosing the proper material for different cases, for instance based on their conductivity and

diffusivity. In welding process, there was a misunderstanding of welding two dissimilar

materials, after taking it into consideration a few changes were taken to fit the system

7.2. Future Recommendation

• Installing a sun tracking system
• Installing a condenser
• Installing a pump
• Changing reflecting material
• Using bigger Dish
• Using a bigger Turbine
• Using a bigger eclectic generator

53
References:

1. “Hydroelectric Power.” Electrical Power Generation from Hydrogen Fuels,

www.mpoweruk.com/hydro_power.htm.
2. (2017, August 11) “Hydro Power Plant – How It Works.” Vattenfall,
corporate.vattenfall.com/about-energy/renewable-energy-sources/hydro-power/how-
it-works/\.
3. Malvik, et al. (2012, October 16) “Hydroelectric Energy Pros and Cons.” Energy
Informative, energyinformative.org/hydroelectric-energy-pros-and-cons/.
4. (E. M., Trans.). (2016, October 22). How a Wind Turbine works: Wind Power:
Renewable Energy Retrieved from
https://www.energymatters.com.au/components/wind-energy/
5. W. E. (Ed.). (2012, April 23). Wind Energy Basics. Retrieved from
http://windeis.anl.gov/guide/basics/
6. W. (2019, February 05). Wind. Retrieved January 31, 2019, from
https://www.cleanenergycouncil.org.au/resources/technologies/wind

7. J.M.K.C. Donev et al. (2017). Energy Education - Coal fired power plant [Online].
Available: (https://energyeducation.ca/encyclopedia/Coal_fired_power_plant.)
[Accessed: January 31, 2019].

8. Oil and gas. (n.d.). Retrieved February 10, 2019, from

https://www.energyinst.org/exploring-energy/topic/oil-and-gas
9. (n.d.). Retrieved February 10, 2019, from
https://www.eia.gov/energyexplained/index.php?page=oil_home
10. J.M.K.C. Donev et al. (2018). Energy Education - Natural gas power plant [Online].
Available:(https://energyeducation.ca/encyclopedia/Natural_gas_power_plant.
[Accessed: February 4, 2019].
11. S. O. (Ed.). (2014, June 12). Oil. Retrieved from
https://www.studentenergy.org/topics/oil
12. (W. B., Trans.). (2014, July 2). Electricity production from natural gas sources.
Retrieved from https://data.worldbank.org/indicator/EG.ELC.NGAS.ZS
13. K., A. (2018, November 12). Advantages and Disadvantages of Natural Gas.
Retrieved from https://www.brighthubengineering.com/power-plants/114797-pros-
and-cons-of-natural-gas-use

54
14. W. J. (Ed.). (2018, February 13). Solar for the grid. Retrieved from
https://www.ashden.org/sustainable-energy/ashden-guides/solar-for-the-
grid?gclid=EAIaIQobChMI0O_bvZeY4AIVx0PTCh1x-
15. S. (n.d.). Concentrating Solar Power (CSP) Technologies. Retrieved February 5, 2019,
from http://solareis.anl.gov/guide/solar/csp/
16. Clark, E., & Clark, E. (2017, October 04). A Beginners Guide To Concentrated Solar
Power (CSP). Retrieved February 5, 2019, from https://medium.com/cleantech-
rising/a-beginners-guide-to-concentrated-solar-power-csp-d5e6f9d12cdc
17. O. (n.d.). Concentrating Solar Power. Retrieved February 7, 2019, from
https://www.energy.gov/eere/solar/concentrating-solar-power
18. A. C. (n.d.). History of Concentrated Solar Power (CSP). Retrieved February 7, 2019,
from https://www.aalborgcsp.com/business-areas/solar-district-heating/csp-
parabolic-troughs/history-of-csp/
19. E. (2014). CRISPTower – A Solar Power Tower R&D Initiative in India. A Solar
Power Tower R&D Initiative in India, 1-10. Retrieved January 31, 2019, from
https://www.researchgate.net/publication/275534227_CRISPTower_-
_A_Solar_Power_Tower_RD_Initiative_in_India.

55
 Appendix

Appendix A: Monthly Progress Reports

Appendix B: Engineering Standards

Appendix C: CAD Drawing and Bill of Materials

Appendix D: Prototype Pictures

Appendix E: Operation Manual

56
Appendix A: Monthly Progress Reports

57
58
59
60
61
62
Appendix B: Engineering Standards

Table 10: ASTM Standards

63
Material Thermal Conductivity (W/K m)

Copper 399

Gold 317

Aluminum 237

Iron 80.2

Carbon Steel 43

Stainless Steel 15.1

Glass 0.81

Material Thermal Diffusivity (m2/s)

Silver 149 × 10−6

Gold 127 × 10−6

Copper 113 × 10−6

Aluminum 97.5 × 10−6

Iron 22.8 × 10−6

Mercury 4.7 × 10−6

Stainless Steel 4.2 × 10−6

64
Appendix C: CAD Drawing and Bill of Materials

65
 Materials Cost (SR)

Two Reflectors 180

Tower 150

Boiler 280

Bases of Reflectors 80

Steam Turbine 510

Foils 100

Pipes 50

Pressure Gauge 60
Valves 50

Total 1460

66
Appendix D: Prototype Pictures

67
Appendix E: Operation Manual

Starting the Experiment:

Step 1:
Locate the focal point by adjusting the reflecting dish.

Step 2:
Add water inside the boiler.

Step 3:
Place the boiler on top of the tower where the focal point hits.

Step 4:
Wait until the water inside the the boiler is boiled and the steam is generated.

Step 5:
Open the valve holding the steam from reaching the turbine.

Step 6:
The turbine is now turning causing the generator to turn and power is generated.

Safety Notes:

- Use safety gloves

- Use safety goggles
- Keep yourself about 2 meters away from the system
- Have a fire distinguisher

68