Method to construct and support tube module assemblies for solid particle solar receiver

Abstract

A solar receiver module includes a front tube sheet with light apertures, a back plate cooperating with the front tube sheet to define a sealed gap, and light channeling tubes optically coupled with the light apertures, extending through the gap and connecting with the back plate. A flowing heat transfer medium flows in the gap over exterior surfaces of the light channeling tubes. Slip joint engagements between light apertures and ends of most or all of the light channeling tubes accommodate thermal expansion. Each slip joint may be defined by an inner or outer perimeter of the light aperture receiving the end of the light channeling tube. A sub-set of the light channeling tubes may be welded to light apertures. A module support post may be secured at a center of the back plate and extend away oppositely from the front tube sheet. A welded or stamped tube sheet provides a seal between tubes at the front face of the tube modules. Thermal expansion provides a seal between adjoining modules at the front face and seal strips provide a seal at the back face.

We claim: 
     
         1 . A solar receiver module comprising:
 a front tube sheet including light apertures;   a back plate cooperating with the front tube sheet to define a sealed gap; and   light channeling tubes having first ends optically coupled with the light apertures and extending through the gap and having second ends connected with the back plate.   
     
     
         2 . The solar receiver module of  claim 1  further comprising a flowing or fluidized heat transfer medium disposed in the gap over exterior surfaces of the light channeling tubes. 
     
     
         3 . The solar receiver module of  claim 2  wherein the flowing or fluidized heat transfer medium comprises a flowing particulate medium such as silica sand or calcined flint clay. 
     
     
         4 . The solar receiver module of  claim 1  further comprising slip joint engagements between light apertures of the front tube sheet and first ends of most or all of the light channeling tubes. 
     
     
         5 . The solar receiver module of  claim 4  wherein each slip joint is defined by an inner or outer perimeter of the light aperture receiving the first end of the light channeling tube. 
     
     
         6 . The solar receiver module of  claim 4  wherein each slip joint is defined by the inner or outer perimeter of a necked down portion of the light aperture receiving the first end of the light channeling tube. 
     
     
         7 . The solar receiver module of  claim 4  comprising slip joint engagements between light apertures of the front tube sheet and first ends of all but a sub-set of the light channeling tubes, the solar receiver further comprising:
 welds between light apertures and the first ends of the sub-set of the light channeling tubes. 
 
     
     
         8 . The solar receiver module of  claim 7  wherein the sub-set of the light channeling tubes consists of one or more light channeling tubes. 
     
     
         9 . The solar receiver module of  claim 4  wherein there are slip joint engagements between light apertures of the front tube sheet and first ends of all of the light channeling tubes and the solar receiver module further comprises:
 tie rods welded between the back plate and the front tube sheet. 
 
     
     
         10 . The solar receiver module of  claim 4  wherein the light channeling tubes are cantilever-supported by the second ends connected with the back plate. 
     
     
         11 . The solar receiver module of  claim 4  wherein the second ends of the light channeling tubes are connected with the back plate by threaded studs extending from the second ends of the light channeling tubes. 
     
     
         12 . The solar receiver module of  claim 1  wherein the front tube sheet comprises said light apertures formed from bent sheet metal and having outer perimeters that are welded together. 
     
     
         13 . The solar receiver module of  claim 1  wherein the front tube sheet comprises single-piece sheet metal having said light apertures punched into the single-piece sheet metal. 
     
     
         14 . The solar receiver module of  claim 1  wherein the light apertures have triangular, circular, square or diamond, regular or flared hexagonal cross-sections. 
     
     
         15 . The solar receiver module of  claim 1  wherein the back plate comprises a metal plate. 
     
     
         16 . The solar receiver module of  claim 1  wherein the light channeling tubes comprise drawn tubes, extruded tubes, or bent sheet metal welded tubes. 
     
     
         17 . The solar receiver module of  claim 1  further comprising:
 a module support post extending away from the back plate on the opposite side of the back plate from the front tube sheet; 
 wherein the module support post is secured at a center of the back plate. 
 
     
     
         18 . A solar receiver comprising a plurality of solar receiver modules as set forth in  claim 1  arranged with adjoining front tube sheets and adjoining back plates to define the solar receiver with an outward facing surface defined by the adjoining front tube sheets and an inward facing surface defined by the adjoining back plates and further having an annular gap between the outward facing surface and the inward facing surface. 
     
     
         19 . The solar receiver of  claim 18  wherein the solar receiver does not include sealing material interposed between the adjoining front tube sheets. 
     
     
         20 . The solar receiver of  claim 18  wherein the front tube sheets have jagged edges defined by peripheral light apertures with flat sides, and the jagged edges with flat sides of adjoining front tube sheets mesh together. 
     
     
         21 . The solar receiver of  claim 18  further comprising:
 sealing strips disposed at interfaces between adjoining back plates. 
 
     
     
         22 . The solar receiver of  claim 21  wherein each sealing strip is attached to only one of any two adjoining solar receiver modules. 
     
     
         23 . A solar power generation system comprising:
 a solar receiver as set forth in  claim 18 ;   a flowing or fluidized heat transfer medium disposed in the annular gap over exterior surfaces of the light channeling tubes of the solar receiver modules; and   a fluidized-bed boiler or heat exchanger arranged to receive heated heat transfer medium from the solar receiver.   
     
     
         24 . A method of operating a solar receiver as set forth in  claim 18 , the method comprising:
 disposing a flowing or fluidized heat transfer medium in the annular gap of the solar receiver over exterior surfaces of the light channeling tubes of the solar receiver modules; and   operating heliostats to concentrate solar energy onto the solar receiver wherein the concentrated solar energy is effective to induce thermal expansion of the solar receiver modules.   
     
     
         25 . The method of  claim 24  wherein the solar receiver modules have slip joint engagements between light apertures of the front tube sheet and first ends of most or all of the light channeling tubes that accommodates thermal expansion of the solar receiver modules. 
     
     
         26 . The method of  claim 24  wherein each solar receiver module further comprises a module support post secured at a center of the back plate and extending inward from the inward facing surface defined by the adjoining back plates whereby thermal expansion of the solar receiver modules increases sealing force between adjoining front tube sheets. 
     
     
         27 . A method of performing maintenance on the solar receiver of  claim 18 , the method comprising:
 disconnecting a solar receiver module support post from the back plate or a support column; and   pulling the disconnected solar receiver module out of the solar receiver.   
     
     
         28 . A method of performing maintenance on the solar receiver module of  claim 1 , the method comprising:
 removing a connection between the light channeling tubes and the back plate of the solar receiver module;   removing the front tube sheet of the solar receiver module by operations including disengaging slip joint engagements between light apertures of the front tube sheet and first ends of light channeling tubes wherein after removal of the front tube sheet the light channeling tubes remain cantilever-supported by the connections of their second ends with the back plate; and   removing a selected light channeling tube by disconnecting the second end of the selected light channeling tube from the back plate.   
     
     
         29 . The method of  claim 28  wherein removing the front tube sheet of the solar receiver module further comprises:
 breaking welds between axial support light channeling tubes and the front tube sheet. 
 
     
     
         30 . The method of  claim 28  wherein removing the front tube sheet of the solar receiver module comprises:
 disconnecting tie rods connecting the back plate and the front tube sheet.