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Printed in Great Britain. Pergamon Press Ltd,
B. WINDOW
CSIRO National Measurement Laboratory, Lindfibld.2070, Australia
and
G. L. HARDING
School of Physics, Universityof Sydney, Sydney. 2006, Australia
(Received 2 July 1982; accepted 21 January 1983)
Abstract--Materials problems in evacuated collectors are reviewed with emphasis on all-glass tubular systems.
Collector design, including selective surface, vacuum insulation and layers for transmission enhancement of the
glass envelope are examined in detail. In addition, design and materials aspects of reflectors and collector
manifoldingsystems are discussed.
609
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(Sectibn 4), optical design and materials (Section 5), niques. Such coatings which have been used extensively
manifolding factors, and the influence of materials on in the U.S.A. are a chromium suboxide interference layer
system design (Section 6). on aluminium on the glass, and a SiOx-Cr-SiOx multi-
layer on aluminium or glass. These surfaces both have
2. SELECTIVE SURFACES solar absorptances of -0.8[46]. Nitto Kohki (Tokyo) are
2.1 Introduction using a sputtered metal-carbon graded interference layer
Selective surfaces improve collector performance by absorber on copper or glass, with a solar absorptance
reducing the radiative loss from the absorbing surface >0.9.
for a given absorber surface temperature. They have All the selective surfaces of absorptance ~>0.9 listed in
been used for many years on flat plate collectors[17- Table 1 incorporate a low refractive index material, (e.g.
23], and improved air stable selective surfaces have been CrOx, SiO2, A1203, amorphous carbon) at the top of the
developed in recent years for high performance flat plate absorbing layer to maximize light transmission into the
collectors and for concentrating trough systems[24--30]. surface. A major problem with most of the selective
However, the need in evacuated collector technology surfaces summarised in Table 1 is the lack of essential
is for high performance selective surfaces which are data such as the solar absorptance and thermal emittance
vacuum stable at the stagnation (no load) temperature for as functions of temperature, degradation modes and
extended periods and at the process temperatures used degradation rates in realistic situations, the heat treat-
to outgas the collector prior to permanently sealing the ment required to degas the surface, and general produc-
glass envelope. tion considerations. Some of this is possibly considered
proprietary and hence is not freely available.
2.2 Available selective surfaces The most extensively studied selective surface for
Few selective surfaces have been intensively studied evacuated all-glass collectors is the metal carbon
with the particular aim of their utilization in evacuated surface[43, 47-51], and its properties are reviewed in the
collectors. A summary of a number of selective absorb- next section.
ing surfaces which have been used in evacuated systems,
or have some potential for this application, is contained 2.3 Properties of metal-carbon surfaces
in Table 1. These surfaces are of the graded interference layer
Most selective surfaces used in all-glass collectors in type, applied using sputtering techniques. Advantages of
mass production have been deposited by vacuum tech- sputtering for the mass production of selective absorbers
Progress in the materials science of ~dl-glass evacuated collectors 61 l
Table I. Fabrication process, selective properties and maximum operating temperature for a selection of selective
surfaces.
Absorbing Layer Metal Base Layer Deposition Process ~ £(T°C) Maxm. operating Reference
temp. °C in vacuum
Black Cobalt
(CoO S ) Thin film Electrodepcsition -0.95 <0.1(20) [6,31,32]
xy silver, copper
f °+........ //1
R "5f
E
o!- lo / 1s +o zs -o4 ~ i
in absorptance (-0.02) was offset by an increase in netron sputtering system for producing the graded stain-
emittance and also by the increased fragility of the film. less steel-carbon surface and related surfaces[48,69].
A second possibility is to sputter the uppermost layer Twenty glass tubes supported on a carousel execute
of the selective surface in high argon pressures (>3Pa). planetary motion about two post cathodes during sput-
This approach results in films of lower density and tering.
consequently lower refractive index[61]. The refractive This coating system has produced metal-carbon selec-
index (n) of amorphous hydrogenated carbon was tive coatings (typically a -0.92 and e - 0.04) at rates of
reduced by -0.1 (from -1.9 to 1.8) over the solar 1 tube/rain actual coating time. The grading profile was
wavelength range by increasing sputtering pressure from controlled by variation of the reactive gas injection rate
0.2 to 40 Pa[62]. This small change does not justify during deposition. The cost of the selective surface mass
sputtering at such high pressures, which result in con- produced by a similar system has been independently
siderably lower deposition rates. estimated by Thornton[52] as $3/m 2. A larger version of
An alternative approach is to texture the copper base this system has been made by Nitto Kohki (Japan) under
layer with structure of dimensions ~<1 ~m[63]. This in- licence to Sydney University. It has a horizontal cham-
creases the absorptance of the copper, and consequently ber, and is producing -1000 tubes/day on a one-shift
the absorptance of the complete selective surface. This basis.
approach has been studied by Golomb[64], Continuous coating which involves translation of glass
Thornton[52,65], and by Harding and Craig using both tubes either sideways or lengthways through sputtering
planar and cylindrical magnetrons[50,66-68]. Textured sources of appropriate design is also pbssible. Tube
copper may be produced by sputtering in relatively high storage and feeding mechanisms are required at both
sputtering gas pressures (>3Pa). The absorptance of ends of the coating chamber.
as-deposited graded stainless steel-carbon selective sur- Prototype continuous coaters where the tubes are fed
faces may be enhanced by 0.01-0.02 by lightly texturing lengthways through in line hollow cathode magnetrons
the copper base layer by depositing 700 nm thick copper have been constructed at Sydney University[70] and
in argon pressure >3Pa. There is an associated small CENG, Grenoble, France[71]. A single glass tube was
increase in emittance[50]. However, after heat treatment fed through a copper magnetron to deposit the low
at 500°C (required during the final evacuation of the emittance copper base layer, followed by a stainless steel
collector), the texture anneals out to a considerable magnetron in which a graded film of stainless steel-
degree, and the selective surface exhibits absorptance carbon cermet was deposited. Grading of the metal car-
and emittance typical of that incorporating smooth bon film was achieved by introducing hydrocarbon gas at
copper. the end of the stainless steel magnetron at which the
coated tube exiied, producing a variation of hydrocarbon
2.4 PrOduction partial pressure along the length of the hollow cathode. It
Designs of chambers for batch production have been was possible to make surfaces comparable to the batch
carried through the pilot stage. Figure 5 shows a mag- production surfaces, buth high rates were not achieved.
3. TRANSMITTANCE COATINGS
Fig. 7. Outgassing rate R(nmHg/mg°C) vs temperature for sam- c~ = (E(reflected)- E(incident))/(E(wall)- E(incident))
ples of graded metal-carbon copper selective surface outgassing
into a volume of 151)cm'. The rate of pressure rise is effectively
measured for the gas at room temperature as the sample is where E is the energy of a reflected, an incident or a wall
heated at 15°C/min. . Sample of as-deposited selective sur- molecule.
face. - . . . . . sample of selective surface after bakeout at 500°C Another factor which must be included is the ad-
in a continuously pumped vacuum furnace.
sorption and desorption of gas molecules from the ab-
sorber surface as it is heated, resulting in a change in the
4.1.3 Outgassing from selective surfaces. The outgass- number of molecules contributing to conduction[82]. A
ing behaviour of the selective surface used in an evacu- range of behaviour from a temperature independent to a
ated collector is important for production, and sub- highly temperature dependent conductivity is expected
sequent operation. Information is only available for the as the molecule-wall interaction becomes stronger.
metal carbon selective surface[82,83] and its behaviour 4.2.2 Experimental studies of conduction losses.
is discussed below. Thermal conduction losses have beeff determined for a
Samples of the selective absorber heated in a silica concentric tubular collector containing air at pressures
tube gave off predominantly hydrogen and carbon 0.5-130 kPa, by measuring the power input required to
monoxide, with small amounts of CO> H20 and hydro- maintain a static temperature rise for a circulating fluid
carbons of the form C,,H_,, +2(n = 1 to 7 at least)[82]. The through the absorber tube[86]. Heat losses at these high
hydrogen and the hydrocarbons came from the acetylene pressures were large for operating temperatures more
decomposition and polymerisation in the discharge. The than 100°C above ambient, and measurements at lower
oxygen came from the decomposition of water during the pressures would be more relevant to typical non-con-
deposilion [60,831. Small amounts of argon, buried in the centrating systems. Ortabasi (1975) has studied heat los-
coating during sputter deposition were observed to evolve ses at the low pressures 10 s-10SPa, but only for air in a
at temperatures above 500°C [83, 84]. metal tube-and-fin evacuated collector[87].
The rate of gas evolution from samples of selective More recently, the accommodation coefficients in the
surface was studied as a function of sample temperature, free molecule conduction regime were measured for an
for samples heated at a constant rate[83]. These assortment Of gases in the concentric cylinder system by
experiments showed that although gas was evolved over calorimetry (balancing the heat losses with electrical
the temperature range 200-900°C, the bulk of the gas was heating[88]. These accommodation coefficients for Ar, H2,
evolved near 480°C. Figure 7 shows the outgassing rate He, CO, N2 and H20 for a glass surface in the temperature
for a sample of selective surface scraped from a freshly range of 20-150°C, and for a metal-carbon selective
coated tube, and the outgassing rate for a sample of surface in the range 100-300°C are shown in Figs. 8 and 9
selective surface which had been baked at 500°C for a respectively. The decreasing accommodation coefficients
few minutes. The 500°C bakeout removed 60 per cent of were attributed to smaller interaction times at higher
the volatile material, and the subsequent gas evolution temperatures.
rate was negligible for temperatures less than 430°C. The behaviour of collectors sealed with various gases
These results indicate that the collector should be sealed inside were also studied[82]. For most gases, it was
at a lower temperature than the bakeout temperature to found that the expected increase in conductivity due to
reduce vacuum deterioration during the cooling of the an increase in pressure on heating one surface was offset
surface [83]. by the decrease in accommodation coefficient on that
surface, and the overall thermal conductivity was close
4.2 Gaseous heat loss studies to being temperature independent over the temperature
4.2.1 Theory. The heat loss due to gas in the vacuum range 100-300°C. Such behaviour was observed in some
space becomes appreciable compared with the solar flux collectors which had been deliberately degraded (Fig.
at pressures (-0.1 Pa) where the mean free path of the 10).
gas molecules is much greater than the gap between the However, for water vapour, a temperature dependent
inner and outer tube walls. This type of heat conduction conductivity was reported, due to the releasing of the
is described as Knudsen or free molecule gas absorbed gas as the inner surface was heated. Such
conduction[85]. Heat conduction depends on the tem- behaviour was also observed in collectors which had
perature difference, but unlike the behaviour at high been sealed without getters and deliberately degraded
616 B. WINDOWand G. L. HARDING
1"0
t
1
oc
~ ~ Ar
0
~2
100I
0.4
o
0 100 203 300
L He
02 ~ ~ H 2 TENPERATURE (*C)
~
SELECTIVE SURFACE
borosilicate. Using this surface, the theoretical minimum
processing time (heat to 500°C, cool to ambient) would
1"0 HzO be about 5 rain. In practice, longer times would be
required. Soda glass, because of its lower tolerance to
thermal shock would require processing times at least
twice as long..
OCo~ -CO Methods of heating the collector vary in effectiveness.
i ~I--- N~ The low emittance and hence high reflectance of the
selective surface for IR radiation causes heating of the
06 inner tube by heating the outer glass tube to be very slow
(-30rain)[58]. It was shown to be better to heat the
inner glass tube directly with electrical elements[58].
~H2 Total process times of about 10 rain were reported for
0~ ~ H e systems which incorporated aluminium-barium getters
~o 500 " -660 fired in the collector for a final clean-up.
TEMPERATURE ( K )
Fig. 9. Accommodation coefficients u vs temperature T for 4.4 Gettering methods
various gases on a graded stainless steel-carbon selective surface Collectors manufactured around the world invariably
on glass. include getters, usually of the aluminium-barium type, so
that the overall process time can be reduced. The getter
(Fig. 10). It has been pointed out that this behaviour may is fired by RF heating after finally sealing off the
be desirable in a collector as it acts to limit stagnation envelope.
temperatures [82]. Little work has been done on other gas absorbing
systems. The barium getters maintain a level of gas far
4.3 Production considerations below that required for negligible conducted thermal
During evacuation the maximum amount of gas must losses, and other simpler methods may give satisfactory
be removed from the collector in the minimum time. The results. There are getters based on zirconium and
collector should be heated and cooled at the maximum titanium which are bulk getters operating at 300°C[90].
rates, and it should be held at the high temperature for Collectors could be regenerated by heating included
the minimum time. Estimates of the heating and cooling chips of alloy, or the material could be applied to the
rates for borosilicate glass heated and cooled from one absorber tube as part of the selective surface, where
side and 1.5 mm thick are 500 and 100°C/min[89]. The stagnation operation would promote the gettering action.
maximum temperatures are set by the tolerance of the Another large surface area within the collector which
selective surface and/or the softening of the glass. could play an important role is the inner surface of the
The metal carbon selective surface can tolerate collector envelope. This surface would strongly adsorb
exposure to temperatures -500°C for periods of 30 rain, most molecules, and if coated with a porous
Progress in the materials science of all-glass evacuated collectors 617
5. REFLECTORMATWALS
A major difference between the all-glass collector and
the flat plate collector is the tubular nature of the collec-
tor surface in the former. This leads to the use of
reflectors to utilise the entire collecting area of the tube,
and introduces a set of materials problems not usually
encountered in flat plate technology, but which have
been investigated in part in connection with concentrat-
ing systems.
The most efficient array in terms of capturing the
maximum solar radiation is one in which the tubes are
placed side by side, with a simple reflector behind.
3w- A 30
Collector Spacing (Diameters)
Spacing the tubes apart lowers the collector efficiency,
but the benefits are fewer tubes per unit area, simplified Fig. Il. Collector efficiencies 70 for normally incident sunlight as
a function of collector spacing (in absorber diameters) for specu-
manifolding of the tubes, and a reduction in the thermal lar and diffusely reflecting mirrors. The selective surface is
losses per unit collecting area. At higher temperatures or assumed to have an absorptance (at normal incidence) of 0.875,
low fluxes, the loss in optical collection efficiency can be and both the specular and diffuse mirrors are assumed to have
more than offset by the decreased thermal losses. reflectance 0.85.
t" '~
fY
_/
Fig. 14. Schematic diagram of a section of a fluid-in-glass mani-
folding system developed by the authors. A, collector tube: B, Fig. 15. Schematic diagram of a fluid-in-glass series manifolding
manifold box: D, division of 1" manifold pipe: 1, polyurethane system involving no fluid feed within the absorber tubes. A,
insulation segments; O, O ring seal onto absorber tube; P, metal Absorber tube: B, metal plugs with O ring seals onto the glass: C.
foil partition in absorber tube (this is absent in the "partitionless" copper tubes: D. fluid inlet to absorber tube; E, fluid exit from
design). absorber tube.
620 B. WINDOWand G. L. HARDING
H l(
i i !
Fig. 17. System design for a demonstration project at the Solar Energy Advisory Centre, Sydney. A, water mains;
B, filter; C, header tank; D, overflow and steam relief pipe; E, pump; F, electromagnetic valves (open in no power
situation); G, heat exchanger: H, collector panels (utilizing manifold described in Fig. 23); I, airbleeds; J, drain
valve: K, globe valves (for flow adjustment): L, isolation valves.
Progress in the materials science of all-glass evacuated collectors 621
important problems which remain. We conclude that 23. A. Andersson, O. Hunderi and C. G. Granqvist, Nickel
although most manufacturers currently use selective pigmented anodic aluminium oxide for selective absorption
of solar energy. J. Appl. Phys. 51,754 (1980).
surfaces of qualities below the best that can be achieved,
24. R. B. Pettit and R. R. Sowell, Thermal Aging characteristics
surfaces with higher performance can be mass produced of etectrodeposited black chrome solar coatings. Proc. ISES
and will be utilized as the market develops. Suitable Cong., Atlanta, p. 1897. Pergamon Press, New York (1979).
evacuation processes can produce collectors of long life, 25. G. B. Smith and A. Ignatiev, The relative merits of black
but more streamlined industrial processes are required. cobalt and black chrome as high temperature selective ab-
sorbers. Solar Energy Matl 2,461 (1980).
The most important problems at present are the need for 26. D, M. Mattox and R. R. Sowell, A survey of selective
reflectors of higher reflectivity and larger lifetime, and solar absorbers and their limitations. J. de Physique
the need for more developmental work and testing of Colloque C--, Suppl. 1, 42, C1-19 (1981).
manifolding schemes. 27. H. G. Craighead, R. Bartynski, R. A. Buhrman, L. Wojcik
and A. J. Sievers, Metal/insulator composite selective ab-
sorbers. Solar Energy Mat 1, 105 (1979).
Acknowledgements--The authors gratefully acknowledge the 28. E. E. Chain, G. E. Carver and B. O. Seraphim Highly
contributions of many others at the University of Sydney to the reflecting molybdenum thin films having significant solar
progress of the Solar Energy Group there, and thank the University absorptance. Thin Solid Films 72, 59 (1980).
of Sydney for supporting the Group in the early 29. R. S. Berg and G. J. Kominiak, Surface texturing by sputter
stages, and the Government of New South Wales for funding the etching. J. Vae. Sci. Technol. 13, 403 (1975).
work later at a level which has resulted in successful develop- 30. G. L. Harding and M. Lake, Sputter etched metal solar
ment of an evacuated collector. Financial support was also selective absorbing surfaces for high temperature thermal
received from His Royal Highness Prince Nawaf Bin Abdul Aziz collectors. Solar Energy Marl 5,445 (1981).
of the Kingdom of Saudi Arabia through the Science Foundation 31. W. Hermann, H. Horster, R. Kersten and F. Mahdjuri, High
for Physics within the University of Sydney. efficiency solar collectors. Proc. ISES Cong., New Delhi,
India, p. 950. Pergamon Press, New York (1978).
32. W. Hermann, H. Horster and R. Kersten, Evacuated selec-
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