3D Printing Unlocks Promising Solar Cavity Receiver Solution

In solar energy production, a solar cavity receiver maximizes light captured from the sun, converting it into thermal energy. However, high-temperature solar receivers tend to distribute heat unevenly, causing thermal stress. This can lead to plastic deformation and a shorter lifetime for the part. To address this issue, three researchers from the King Abdullah University of Science and Technology (KAUST) in Saudi Arabia designed a solar cavity receiver to ameliorate how heat is distributed. What interests us is that 3D printing has played a vital role in the model’s development.

Current cavity receivers are designed with vertical tubes that do not allow heat to flow evenly. The non-uniform heat influx distribution and a temperature gradient between the front and back of the tube walls result in thermal stress. These issues are particularly pronounced in the case of gas solar receivers because of gasses’ lower thermal conductivity.

Current solar receiver with non-uniform heat distribution. (Image credits: International Journal of Heat and Mass Transfer 135 (2019) 732–745)

By contrast, the KAUST team’s model has a conical cavity receiver with a honeycomb lattice structure—entirely 3D printed. The device features a double helix heat exchanger, as opposed to vertical tubes, to reduce thermal stress, improving heat transfer and radiation trapping. This design enhances optical performance and facilitates radiation reaching the back of the helical tube. Heat is moved throughout the device’s inner tube because of pressurized air, which is heated by concentrated sunlight. Simultaneously, the honeycomb lattice structure regulates heat distribution, reducing thermal stress.