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Sunny Skies

Taking advantage of off-the-shelf components—including a Delphi Solar Heat Exchanger—one company is helping provide a renewable energy source at a fraction of the cost of competitive methods.

A junkyard isn't exactly where one would expect a company building a prototype solar power generator to look for a critical component. But when Solar Energy Production Corporation (SEPCOR) needed a heat exchanger to help prove its technology was viable, an old radiator from a California salvage yard got the job done.

Fast-forward a couple years, and something more substantial (and reliable) became necessary to put the solar power system into production. So SEPCOR President Michael Yambrach made some calls to boyhood friends in Michigan who worked in the auto industry, which led to a connection with Delphi, a world leader in supplying thermal exchangers to vehicle manufacturers. While a bit unorthodox, it turned out to be exactly what SEPCOR needed.

"From the very beginning, we've approached the challenge of creating new energy sources by thinking outside the box," said Yambrach. "Our entire concept is driven by economics. In this case, that largely means using available, proven components from established companies to create something new. Don't be fooled by the simplicity. The approach is proprietary and includes many features which make the SEPCOR system truly unique."

A bright idea

	Prototype solar power generation system equipped with the Delphi Solar Heat Exchanger

The SEPCOR system converts sunlight into heat and heat into ready-to-use 480/3-phase power mechanically via the Rankine Cycle. This stands in stark contrast to solar photovoltaic systems that directly convert sunlight into low voltage DC power chemically. Using an inexpensive flat panel, the system takes advantage of the sun's energy to heat a working fluid to about 200°F (93°C). This is then used to heat an environmentally friendly working fluid, which is pressurized and heated to boiling. The resulting high-pressure vapor is run through an expander, which is connected to a standard three-phase induction generator that can generate 30 kW of AC electricity during peak periods. That's enough to power about 25 homes at any given time.

The Delphi Solar Heat Exchanger is prominently featured in the SEPCOR collector unit, the most visible of the components in the system, and serves the primary purpose of heating the working fluid to levels sufficient to vaporize the refrigerant housed in the secondary loop. The Delphi Solar Heat Exchanger harnesses the sun's power and is truly the engine behind this novel approach.

Power output can be maintained 24 hours a day by utilizing a conventionally fueled topping cycle. This topping cycle can be run during periods of cloud cover as well to level the output from the power plant. In many locales there are allowances for topping cycles that do not jeopardize the system status as a renewable power source. Thermal storage bladders integral to the system also contribute to the ability to create power around the clock.

"Providing reliable, clean power is the driving force behind this setup," said Yambrach. "It is designed to provide longer hours of operation with the ability to load shift. The end user will not be able to tell the difference between a kWh produced by a fossil burning plant and one produced by a renewable energy source."

An additional benefit of using readily available components is it simplifies installation and maintenance. Essentially any installer with knowledge of HVAC systems can do it. And since the system is modular, elements can simply be added or taken away to fulfill nearly any energy requirement.

"If the economics of adding something or doing something does not make sense, we don't do it," said Yambrach. "You can't fool Mother Nature, so why over-engineer something like this? We have found that there are natural, sustainable ways of engineering things that are not cost prohibitive, and reliability and safety do not need to be compromised in the name of economy. This innovative system truly answers the call to provide a simple, environmentally friendly, sustainable, and cost-effective option to meet demands by government agencies, regulators, and citizens for a renewable power source at a price that does not affect the pocketbooks of end users."

The SEPCOR system is indeed environmentally friendly. A one (1) MW system will reduce NO_x emissions by 15,984 kg, SO_x emissions by 8991 kg, particulates by 600 kg, and CO₂ emissions by 22,977,000 kg per year compared to traditional methods that generate the same amount of energy. This is the equivalent of taking 400 automobiles off the road.

Something shiny

The Solar Heat Exchanger that Delphi supplies to SEPCOR is very similar to the automotive condenser sold to vehicle manufacturers around the world. While initially not sure what to do with SEPCOR's request, Delphi quickly saw an opportunity to contribute to something that could have a significant impact on creating a new energy source.

"This has been a fascinating experience for everyone involved at Delphi," said Joseph Dunlop, commercial manager, Thermal Energy Systems, Delphi Thermal Systems. "Delphi's corporate values support the quest for environmentally friendly power generation, so it has turned out to be a great fit for us. It's not every day you get the chance to be involved in something that has this kind of potential impact. We are very excited about our role, and look forward to developing more products and systems that address the energy challenges facing a changing world."

For more information about the SEPCOR system, visit www.sepcor.net. For more information about Delphi's Solar Heat Exchanger, click here.

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