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promising low-cost reflector material, a silvered specular substrate protected by an alumina coating several microns thick, developed under a previous subcontract on a laboratory scale roll-coater. The second subcontract with Swisher and Associates was to perform a new cost analysis of this material. The third subcontract with ReflecTech was to improve the UV stability of a polymeric solar reflector, developed under a previous subcontract, and to make a pilot run of the improved UV stable reflector. Budget allocations by task are provided below. Trough mirrors (used in commercial solar plants), manufactured by Flabeg, use silvered, thick, slumped glass with a proprietary multilayer paint system designed for outdoor exposure and have been very durable. Flabeg recently converted their mirror line to the copper-free process and a new lead-free paint system. The manufacturer reports durability is expected to be equivalent. Side-by- side exposure testing began in middle of FY 2004. Testing of samples of Pilkington (4-mm copper- free) mirrors and “Spanish” (Cristaleria Espanola S.A) glass mirrors (3 mm, copper-free, and lead- free paint), bonded to steel with four different candidate adhesives, was initiated in FY 2001 for possible use at Solar Tres. Neither Pilkington nor Spanish mirrors exposed outdoors show degradation after 30 months, but in accelerated testing using the Altas Ci5000 WeatherOmeter (WOM), the Pilkington mirrors exhibit better optical durability, and adhesive-related degradation is more prevalent with Spanish glass mirrors. Thin-glass mirrors also use traditional wet- silvered processes on thin (<1 mm), relatively lightweight glass. Choice of adhesive affects the performance of weathered thin-glass mirrors, and corrosion has been observed in deployed mirrors. Initial analysis of a thin glass mirror matrix exposed in the WOM indicates commercial (non- mirror) back protective paint applied post mirror manufacturing is not beneficial. CPV manufacturers have expressed significant concern regarding the durability of thin-glass mirrors made with copper-free and lead-free paint systems. Although glass mirrors with copper backlayers and heavily leaded paints have been historically considered robust outdoors, the new copper-free back layer and lead-free paint systems were designed for interior mirror applications and do not have the same durability. Development of a mirror-backing paint system suitable for outdoor applications, to be applied during mirror manufacturing, will be required to provide sufficientdurability. Task Title Durability Testing of Optical Materials Advanced Reflector Materials 3. Results and Accomplishments FY 2004 Budget ($K) 90 20 • Published results of durability testing of several mirror types (06/04). • Performed secondary cost analysis, and published original and secondary cost analysis results of ASRM (11/03, 06/04). • Completed pilot-scale run of ReflecTech material with improved UV stability (8/04). • Provided status of test results of candidate solar mirror samples and identify promising candidates (09/04). • Published Review Meeting proceedings (09/04). • Provided significant industry support about reflectors to concentrating photovoltaics (CPV) industry. 3.1 Glass Mirrors Glass mirrors have excellent durability in terms of corrosion of reflective layer, are readily available, have the confidence of the solar manufacturing industry, and are commercially deployed. However, they are heavy and fragile and require slumped glass for curved shapes, which is expensive. Recently, two significant changes in mirror manufacturing have occurred in the classical wet chemistry process because of environmental concerns. The first is the method of forming a copper-free reflective mirror, and the second is the use of lead-free paints.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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