Browsing by Author "Almond, Heather"
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Item Open Access Airborne sand and dust soiling of solar collecting mirrors(AIP, 2017-06-27) Sansom, Christopher L.; Almond, Heather; King, Peter; Endaya, Essam; Bouaichaoui, SofianeThe reflectance of solar collecting mirrors can be significantly reduced by sand and dust soiling, particularly in arid environments. Larger airborne sand and dust particles can also cause damage by erosion, again reducing reflectance. This work describes investigations of the airborne particle size, shape, and composition in three arid locations that are considered suitable for CSP plants, namely in Iran, Libya, and Algeria. Sand and dust has been collected at heights between 0.5 to 2.0m by a variety of techniques, but are shown not to be representative of the particle size found either in ground dust and sand, or on the solar collecting mirror facets themselves. The possible reasons for this are proposed, most notably that larger particles may rebound from the mirror surface. The implications for mirror cleaning and collector facet erosion are discussedItem Open Access Alignment measurements uncertainties for large assemblies using probabilistic analysis techniques.(2017-12) Doytchinov, Iordan; Tonnellier, Xavier P.; Almond, HeatherBig science and ambitious industrial projects continually push forward with technical requirements beyond the grasp of conventional engineering techniques. Example of those are ultra-high precision requirements in the field of celestial telescopes, particle accelerators and aerospace industry. Such extreme requirements are limited largely by the capability of the metrology used, namely, it’s uncertainty in relation to the alignment tolerance required. The current work was initiated as part of Maria Curie European research project held at CERN, Geneva aiming to answer those challenges as related to future accelerators requiring alignment of 2 m large assemblies to tolerances in the 10 µm range. The thesis has found several gaps in current knowledge limiting such capability. Among those was the lack of application of state of the art uncertainty propagation methods in alignment measurements metrology. Another major limiting factor found was the lack of uncertainty statements in the thermal errors compensations applied to assembly’s alignment metrology. A novel methodology was developed by which mixture of probabilistic modelling and high precision traceable reference measurements were used to quantify both measurement and thermal models compensation uncertainty accurately. Results have shown that the suggested methodology can accurately predict CMM specific measurement uncertainty as well as thermal drift compensation made by empirical, FEM and FEM metamodels. The CMM task-specific measurement uncertainties made at metrology laboratory were validated to be of maximum 7.96 µm (1σ) for the largest 2 m assemblies. The analysis of the results further showed how using this method a ‘virtual twins’ of the engineering structures can be calibrated with the known uncertainty of thermal drift prediction behaviour in the micrometric range. Namely, the Empirical, FEM and FEM Metamodels uncertainties of predictions were validated to be of maximum: 8.7 µm (1σ), 11.28 µm (1σ) and 12.24 µm (1σ).Item Open Access Contact cleaning of polymer film solar reflectors(AIP Publishing, 2016-01-31) Sansom, Christopher L.; Fernández-García, Aránzazu; Sutter, Florian; Almond, Heather; King, HelenThis paper describes the accelerated ageing of polymer film reflecting surfaces under the conditions to be found during contact cleaning of Concentrating Solar Power (CSP) collectors in the presence of dust and sand particles. In these situations, contact cleaning using brushes and water is required to clean the reflecting surfaces. Whilst suitable for glass reflectors, this paper discusses the effects of existing cleaning processes on the optical and visual properties of polymer film surfaces, and then describes the development of a more benign but effective contact cleaning process for cleaning polymer reflectors. The effects of a range of cleaning brushes are discussed, with and without the presence of water, in the presence of sand and dust particles from selected representative locations. Reflectance measurements and visual inspection shows that a soft cleaning brush with a small amount of water can clean polymer film reflecting surfaces without inflicting surface damage or reducing specular reflectance.Item Open Access Data in support of: PTFE layer formation during brush electroplating of nickel(Cranfield University, 2024-10-28) Isern Arrom, Luis; Impey, Sue; Endrino Armenteros, Jose Luis; Almond, HeatherItem Open Access The design and modification of a parabolic trough system for the hydrothermal liquefaction of waste(AIP Publishing, 2019-07-26) Almond, Heather; Tonnellier, Xavier; Sansom, Christopher L.; Pearce, Matt; Sengar, NamrataWe describe the design of a small-scale parabolic trough with a high-pressure absorber bundle to convert microalgae into bio-oil. The “proof-of-concept” system uses an existing Global CSP solar captor, with its reflectance enhanced by the addition of Skyfuel® ReflecTech Plus polymer film and has its original receiver tube replaced by a novel high-pressure multi-tube absorber and reactor. Initial results obtained at Kota University in Rajasthan, India demonstrated that temperatures up to 320°C are possible, and a bio-oil, similar to palm oil, was extracted from the reactor.Item Open Access The design of dust barriers to reduce collector mirror soiling in CSP plants(American Institute of Physics, 2018-11-08) Sansom, Christopher L.; King, Peter; Fernandez-Garcia, Aranzazu; Almond, Heather; Kayani, Talib; Boujjat, HoussammeIn this work we investigate, design, and evaluate a number of dust barrier designs that would be appropriate to reduce soiling of glass mirror solar collectors in the solar field of an existing CSP plant. The principal objective was to reduce the amount of soiling (and hence the amount of cleaning water consumed) by 50% in comparison with current cleaning procedures (considering particles of size >25 µm). “Fluent” CFD software was used to model of a range of potential dust barrier shapes, sizes, and porosities. Airflows and wind loadings were analyzed in this way. A number of potential designs were then taken forward for experimental validation. Initial validation involved wind tunnel evaluation of a small number of potential designs, using a new wind tunnel specifically designed and built for this project. Larger-scale outdoor validation was carried out both at Cranfield University in the UK and at CIEMAT-PSA (Plataforma Solar de Almeria) in Spain. Initial results were independent of location and barrier shape and showed that the percentage of particles that were stopped completely or travelled less than 1m beyond the barrier was in the range 45.8 ± 5%.Item Open Access Design Principles for FES Concept Development(Cranfield University, 2013-10) Dakin, Samuel; Williams, Leon; Almond, HeatherA variety of pathologies can cause injury to the spinal cord and hinder movement. A range of equipment is available to help spinal injury sufferers move their affected limbs. One method of rehabilitation is functional electrical stimulation (FES). FES is a technique where small electrical currents are applied to the surface of the user’s legs to stimulate the muscles. Studies have demonstrated the benefits of using this method and it has also been incorporated into a number of devices. The aim of the project was to produce a number of designs for a new device that uses FES technology. The project was completed in conjunction with an industrial partner. A review of the literature and consultation with industrial experts suggested a number of ways current devices could be improved. These included encouraging the user to lean forwards while walking and powering the device using a more ergonomic method. A group of designers were used to produce designs that allowed the user to walk with a more natural gait and avoided cumbersome power packs. The most effective of these designs were combined to form one design that solved both problems. A 3-dimensional model of this design was simulated using computer-aided design software. Groups of engineers, scientists and consumers were also invited to provide input on how a new device should function. Each of these groups provided a design that reflected their specific needs, depending on their experience with similar technology. Low level prototypes were produced of these designs. A group of designers were also used to design concepts for a functional electrical stimulation device based on an introduction given by industry experts. Each of the designs was presented to experienced professionals to obtain feedback. A set of guidelines were also produced during the project that instructed how to create the designs.Item Open Access Impact of dust on electrical power output of solar PV modules in North-East, Nigeria(Niger State College of Education, 2022-05-30) Abdulkarim, Hauwa Talatu; Sansom, Christopher L.; Patchigolla, Kumar; Almond, Heather; Karim, MouniaThe impact of dust on the solar PV modules deserves more attention. North-eastern Nigeria has high potential of solar irradiance but it is proned to dust accumulation. This paper therefore, investigated the impact of dust on the performance of solar Photovoltaic modules in North-Eastern Nigeria. The investigation entailed field experiment carried out in Maiduguri to assess the performance of the module based on continuous dust deposition for 14 days during dust accumulation period. The results show that more than 50% loss in power output was recorded under 14 days of continuous deposition. The efficiency of the module reduced from 17.1% on the first day to 7.2% on the fourteenth day of the experimentation. The investigation also shows that at high humidity the PV performance drops. Solar irradiance increases the performance. The deployment of solar PV energy supply system is recommended in spite of dust accumulation challenges. To maintain adequate performance of the system, a once a week cleaning is recommended during intense dust accumulation period.Item Open Access Investigation of pre and post plating surface roughness of electroless nickel phosphorus coated substrate for diamond turning application(European Society for Precision Engineering and Nanotechnology, 2016-06-30) Xia, Peter; Almond, Heather; Impey, Susan A.In an overarching project to reduce the number of defects found in electroless nickel phosphorus alloy (EN-P) coatings on large diamond-turned components used in the next generation of reel-to-reel (R2R) printing stations, the significance of the coating surface on achieving a wear resistant and optically smooth surface has been investigated. This paper presents an investigation that focuses on the substrate roughness variation achieved through different pre-treatment methods prior to coating using a commercial plating solution. It looks at the number of features observed pre and post plating. The results provide some suggestions with respect to the diamond machining of a 100 micron thick EN-P coating.Item Open Access Investigation of the Thermo-hydraulic performance of a roughened Parabolic trough collector(Elsevier, 2022-10-28) Allauddin, Usman; Rafique, Muhammad U.; Malik, Osama; Rashid, Osama; Waseem, Ashir; King, Peter; Karim, Mounia; Almond, HeatherParabolic trough collectors (PTC) are an already established technology set to prove its competitiveness. Recently, a lot of research is ongoing to further enhance the thermal performance of PTC systems. Computational Fluid Dynamics (CFD) can help in the design and development of PTCs with optimized thermal efficiency. In the current work, a combined enhancement in the performance of a PTC is evaluated, involving modifications to the geometry of the absorber tube and the use of a heat transfer fluid (HTF) (Syltherm800). Absorber tube geometries involving dimpled protrusions (d-PTC) and circumferential inclined ribs (IR-PTC) are used. The performance of PTC with and without turbulators is compared with that of a smooth absorber tube by calculating the Nusselt number (Nu), friction factor (f) and performance evaluation criterion (PEC). PEC values of 1.46 and 1.18 are observed by using inclined ribs and dimpled protrusions, respectively at an absorber tube inlet temperature (Tin) of 500 K and mass flow rate (m) of 0.5 kg s−1. Thus, a significant enhancement in thermo-hydraulic performance of PTC is observed with inclined rib turbulators.Item Open Access Low-profile and wearable energy harvester based on plucked piezoelectric cantilevers(Society of Photo-optical Instrumentation Engineers, 2015-05-21) Pozzi, Michele; Almond, Heather; Leighton, Glenn J. T.; Moriarty, Roy J.The Pizzicato Energy Harvester (EH) introduced the technique of frequency up-conversion to piezoelectric EHs wearable on the lateral side of the knee-joint. The operation principle is to pluck the piezoelectric bimorphs with plectra so that they produce electrical energy during the ensuing mechanical vibrations. The device presented in this work is, in some ways, an evolution of the earlier Pizzicato: it is a significantly more compact and lighter device; the central hub holds 16 piezoelectric bimorphs shaped as trapezoids, which permits a sleek design and potentially increased energy output for the same bimorph area. Plectra were formed by Photochemical Machining of a 100-μm-thick steel sheet. To avoid the risk of short-circuiting, the plectra were electrically passivated by sputtering a 100 nm layer of ZrO2. Bench tests with the steel plectra showed a very large energy generation. Polyimide plectra were also manufactured with a cutting plotter from a 125μm-thick film. Besides bench tests, a volunteer wore the device while walking on flat ground or climbing stairs, with a measured energy output of approximately 0.8 mJ per step. Whereas most of the tests were performed by the traditional method of discharging the rectified output from the EH onto a resistive load, tests were performed also with a circuit offering a stabilised 3.3 V supply. The circuit produced a stable 0.1 mA supply during running gait with kapton plectra.Item Open Access Microfabrication processing of titanium for biomedical devices with reduced impact on the environment(Cranfield University, 2012-09) Gastol, Dominika A.; Allen, David; Almond, HeatherThis thesis presents research on a novel method of microfabrication of titanium (Ti) biomedical devices. The aim of the work was to develop a commercial process to fabricate Ti in a more environmentally friendly manner than current chemical etching techniques. The emphasis was placed on electrolytic etching, which enables the replacement of hazardous hydrofluoric acid-based etchants that are used by necessity when using Photochemical Machining (PCM) to produce intricate features in sheet Ti on a mass scale. Titanium is inherently difficult to etch (it is designed for its corrosion-resistant attributes) and as a result, Hydrofluoric acid (HF) is used in combination with a strong and durable mask to achieve selective etching. The use of HF introduces serious health and safety implications for those working with the process. The new technique introduces the use of a “sandwich structure”, comprising anode/insulator/cathode, directly in contact with each other and placed in an electrolytic etching cell. In this technique the same photolithography process is utilised to achieve selective etching on a metal substrate as in the PCM process. However, for the electrolytic etching stage, the inter- electrode gap (IEG) is reduced significantly from a few centimetres, as usually applied in electrochemical processes, to 4 μm. The intention behind this was to improve the current distribution experienced at the anode (Ti) during subsequent electrolytic etching. The sandwich structure was developed by deposition of a photoresist S1818 and Copper (Cu) on top of Ti. Firstly, a manual sanding of the substrate was applied in order to eliminate the oxide layers which could strongly affect a final electrolytic etching. The soft- and hard-bake stages involved in the processing of the S1818 resist were optimised to produce a stress-free Ti/S1818/Cu/S1818 structure. Ultimately a pattern would be imparted onto the S1818/Cu/S1818 that would ultimately be imparted through to the Ti layer during the last stage, electrolytic etching. In order to achieve this, a Cu electroless deposition was developed as a technique to obtain a conductive film which would act as a cathode during the electrolytic etching of the target, Ti layer. The results of the electrolytic etching of the Ti sandwich structure revealed flat-base profiles of half-etched (“half-etch” is the term used to signify an etch that does not penetrate completely through the thickness of the metal sheet) micro-holes in the Ti layer. The problem of delamination of the electroless Cu, in 10 % w/v HCl electrolyte used as an etchant, was solved by electroplating a 12 μm layer of Cu on top of the 60 nm Cu electroless deposited film. Using this technique, micro-features were achieved in Ti. The half-etched micro-holes were characterised to have an overall spherical shape corresponding to the imaged pattern and a preferred flat-base profiles (typically a raised land of material arises in conventional electrolytic etching). A series of parameters were tested in order to control the process of electrolytic etching through the Ti sandwich structure by measuring etch rate, surface roughness of the etched pattern and the etch factor. The applied current densities (CD) of 10, 15, 20, and 25 A/cm2 showed proportional dissolution to the applied current. Electrolytic etching with a CD of 20 A/cm2 demonstrated a high etch rate of 40 μm/min. and a relatively low Ra of 2.8 μm, therefore, it was utilised in further experimental work. The highest etch rate of 50 μm/min. and an improved distribution of half-etched micro-holes was achieved by the introduction of 4 crocodile connectors (2 per electrode) and mechanically stirring of the electrolyte (800 rpm) while performing the electrolytic etching. The maximum etch depth of 143.9 μm was produced in Ti when the electrolytic etching was performed at the same conditions for 3 minutes. The incorporation of ultrasonic agitation to the electrolytic etching and an electrolyte temperature of 130 C resulted in a decrease of the surface roughness of the etched micro-holes to 0.5 μm. The results of the Ti sandwich structure electrolytic etching proved the concept of minimising the IEG in order to obtain a uniform Ti dissolution on a feature scale, improved control of the electrolytic dissolution over the whole area of the sample with utilisation of the lower hazard etchant at the same time.Item Open Access Predicting the effects of sand erosion on collector surfaces in CSP plants(Elsevier, 2015-06-05) Sansom, Christopher L.; Comley, Paul; King, Peter; Almond, Heather; Atkinson, C.; Endaya, E.This paper presents a methodology to predict the optical performance and physical topography of the glass collector surfaces of any given CSP plant in the presence of sand and dust storms, providing that local climate conditions are known and representative sand and dust particles samples are available. Using existing meteorological data for a defined CSP plant in Egypt, plus sand and dust samples from two desert locations in Libya, we describe how to derive air speed, duration, and sand concentrations to use within the Global CSP Laboratory sand erosion simulation rig at Cranfield University. This then allows us to predict the optical performance of parabolic trough collector glass after an extended period by the use of accelerated ageing. However the behavior of particles in sandstorms is complex and has prompted a theoretical analysis of sand particle dynamics which is also described in this paper.Item Open Access PTFE layer formation during brush electroplating of nickel(Springer, 2024-10-14) Isern, Luis; Impey, Sue; Almond, Heather; Clouser, SJ; Endrino, JLBrush electrodeposition of Ni/PTFE composite coatings was explored using a nickel high speed solution and polytetrafluoroethylene (PTFE) particles 6–9 μm in diameter. A novel bilayer-like, partially intercalated structure was produced, consisting of a rough nickel sublayer covered by an outer, compact, smooth PTFE layer. The study of the coating growth revealed that the PTFE particles bind together on the nickel coating valleys and grow until all the surface is covered by a polymer layer without the need of a baking stage. The resulting coating presents a hydrophobic surface with a low coefficient of friction (0.10) and higher corrosion resistance to salt spray testing than the nodular nickel coating. The coatings were produced using an aqueous nickel plating solution, where the hydrophobic PTFE particles were suspended using different substances: cetrimonium bromide (CTAB) cationic surfactant, isopropyl alcohol premixed with the particles, and ethanol premixed with the particles. High concentrations of the suspending products were detrimental for the deposition process, but optimal values of 0.1 g/l, 3 ml/l and 3 ml/l respectively were found. All compounds successfully suspended the PTFE particles and both alcohols produced the Ni/PTFE coating described before, but the CTAB failed to co-deposit the polymer.Item Open Access Soiling and cleaning of polymer film solar reflectors(MDPI, 2016-11-29) Sansom, Christopher L.; Fernández-García, Aránzazu; Sutter, Florian; Almond, Heather; King, Peter; Martínez-Arcos, LucíaThis paper describes the accelerated ageing of commercially available silvered polymer film by contact cleaning using brushes and water in the presence of soiling created by dust and sand particles. These conditions represent cleaning regimes in real concentrating solar power (CSP) solar fields in arid environments, where contact cleaning using brushes and water is often required to clean the reflecting surfaces. Whilst suitable for glass reflectors, this paper discusses the effects of these established cleaning processes on the optical and visual characteristics of polymer film surfaces, and then describes the development of a more benign but effective contact cleaning process for cleaning polymer reflectors. The effects of a range of cleaning brushes are discussed, with and without the presence of water, in the presence of sand and dust particles from selected representative locations. The experiments were repeated using different experimental equipment at Plataforma Solar de Almería (PSA) in Spain and Cranfield University in the UK. The results highlight differences that are attributable to the experimental methods used. Reflectance measurements and visual inspection show that a soft cleaning brush with a small amount of water, used in a cleaning head with both linear and rotational motion, can clean polymer film reflecting surfaces without inflicting surface damage or reducing specular reflectance.Item Open Access Structure zone diagram and particle incorporation of nickel brush plated composite coatings(Nature Publishing Group, 2017-03-16) Isern, Luis; Impey, Susan A.; Almond, Heather; Clouser, S. J.; Endrino Armenteros, JoseThis work studies the deposition of aluminium-incorporated nickel coatings by brush electroplating, focusing on the electroplating setup and processing parameters. The setup was optimised in order to increase the volume of particle incorporation. The optimised design focused on increasing the plating solution flow to avoid sedimentation, and as a result the particle transport experienced a three-fold increase when compared with the traditional setup. The influence of bath load, current density and the brush material used was investigated. Both current density and brush material have a significant impact on the morphology and composition of the coatings. Higher current densities and non-abrasive brushes produce rough, particle-rich samples. Different combinations of these two parameters influence the surface characteristics differently, as illustrated in a Structure Zone Diagram. Finally, surfaces featuring crevices and peaks incorporate between 3.5 and 20 times more particles than smoother coatings. The presence of such features has been quantified using average surface roughness Ra and Abbott-Firestone curves. The combination of optimised setup and rough surface increased the particle content of the composite to 28 at.%.