3D-Printed Solar Cavity Receiver for Heating Pressurized Air – A Preliminary Evaluation

High-temperature solar receivers experience non-uniform solar flux, which induces thermal stress in the receiver tubes. This stress is more pronounced in gas solar receivers due to the lower thermal conductivity of gases. To address these limitations, this paper introduces a novel 3D-printed solar receiver featuring a conical cavity and a honeycomb lattice structure. The design integrates a double helix heat exchanger with a tear-drop cross section to reduce thermal stress, enhance optical performance. Manufactured using Direct Metal Printing (DMP) with Nickel superalloy Inconel 718, the receiver is designed for high-temperature and high-pressure applications. Simulation results, conducted using Ansys-Fluent and an in-house code, demonstrate the temperature distribution, pressure drop, and outlet temperature variations as a function of heat flux and air mass flow rate. The findings indicate that the receiver can operate under a maximum heat flux density of 230 kW/m², corresponding to the maximum working temperature of Inconel 718 (1000°C), with minimal pressure drop, making it a promising solution for mitigating thermal stress in solar receivers.