Dual-use solar energy conversion system
09705448 ยท 2017-07-11
Assignee
Inventors
Cpc classification
F24S23/74
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B10/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H10F77/67
ELECTRICITY
Y02E10/47
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02S40/425
ELECTRICITY
Y02E10/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02S40/44
ELECTRICITY
Y02B10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S30/452
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E10/52
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02B10/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H02S40/44
ELECTRICITY
Abstract
A dual-use solar energy conversion system has an innovative structural framework which accurately maintains the relative position and alignment of functional system components. The system has parabolic trough reflectors which focus solar radiation onto arrays of solar cells. The cells convert a portion of the incident radiation into electrical energy and the rest is collected in a cooling fluid and subsequently discharged as low-grade thermal energy to an energy storage medium. During operation, the entire system rotates about a vertical axis to track the azimuthal position of the sun.
Claims
1. A solar energy conversion system comprising the following: a) a multiplicity of parabolic trough reflector assemblies aligned in parallel rows, with each of said parabolic trough reflector assemblies including a parabolic trough reflector which is highly reflective of solar radiation b) a multiplicity of receiver assemblies aligned in parallel rows in one-to-one correspondence with the aforementioned rows of parabolic trough reflector assemblies, with each of said receiver assemblies including i) a cooling channel wherein flows a coolant capable of absorbing thermal energy from the cooling channel walls, with said cooling channel having one planar wall extending along its full length, and with said cooling channel positioned and oriented so that its planar wall is perpendicular to, and bisected by, the optical plane of its associated parabolic trough reflector, and ii) a planar array of solar cells extending along the length of the planar wall of the aforementioned cooling channel, with said planar array of solar cells maintained in intimate thermal contact with the planar wall of its associated cooling channel, and with the width of said solar cell array being substantially equal to the width of the planar wall of its associated cooling channel; c) a multiplicity of coolant supply lines, one of which is attached to each of the aforementioned cooling channels, and with each of said coolant supply lines equipped with a variable speed pump capable of providing a flow of coolant through its associated cooling channel; d) a coolant supply reservoir which is spatially disposed at the periphery of the aforementioned system in such a manner that the coolant in said coolant supply reservoir is continuously available to each of the aforementioned coolant supply lines, regardless of the angular orientation of said system; e) a multiplicity of coolant discharge lines, one of which is attached to each of the aforementioned cooling channels; f) a coolant discharge reservoir which is spatially disposed at the periphery of the aforementioned system in such a manner that heated coolant which is discharged by the said coolant discharge lines flows freely and directly into said coolant discharge reservoir, regardless of the angular orientation of said system; g) a structural framework including i) main support trusses, with said main support trusses located at the edges of the aforementioned parabolic trough reflector assemblies and extending the full length of said parabolic trough reflector assemblies in a direction parallel to their longitudinal axes, and ii) parabolic trough reflector support trusses, with said parabolic trough reflector support trusses located at regular intervals along the length of the aforementioned parabolic trough reflectors, and with said parabolic trough reflector support trusses attached to the aforementioned main support trusses, thereby transferring the gravitational loads of said parabolic trough reflector assemblies to said main support trusses, and iii) receiver assembly support structure which supports individual receiver assemblies, with said receiver assembly support structure consisting of diagonal support members connected between attach points on said receiver assembly's cooling channel and attach points on the two main support trusses that extend along the longitudinal edges of said receiver assembly's associated parabolic trough reflector; h) a set of wheel assemblies attached to the aforementioned main support trusses, with said wheel assemblies providing support for the system and mobility for the system in a horizontal plane; i) a motive mechanism provided to one or more of the aforementioned wheel assemblies, with said motive mechanism providing a capability for forcing rotation of the system in a horizontal plane about a central vertical axis.
2. A system as described in claim 1 wherein all structural members comprising the aforementioned structural framework are external to the focal volume of any parabolic trough reflector.
3. A system as described in claim 1 wherein all structural members located in the solar field of any parabolic trough reflector are oriented such that their major directional components are parallel to the longitudinal axis of said parabolic trough reflector.
4. A system as described in claim 1 wherein the motive mechanism provided to the aforementioned wheel assemblies has two operational modes, namely, a low-power sun-tracking mode wherein the motive mechanism is capable of rotating the system at rates in the range from 0.2 to 0.3 degrees per minute, and a high-power, wind-response mode wherein the motive mechanism is capable of rotating the system at rates in the range from 15 to 20 degrees per minute.
5. A system as described in claim 4 wherein the motive mechanism responsible for rotating the system is controlled by signals generated by optical sensors located on the system and by wind sensors located remotely from the system.
6. A system as described in claim 1 wherein each wheel assembly is equipped with a vertical pneumatic drive mechanism which acts upon its associated main support truss in response to signals from level sensors on the system, with all of said pneumatic drive mechanisms acting in concert to maintain vertical orientation of each parabolic trough reflector's optical plane, in spite of irregularities in the surface over which the system rotates.
7. A system as described in claim 1 wherein the coolant flow through each individual cooling channel is independently controlled by an associated variable speed pump, and with each variable speed pump controlled by signals from temperature sensors located along the length of said cooling channel.
8. A system as described in claim 7 wherein the coolant is recycled after passing through the multiplicity of cooling channels, with the recycling accomplished by transferring the warm coolant to an energy storage reservoir, either directly, or indirectly as through a heat exchanger, and then returning the coolant to the cooling channels, either directly, or indirectly as through a heat exchanger.
9. A system as described in claim 1 wherein each solar cell array consists of one or more parallel rows of solar cells that are electrically connected in series, and with said rows of series-connected solar cells extending in a direction parallel to the longitudinal axis of the associated cooling channel.
10. A system as described in claim 1 wherein, for each receiver assembly, the solar cell array is set at a fixed distance from the vertex of the associated parabolic trough reflector, with the fixed distance being in the range from 0.9 to 1.0 times the focal length of said parabolic trough reflector.
11. A system as described in claim 1 wherein each cooling channel has two external fins extending along its full length, with said fins located adjacent to, and on opposite sides of, the planar wall of said cooling channel.
12. A system as described in claim 11 wherein, for each parabolic trough reflector, the ratio of the parabolic trough reflector's focal length to its width is 0.6 or greater and, for each cooling channel, the external fins have coatings that are highly reflective of solar radiation on the surfaces adjacent to the planar wall of said cooling channel, and with said external fins extending downward at an angle relative to vertical which is equal to the rim angle of the associated parabolic trough reflector.
13. A system as described in claim 12 wherein, for each receiver assembly, the common width of the planar wall of the cooling channel and the attached solar cell array is 5% to 25% less than the width of the solar image at the location of said planar wall, thus positioning the highly reflective surfaces of the aforementioned external fins so as to redirect light at the edges of the solar image onto the arrays of solar cells.
14. A system as described in claim 1 wherein the full length and width of the internal surface of the planar wall of each cooling channel has longitudinal grooves of sufficient depth and width that the internal surface area of said planar wall is 2 to 2.75 times as great as the flat external surface area of said planar wall.
15. A system as described in claim 1 wherein the parabolic surface of each parabolic trough reflector is discontinuous in the region near its vertex which is shaded from direct sunlight by the associated receiver assembly, with said shaded region depressed in elevation relative to the parabolic surface of the reflector so as to provide a concave drainage conduit for rainwater and cleaning fluids, and with said depressed region extending the full length of said parabolic trough reflector.
16. A system as described in claim 1 wherein a horizontal support rail is attached to each face of each main support truss, and with each of said horizontal support rails extending the full length of its associated main support truss, and with all of the system's horizontal support rails located in the same horizontal plane, so as to provide the capability for supporting and guiding a service cart that is the full width of the aforementioned parabolic trough reflectors.
17. A system as described in claim 1 wherein, for each main support truss, vertical support towers are set above each of the attached wheel assemblies, with said support towers rising in elevation above said main support trusses, and with a suspension cable extending between each adjacent pair of support towers along the lengths of said main support trusses, and with vertical cables (hangers) connecting each of said suspension cables to the associated main support truss.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(8) A discussion of terminology is presented as a prelude to the detailed description of the invention.
(9) A parabolic trough reflector is characterized by its width, W, its length, L, and its focal length, F. All lateral (crosswise) sections of the reflector surface produce identical parabolas. A parabolic trough reflector has a vertex line which passes through the vertex points of its cross-sectional parabolas and it has a focal line which passes through the focal points of the cross-sectional parabolas. The vertex line and the focal line are parallel and are separated by a distance F. The optical plane of a parabolic trough reflector is the plane containing the reflector's vertex line and its focal line. The longitudinal axis of a parabolic trough reflector is parallel to its vertex and focal lines and the transverse axis is perpendicular the reflector's optical plane. The focal plane of a parabolic trough reflector is the plane which contains the reflector's focal line and is perpendicular to its optical plane. The solar disk is the circular area in the sky from which the sun appears to radiate energy. A parabolic trough reflector is properly aligned to collect and focus solar radiation when its extended optical plane bisects the solar disk. In the present system, each reflector is aligned and oriented so that its optical plane maintains verticality in addition to bisecting the solar disk. (Alignment schemes with non-vertical optical planes are possible but they negate advantages offered by the VATR concept.) Solar radiation collected and focused (redirected) by a parabolic trough reflector forms an elongated planar image of the sun referred to herein as the solar image. If reflected radiation coming from the surface of a parabolic trough reflector impinges upon a planar surface positioned within the reflector focal plane, the solar image formed on the surface is said to be focused. If the planar surface is not in the focal plane, the solar image formed on it is said to be defocused.
(10) The term solar field as used herein refers to the volume encompassing all the solar radiation propagating towards a parabolic trough reflector's surface. (Any opaque object located within the solar field will cast a shadow on the reflector surface.) The term focal volume as used herein designates the volume encompassing all the reflected solar radiation propagating away from the surface of a parabolic trough reflector towards its focal plane. (Any opaque object located within the focal volume will intercept focused radiation that would otherwise illuminate a portion of the solar image.) The term rim angle as used herein designates the angle between a parabolic trough reflector's optical plane and a line drawn perpendicularly from any point on the reflector's focal line to a point on either edge of the reflector surface. The three fundamental optical parameters of any parabolic trough reflector are its width, its focal length, and its rim angle. Only two of these parameters may be independently chosen. That is, if two of the three are given, the third may be calculated.
(11) The defining feature of a parabolic trough reflector is that incident light rays that are parallel to the reflector's optical plane are focused (redirected) onto the reflector's focal line. However, when the sun is shining at a point on the earth's surface, the point is not illuminated by parallel rays. Instead, as shown in
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(13) As shown in
(14) The first problem is that mechanical structure located within a parabolic trough reflector's focal volume can produce localized shadowing in the solar image plane by intercepting focused radiation. In particular, severe shadowing problems are produced by support structure that extends from the vertex line of the reflector up to its focal line, because structure in that location intercepts strongly focused radiation. This shadowing is a minor problem for solar-thermal energy conversion systems but it is a severe problem for solar-cell-based systems because solar cells are always electrically connected in series or in series/parallel arrays. Localized shadowing of even one cell in an array can proportionately limit the electrical output of a whole chain of cells. This sensitivity to shadowing by structural members within the focal volume leads to the first design constraint of the present system, namely, that there will be no structural member located within the focal volume of any reflector.
(15) The second problem is that, since rays illuminating an area within the solar image come from points that are located transversely across the width of the parabolic trough reflector surface, any structural member or grouping of structural members that is substantially transverse to the direction of the reflector's longitudinal axis will preferentially shadow a transverse band on the reflector surface, thereby preferentially shadowing a certain solar cell or group of cells positioned in or near the focal plane. As mentioned above, preferential shadowing can reduce the performance of a whole chain of cells that is connected to the shaded cell or cells. This leads to the second design constraint of the present system, namely, that no grouping of structural members that is located within the solar field of any parabolic trough reflector (i.e. located so as to intercept rays that would otherwise be incident on the reflector surface) will be positioned perpendicular to, or substantially transverse to, the direction of the reflector's longitudinal axis. For the presently disclosed structural framework, this means that structural members located in the solar field of any parabolic trough reflector will all be oriented so that their primary directional component is parallel to the longitudinal axis of the reflector, thus assuring that only a small portion of the shadow will fall in any particular transverse band on the reflector surface. This eliminates preferential shadowing of any solar cells.
(16) Another important optical consideration for parabolic trough reflector systems is the ratio of reflector focal length to reflector width (F/W). Most parabolic trough reflector systems in use today have relatively small values of F/W, (typically values of 0.3 or less) because small F/W values make it easier to maintain accurate optical alignment of the receiver relative to the reflector. Solar-cell-based systems benefit from high F/W values. There are two reasons for this. First, higher F/W values produce more uniform radiation intensity across the solar image, a situation which enhances the performance of irradiated solar cells. Second, higher F/W values produce lower angles of incidenceand lower reflection lossesfor light striking the planar solar cell surfaces. As an example, an F/W value of 0.3 provides angles of incidence of more than 80 degrees (the actual angle of incidence depends on the sun's angle of elevation) for rays passing from the edges of a parabolic trough reflector to solar cells located near its focal plane. Since solar cells are usually covered with a protective layer of glass, Fresnel reflection losses for the near-edge rays would be as high as 40% for the first face of the protective glass layer. (Anti-reflection coatings and surface texturing can be used reduce Fresnel reflection losses, but the effectiveness of these techniques is reduced at high incidence angles.) An F/W value of 0.6 produces an angle of incidence of roughly 45 degrees for rays passing from the edges of the reflector to the receiver assembly, with Fresnel reflection losses of only 5% for the first surface of the glass. Thus, consideration of reflection losses indicates that an F/W value in the range of 0.6 or higher would provide significant benefits for solar-cell-based systems with parabolic trough reflectors. However, an F/W of 0.6 provides a theoretical energy concentration ratio of more than 100 near the focal plane, a value which produces such a high heat flux that adequately cooling the solar cells would be problematic. This problem can be alleviated by simply defocusing the system slightly. The defocusing can be accomplished by moving the solar cell arrays down from the focal plane to a location that is closer to the reflector vertex by a few percent of the reflector focal length. Forming a defocused solar image in this way provides a means of selecting a lower energy concentration ratio (such as in the range of 20 to 50 where cooling the solar cells is less of an issue) without significantly affecting the angles of incidence for rays originating near the edges of the reflector. Defocusing has the additional advantage of reducing spatial intensity variations of the radiation impinging on the solar cells arrays.
(17) For any particular solar-cell-based system, the optimum F/W ratio will depend to some degree on the techniques used to manufacture the solar cells and on the latitude at which the system is deployed, but it is clear that systems with trough reflectors and planar solar cell receivers will benefit from F/W ratios that are much higher than are currently used in commercial trough reflector systems. The relatively large values of F/W that are desirable for solar-cell-based systems present challenging alignment and stability issues because the receiver assemblies in these systems are a relatively long distance from the trough reflector vertices. The structural framework disclosed in the present invention assures stable, accurate positioning and alignment of system components, even for F/W ratios in the range of 0.6 or greater.
(18) To summarize, the implications of the above optics discussion are that the performance of solar-cell-based systems with parabolic trough reflectors can be enhanced by implementing a support/alignment structure which; first, has no structural element located within the focal volume of any trough reflector; second, has no structural element or grouping of structural elements positioned so as to preferentially shadow a solar cell or cells located in or near the focal plane of any trough reflector; and third, has a reflector F/W value that is large enough (in the range of 0.6 or larger) that reflection losses are low and adequate cooling can be easily provided. The structural framework disclosed in the present invention meets these three design constraints and offers other important advances for VATR systems.
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(20) The major components of the system shown in
(21) The structural framework holds each parabolic trough reflector 101 so that its optical plane is vertical and its associated receiver assembly (cooling channel and attached solar cells) is at the desired distance from the trough reflector's vertex line. During operation, the system rotates about a central vertical axis to track the azimuthal position of the sun. Each parabolic trough reflector 101 focuses solar radiation onto an array of solar cells located in or near its focal plane. The solar cell arrays are mounted to planar walls (the walls facing the parabolic trough reflectors' vertices) of the cooling channels. Coolant flowing within the cooling channels collects the thermal energy produced within the solar cell arrays as it is conducted through the cooling channel walls.
(22) In the embodiment of the present invention shown in
(23) Other implementations of the coolant supply and discharge lines are possible, and some, such as variations of center-fed cooling channels, have been proposed previously for thermal systems, (e.g. U.S. Pat. No. 8,056,554) but such implementations are not optimal for solar-cell-based systems because they produce preferential shadowing of solar cells. Also, center-fed cooling systems lack the flexibility of the present system for independently controlling the coolant flow to individual cooling channels.
(24) The structural framework disclosed in the present invention is made up of three truss types that interconnect and support the operative system components. Referring again to
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(28) In the preferred embodiment of the present invention, the disclosed system rotates on a solid, flat surface by means of wheel assemblies located under, and attached to, the main support trusses.
(29) As the system rotates to track the sun, each of the system's hydraulic drive assemblies 526 responds to signals from system level sensors (not shown) by driving vertical hydraulic pistons 527. The system's hydraulic drive assemblies (one for each wheel) work in concert to keep each portion of each main support truss in a horizontal plane as the entire system rotates, in spite of any surface irregularities. This assures that the optical plane of each parabolic trough reflector remains vertical.
(30) The system's wheels may be inflatable (tires) for movement on a circular paved surface, or they may be metal wheels moving on a circular rail structure, or they may be some combination thereof. It is anticipated that the wheels farthest from the system center will be metal wheels moving on rails, thus providing guidance for the system as it rotates and maintaining for the system a true circular movement.
(31) Some or all of the support wheels will be motor driven. The motors (not shown) will force rotation of the system about its central vertical axis. The motors will have two operational modes: a low power sun-tracking mode and a higher power wind-response mode. Since the system rotates very slowly as it tracks the sun, motive power for sun-tracking rotation can be provided by motors operating in a low power mode, with the motors engaged so as to provide high torque to wheels rotating at very low angular velocity. During sun-tracking operation, the motors will be controlled by optical sensors on the main structure, thus assuring that the system constantly maintains its proper orientation relative to the sun's position throughout the course of the day. When wind sensors located near the system indicate that high wind conditions are imminent, the motors driving the system will transition to a higher power mode so as to rapidly rotate the system to an orientation such that the longitudinal axes of the parabolic trough reflector are aligned with the direction of the wind velocity, thus greatly reducing wind-induced stresses on the system and reducing the possibility of damage. Wind response capability is lacking in TTR systems because they have a fixed axis of orientation.
(32) Thermal expansion or contraction of the various members comprising the structural framework will not affect the horizontal location or the orientation of the parabolic trough reflectors relative to the solar cells in the receiver assemblies. As the ambient temperature rises and falls, the solar cells will remain centered vertically above the vertex line of the trough reflectors. Thermal expansion or contraction of the reflector support trusses will not significantly affect the focal length or the parabolic shape of the parabolic trough reflectors. Thermal expansion or contraction of the webbing in the receiver support trusses will raise or lower the receiver assemblies slightly relative to trough reflector vertices, but the size of the solar image is relatively insensitive to this vertical movement and any thermally induced displacement of the solar cells relative to the focal plane will not significantly affect the performance of the system.
(33) It is anticipated that the design of the parabolic trough reflectors used in the present system will benefit from advances made in reflector technology during past decades. These advances relate to the development of rugged, lightweight, highly reflective surfaces that can be accurately manufactured and assembled into the required shapes. On the other hand, the reflector support trusses in the present system are a significant departure from reflector support structures currently in use. The reflector support trusses of the present system are designed to support a constant vertical load that is always in a direction perpendicular to the reflector vertex. They will be held in a fixed horizontal position while being supported by the main support trusses at the reflector edges. They will not require the torque tubes or other bearing structure required by TTR systems. These factors simplify the design of the present system's reflector support trusses and enable wider reflector designs with greatly reduced weight and lower cost.
(34) In the presently disclosed system, the cooling channels are an integral part of the structural framework which defines and stabilizes the position and alignment of functional system components. As such, the cooling channels are required to withstand, without significant bending, vertical loads associated with their own weight and horizontal loads produced by the wind. In a preferred embodiment, the cooling channels will be made of a thermally conductive, light-weight metal alloy, such as an aluminum alloy, with the solar cell arrays mounted directly to the planar walls of the cooling channels. Plastic or composite material may also be used in fabricating the cooling channels, in which case a metal plate (with solar cells attached) would be installed as one wall of the cooling channels.
(35) In a further embodiment of the present system, also illustrated in
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(37) The previous paragraphs have discussed embodiments of the present invention wherein solar cells are installed along the entire length of the cooling channels. In these embodiments, the flow rates in the cooling channels are controlled so that some nominal maximum temperature of the coolant (and therefore of the solar cells) is not exceeded at the channel outlets. However, it may be desirable to deliver the system's low-grade thermal energy to a storage medium at temperatures higher than the maximum desired for the solar cells. This eventuality may be realized by an embodiment of the present system wherein solar cells are only installed along a portion of the cooling channel length, with a radiation absorbent coating along the rest of the length. It is then possible to keep the temperature of the solar cells below the desired maximum while at the same time delivering the coolant to the energy storage reservoir at some desired higher temperature.
(38) In summary, this application does not seek rights of patent protection for the concept of a VATR system, or for a VATR system that uses trough reflectors to focus solar energy onto solar cell arrays, or for a dual-use system that provides both electricity and thermal energy. Instead, the present application seeks patent protection for a system characterized by a specific arrangement and interconnection of structural and functional elements, with said elements having particular features and responding to specific control techniques. The system thus disclosed provides enabling technology which allows the inherent advantages of the VATR concept to be realized in the form of a practical, dual-use solar energy conversion system which makes optimal use of incident solar radiation.