Hyperlight Energy is developing a novel concentrated solar power reflector and receiver system called Hylux™. The reflector system consists of a water-borne, extruded plastic tube structure upon which flat glass mirror slats are mounted. Arrays of these tubes are connected using simple four bar linkages, which control the alignment of the mirrors and track the sun through the day. Using low-cost, long-life plastic, and minimizing the use of steel and concrete, substantial cost savings are achieved. This project sought to move Hylux™ through the final stages of development, in preparation for commercial operation. Initial testing of a Hylux™ pilot production line and a reflector array was conducted at Hyperlight’s facility in Lakeside, California, followed by limited on-sun testing of an array at the company’s Brawley, California test site. Subsequently, a half-acre array of reflectors was manufactured, installed and tested in Brawley, California. Thermal efficiency achieved in testing has so far been in the range of 60 percent to 85 percent of modeled efficiency. Important milestones achieved in this project include the mass manufacture and installation of the tube structural components required to achieve the full cost-savings possible with the Hylux™ design. Issues in manufacturing and installation with unskilled labor were identified. Design improvements to make the manufacturing and installation processes simpler and more robust are identified and planned for the future. Importantly, the level of performance thus far achieved supports economical installation at customer sites under existing commercial grant programs.
