stirling energy by solar

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Sun catchers tuned to crank out the juice

R. Colin Johnson11/22/2004 03:00 PM EST

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PORTLAND, Ore.EEs are turning a 19th-century invention into a 21st-century alternative-energy source.

The last leg of a two-decades-long effort by the U.S. Energy Deaprtment to unleashsuperefficient solar power by 2011 is homing in on the so-called Stirling engine, which is beingused to drive solar generators. DOE test site measurements suggest the setup could bring the costof solar power on a par with traditional fossil fuels and hydroelectric sources assuming theproject engineers can balance the separate power feeds from farms of thousands ofsimultaneously online 25-kilowatt Stirling solar dishes.

The heart of the design, the engine itself, was invented by the Scottish minister Robert Stirling in1816.

"The Stirling engine makes solar power so much more efficiently than photovoltaic solar cells

can," said Robert Liden, chief administrative officer at Stirling Energy Systems Inc. (Phoenix)."That's because the Stirling solar dish directly converts solar heat into mechanical energy, whichturns an ac electrical generator." The bottom line, he said, "is that large farms of Stirling solardishessay, 20,000-dish farmscould deliver cheap solar electricity that rivals what we payfor electricity today."

Under a multiyear Energy Department contract that started in 2004, Stirling Energy Systems willsupply Sandia National Laboratories with solar dishes for integration into full-fledged power-generation substations capable of direct connections to the existing U.S. power grid. Right nowabout 20 EEs, including more than a dozen from Stirling Energy Systems, are working full timeat Sandia to create the electrical-control systems to manage these sunshine stations.

By the end of 2005, they plan to have six dishes connected into a miniature power stationcapable of supplying enough 480-volt three-phase electricity to power about 40 homes (150 kW).The next step, in 2006, is a 40-dish power plant that will transform the combined output of thefarm from 480 to 13,000 V, for distribution of industrial-level power to an existing substation.From 2007 to 2010, the program proposes mass-producing dishes to create a 20,000-dish farmsupplying 230,000 V of long-haul power from its own substation directly connected to the grid.
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If the project succeeds, the DOE predicts that by 2011, Stirling solar-dish farms could bedelivering electricity to the grid at costs comparable to traditional electricity sources, therebyreducing the U.S. need for foreign sources of fossil fuels.

Eventually, according to DOE estimates, an 11-square-mile farm of Stirling solar dishes could

generate as much electricity as the Hoover Dam, and a 100 x 100-mile farm could supply all thedaytime needs for electricity in the United States. By storing the energy in hydrogen fuel cellsduring the day, Stirling solar-dish farms could supply U.S. electrical-energy needs at night too,as well as enough juice for future fuel-cell-powered automobiles, the DOE believes.

Power today costs from about 3 cents to 12 cents per kilowatt-hour, depending upon thecustomer's location and the time of day. The average is 6.6 cents/kW-hr for the industrial sectorin 2004, according toDOE.In contrast, the Stirling solar-powered substations operate onlyduring peak hours (daytime) but at potentially the same or less than the peak rates paid todayor "about 6.5 cents per kilowatt-hour during peak periods," said Liden of Stirling EnergySystems.

Prior DOE tests settled on the Stirling solar dishes by comparing traditional solar power withthree kinds of "focused thermal" solar energyall of which operate in a manner similar to thesolar-power generator in the James Bond movie The Man with a Golden Gun. There, RogerMoore narrowly escapes being fried by the concentrated beam from a focused solar mirror thatuses the same principle whereby leaves are set on fire with the focused sunlight from amagnifying glass.

The DOE compared the Stirling solar dish, parabolic troughs, power towers and concentratedphotovoltaics. The study, conducted at Sandia National Laboratories' Solar Thermal TestFacility, concluded that Stirling dishes outperformed all other sources of solar power.

Today Stirling-powered solar dishes at the Sandia test facility operate at 30 percent efficiencywhile delivering grid-ready alternating current. In contrast, 30-percent-efficient solar cells aredirect current and drop to 16 percent efficiency by the time they generate grid-ready ac. Andthat's on a hot day. Efficiency can drop as low as 10 percent on a cool day.

"Tests have already shown that the Stirling engine can be made into a very efficient powergenerator," said Chuck Andraka, project leader at Sandia's Solar Technology Department. "Nowwhat we need to show is that many small Stirling engines can be coordinated in farms thattogether rival traditional power sources."

Time for a change

Historically, the Stirling engine could never compete with the bigger bang per cubic inch of agas-guzzling internal-combustion engine. However, dependence on foreign oil, increasingpollution and America's seemingly unquenchable thirst for more energy hint that it might be timefor a turnaround.
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mproved Solar Power Dish with Stirling

Engine Made by Car Parts Suppliers

Michael Graham RichardTechnology/Solar TechnologyJuly 9, 2009

Photo: Stirling Energy

SystemsNew and Improved Solar Thermal Collection DishWhile a lot of people think aboutphotovoltaic panelswhen "solar power" is mentioned,solar thermalmust not be underestimated.One of the players in that field isStirling Energy Systems(SES), who we've written about beforewhen they set a new world record for"solar-to-grid system conversion efficiency"(31.25percent, beating the previous record of 29.4 percent). Well, in collaboration withSandia NationalLaboratories,SES has refined its SunCatcher design. Read on to find out how the new version
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compares to the old one.Image: Stirling Energy SystemsNot Reinventing the WheelThe new Suncatcher is evolutionaryrather than revolutionary (you can compare it to the older design by looking at the photo below),but according to the specs released by Sandia National Laboratories, it seems like a significantimprovement:

The new SunCatcher is about 5,000 pounds lighterthan the original, is round instead ofrectangular to allow for more efficient use of steel, has improved optics, and consists of 60percent fewer engine parts. The revised design also has fewer mirrors40 instead of 80.The reflective mirrors are formed into a parabolic shape using stamped sheet metal similar to thehood of a car. The mirrors are made by using automobile manufacturing techniques. Theimprovements will result in high-volume production, cost reductions, and easier maintenance.

90% of the Suncatcher components will be made in the US, and by using automobile suppliers tomake the parts, Stirling Energy Systems is leveraging their manufacturing expertise (and I betthat auto suppliers are glad to get the extra work). By utilizing the automotive supply chain tomanufacture the SunCatcher, were leveraging the talents of an industry that has refined high-

volume production through an assembly line process. More than 90 percent of the SunCatchercomponents will be manufactured in North America," says Steve Cowman, Stirling EnergySystems CEO.

Last year, Tim wrote about how a Suncatcher unit set asolar power conversion efficiency worldrecord.I'll be curious to know if these upgraded versions will do even better.
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Photo: Stirling EnergySystems

Above is the older version of the Stirling Energy Systems Suncatcher.

ViaSandia National LaboratoriesMore Thermal Solar PowerHow Much Land to Power TheWhole World with Solar?Solar Thermal Power in North-Africa: How Much Land to Power theWorld?Stirling Energy Systems Sets World Record850 MW Solar Thermal Power Plant SeeksCalifor

Tessera Solar and Stirling Energy Systems (SES) have

unveiled new designs of their SunCatcher system at Sandia

National Laboratories National Solar Thermal Test Facility(NSTTF). The new system offers better efficiency at a low

cost being used in commercial-scale deployments of the units

beginning in 2010.

The four new dishes are the next-generation model of the original SunCatcher system. Sixfirst-generationSunCatchersbuilt over the past several years at the NSTTFhave beenproducing up to 150KW [kilowatts] of grid-readyelectrical powerduring the day, says ChuckAndraka, the lead Sandia project engineer. Every part of the new system has been upgraded to

allow for a high rate of production and cost reduction.

SunCatcheris based on the use of precision mirrors that are attached to a parabolic dish. Thisdish focuses light onto a receiver, which transmit the heat to a Stirling engine. The engine isfilled with hydrogenand utilizes the change in temperature of the gas to drive a turbine, whichgenerateselectric energy.
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This new system is about 5,000 pounds lighter than the original system and utilizes just 40mirrors instead of the 80 that were used previously. SunCatcherwill produce about 1000MW ofgreen energyby 2012, being deployed in some of theworlds largest solar plantsin SouthernCalifornia.

The new design of the SunCatcherrepresents more than a decade of innovative engineeringand validation testing, making it ready for commercialization, says Steve Cowman,StirlingEnergy Systems CEO. By utilizing the automotive supply chain to manufacture theSunCatcher, were leveraging the talents of an industry that has refined high-volume productionthrough an assembly line process. More than 90 percent of theSunCatchercomponents will bemanufactured in North America.

Stirling Energy latest solar bankruptcy:

What is next for U.S. solar industry?Comment0

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Brian CoppaPhoenix Green Business Examiner

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October 4, 2011

Scottsdale, Arizona based Solar-power equipment manufacturerStirling Energy SystemsInc.recently filed for Chapter 7 bankruptcy, adding to U.S. solar industry woes including soft

demand, falling prices and difficulty raising money. In the case of Chapter 11 bankruptcy, thecompany could reorganize and attempt to become profitable; however, under Chapter 7 of theU.S. bankruptcy code, the company is forced to discontinue all operations and liquidate its assetportfolio.

Stirling Energy, maker of the SunCatcher, a 25-kW solar-powered stirling engine designedspecifically for the utility market,developed equipment for two solar power plants designed toconvert heat from the sun into electricity usingconcentrated solar power(CSP) technology, asopposed to more conventionalphotovoltaic(PV) solar panels. Neither of the plants were able toobtain U.S. Department of Energy loan guarantees, even though both were sited on public land inCalifornia and received fast-track construction permits from the Obama administration.

Stirling had deployed a pilot project using its stirling engines in early 2010 with the 1.5MWMaricopa Solar Power Plant in Arizona associated with local power utility- SRP. In 2008, thecompany agreed to supply its dish-engine technology to a massive 850-MW power plant in SanBernadino County, California. However, the project developer Tessera Solar, sold the project toK Road Power Holdings in late December 2010 shortly after receiving approvals from theCalifornia Energy Commission. Thereafter, K-Road announced that 750MW of the 850-MWproject would be developed using less expensive PV instead of CSP, with only the last 100 MW
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phase of the project using Stirling solar power systems. CSP, once considered the preferred solarpower technology in sunny Southern California and other desert areas, is becoming increasinglysqueezed out of that position to cheaper PV solar. As Stirling lost these primary customercontracts, without additional future projects on tap, coupled with difficult capital financing andcheaper solar alternatives, there was little for Stirling to do other than to file for Chapter 7

bankruptcy.

This bankruptcy filing is one of the latest in a series of U.S. solar company bankruptcies, as softglobal demand for solar power, falling prices and a glut of solar panels from Asia have severelyaffected domestic manufacturers. First and foremost, California solar-panel makerSolyndraInc.filed for bankruptcy after receiving over $500 million in U.S.government loansassociated withtheStimulusor Recovery Act program. In August, Massachusetts-based Evergreen Solar Inc.also filed for bankruptcy. These two companies had similar business models, which were basedon less mainstream technologies whose competitiveness depended on the use of lesspolycrystalline silicon, the main material for the majority of solar panels on the market. Aspolysilicon priceshave fallen dramatically in the last three years, which was formerly an issue

for market adoption, there was less advantage and demand for these products.

On top of that, an Intel spin-off company formed in 2008, SpectraWatt, which had facilities inNew York and Oregon, filed in August for Chapter 11 bankruptcy after raising over $90 millionin private investment and receiving state aid in New York.

All of this spells more negative sentiment for U.S. solar manufacturing competitiveness globallyand especially in theclean energy raceversusChina,which is increasing its dominant marketshare in this sector. In addition, there is superior government support forsolar manufacturing inChinaincluding loans at very low rates from state-owned banks in Beijing and cheap or free landfrom local and provincial governments that are set to capitalize on low labor manufacturing cost

advantages. The U.S. lacks a comprehensive clean energy policy that includes both on-goingsupport for domestic research and development, manufacturing, and deployment, since the U.S.Congress was unable to pass related legislation in 2009 including carboncap-and-tradepoliciesandmanufacturing tax breaks.Moreover, global energy demand has lessened in recent years dueto global economic declines causing a shakeout of weaker clean energy market players.

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Are Stirling Energy, Tessera Solar in

Trouble?
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Executives scatter and layoffs occur at sister companies promoting Stirling

engines to produce power.

Michael Kanellos

December 7, 2010

Days after getting an administrative reprieve for a massive solar project, things aren't looking sohot for Stirling Energy Systems and its development partner, Tessera Solar.

Steve Cowman, who was the CEO at SES until recently, has left the company, as have a numberof other executives. Meanwhile, Tessera laid off between 50% to 80% of its employees lastmonth, according to sources. Rumors began percolating about problems at the companies, whichwork together and are part of an Irish conglomerate called NTR, last month. Sources close to thecompany have now confirmed Cowman's departure and the layoffs, but not the number of

layoffs.

Tessera and SES want to build massive solar thermal parks in the Southwest based around theSunCatcher, a mirrored dish that directs hot air toward a Stirling engine to produce power. Anindividual SunCatcher can generate up to 25 kilowatts of power.In October,the Department ofthe Interior approved two projects proposed by SES and Tessera: the 709-megawattImperialValley projectand the 663-megawatt Calico project. California regulators approved Calico (afterfirst rejecting it) on December 1.

Unfortunately, the companies also need money. Brett Prior at GTM Research estimated inOctober that the companies would need to raise $200 million in equity and $160 million in debt

and qualify for federal conditional loan guarantees before the end of the year in order to qualifyfor U.S. Treasury grants that will cover a substantial part of the construction on Calico alone.The deadline for the grants is the end of the year and the equity, debt and loans will be needed tostart construction or buy equipment for it, necessary preludes to the Treasury grants. In all,Calico might cost $2 billion or more.

The layoffs and executive departures (Cowman was not the founding CEO, by the way: he gotthe job in 2008) could be a hint that the fundraising process is not going as planned.
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We dont discuss individual staff-related actions. I can confirm, however, that as we transitionout of the active development stage now that the California projects have been approved, weverecently restructured the businesses to manage expenditures, said an official spokesperson forTessera.

The bright side could be the projects themselves. Conceivably, SES and Tessera could sell theirprojects to other solar developers with different solar technologies and money in hand if SES andTessera can't get loans and funding. Stay tuned.

Rival Brightsource Energy, which relies on a very different technology known as power tower,received administrative approvals around the same time, but it also has received a conditionalloan guarantee on its Ivanpah project and started work. NRG Energy also agreed recently toinvest $300 million into Ivanpah.

Beyond the usual headaches surrounding raising millions of dollars in a short period of time,SES and Tessera face perhaps an even bigger hurdle. Solar thermal plants aren't as attractive as

they were in 2007. Back then, solar thermal was the technology of choice for big solar parks.Declining prices of silicon and silicon solar panels, however, have caused developers andutilities to switch over to building these with PV panels.

In 2010, the price to build a solar thermal park run by troughs, power towers or dish engines runsbetween $5.00 and $6.55 per watt. On the other hand, utility-scale PV projects can squeakthrough at less than $3.50 per watt, as we noted in anarticle in October.One of the big symbolsof this shift came when First Solar, the big PV maker, took over a project from thermal specialistAusra in 2009 and turned it into a PV project.

By 2020, the thermal solutions are expected to be in the $2.40 to $3.80 per watt range, but by

that time, PV plants could be below $2 a watt. Trough and tower plants could conceivably catchup and beat PV in price on large-scale projects, but it would be tough.

Solar PV parks are also modular: developers can build 10 megawatt parks, or scale them up to250 megawatts. Solar thermal parks are larger, and thus come with more logistical headaches.

To top it off, unlike troughs or power towers, Stirling engines do not have inherent capabilitiesfor storing heat to make power after the sun goes down. (The other technologies transfer heat vialiquids; Stirlings use air hydrogen.) While some utilities are opting not to put storage capabilitiesinto their solar thermal parks at the moment, it remains one of the more attractive features ofsolar thermal. Stirling engines also have more fast-moving parts, which can break down morereadily.

SunCatcher |CSP Electricity Generation Technology

Developed Here |Manufactured Here

Prototype systems of the SunCatcher sysbeen operating for more than two decades. Dtime, the critical elements of the system, the
http://www.greentechmedia.com/articles/read/is-CSP-doomed/http://www.greentechmedia.com/articles/read/is-CSP-doomed/http://www.greentechmedia.com/articles/read/is-CSP-doomed/http://www.greentechmedia.com/articles/read/is-CSP-doomed/


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Harnessing the suns energy affordably, without consuminglimited water resources requires a revolutionary solution.The SunCatcher solar dish Stirling system is truly thatnext generation CSP technology and represents a utility-scale deployable solar energy solution on a global basis.

The SunCatcher is a proprietary solar-to-grid-qualityelectricity generation technology. It is a 25-kilowatt-electric(kWe) solar dish Stirling system that is designed toautomatically track the sun so as to collect and focus solarenergy on to a power conversion unit (PCU), whichgenerates electricity. The system consists of a solarconcentrator in a dish structure that supports an array ofcurved glass mirror facets. These mirrors collect andconcentrate solar energy into grid-quality electricity. Theconversion process in the PCU involves a closed-loop, high-efficiency four-cylinder reciprocating Solar Stirling Engine,

using an internal working fluid that is recycled through theengine. The PCU solar receiver is an external heat exchangerthat absorbs the incoming solar thermal energy. This heatsand pressurizes the internal working fluid in the heatexchanger tubing and this pressurized gas in turn powers theSolar Stirling Engine.

Todays SES SunCatcher is the resultof over a decade of

well as the dish concentrator have been comredesigned for greater efficiency and perforso that it can be easily manufactured using manufacturing methods. It has recorded on hundreds of thousands of hours of on-sun te

sub-systems, including complete system onat Sandia National Laboratories in AlbuqueMexico and Maricopa Solar in Peoria, Ariz

SunCatcher Highlights

World record for highestefficiency conversion of solarenergy into grid electricity

Lower costbest fit solar solution

Only water needed by theSunCatcher is to wash itsmirrors!

Scalable technology


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innovative engineering and validation testing, with hundredsof thousands of hours of on-sun testing on each major sub-system, and on-sun testing for the complete system.

The SunCatcher Electric Power System

The SunCatcher is a rare combination of breakthrough engineering and proven technology that can delin even the most demanding environments. The SunCatcher generates 55,000 - 60,000 kWh of utility-quality electricity per year by concentrating the suns energy by a factor of 1,100 times and holds the wofor highest sun-to-grid solar efficiency, converting it into clean, renewable power. The SunCatcher is menough to deliver todays grid quality electricity at 1.5MW and scale easily to 1000MW, as needed to metomorrows growing power needs.

SunCatcher Technology |

How It Works

The SunCatcher is a 25-kilowatt-electrical (kWe) solar dish Stirlingsystem designed to automatically track the sun and collect and focussolar energy onto a PCU, which generates electricity. The systemconsists of a solar concentrator in a dish structure that supports an arrayof curved glass mirror facets. These mirrors collect and concentratesolar energy onto the solar receiver of the Power Conversion Unit(PCU).

Power Conversion Unit (PCU)

The PCU converts the focused solar thermal energy into grid-qualityelectricity. The conversion process in the PCU involves a closed-cycle,high-efficiency four-cylinder, reciprocating Solar Stirling Engineutilizing an internal working fluid that is recycled through the engine.The Solar Stirling Engine operates with heat input from the sun that isfocusedby the SunCatchers dish assembly mirrors onto the PCUssolar receiver tubes which contain hydrogen gas. The PCU solar

receiver is an external heat exchanger that absorbs the incoming solarthermal energy. This heats and pressurizes the gas in the heat exchangertubing, and this gas in turn powers the Solar Stirling Engine.

A generator is connected to the Solar Stirling Engine; this generatorproduces the grid-quality electrical output of the SunCatcher. Waste


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heat from the engine is transferred to the ambient air via a radiatorsystem similar to those used in automobiles. The gas is cooled by aradiator system and is continually recycled within the engine during thepower cycle. The conversion process does not consume water, as isrequired by most thermal-powered generating systems.

Parabolic Dish Design

The SunCatcher uses an innovative radial design for the concentrating mirrors. At sunrise, each SunCaautomatically rotates to face the sun. Through sophisticated automation software, the SunCatcher will collect, and focus the suns energy onto a single point, the Power Conversion Unit.

Power Projects

Maricopa Solar | Maricopa County, Arizona (Near Phoenix) | Salt River Project (SRP)1.5MW | Total of 60 SunCatcher Power Systems.Operating since January 2010.


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SunCatcher |CSP Electricity Generation Technology

Harnessing the suns energy affordably, without consuminglimited water resources requires a revolutionary solution.The SunCatcher solar dish Stirling system is truly thatnext generation CSP technology and represents a utility-scale deployable solar energy solution on a global basis.

The SunCatcher is a proprietary solar-to-grid-qualityelectricity generation technology. It is a 25-kilowatt-electric

(kWe) solar dish Stirling system that is designed toautomatically track the sun so as to collect and focus solarenergy on to a power conversion unit (PCU), whichgenerates electricity. The system consists of a solarconcentrator in a dish structure that supports an array ofcurved glass mirror facets. These mirrors collect andconcentrate solar energy into grid-quality electricity. Theconversion process in the PCU involves a closed-loop, high-

Developed Here |Manufactured Here

Prototype systems of the SunCatcher systbeen operating for more than two decades. Dtime, the critical elements of the system, thewell as the dish concentrator have been comredesigned for greater efficiency and perforso that it can be easily manufactured using manufacturing methods. It has recorded on

hundreds of thousands of hours of on-sun tesub-systems, including complete system onat Sandia National Laboratories in AlbuqueMexico and Maricopa Solar in Peoria, Ariz

SunCatcher Highlights

World record for highestefficiency conversion of solar

energy into grid electricity

Lower costbest fit solar solution

Only water needed by theSunCatcher is to wash itsmirrors!

Scalable technology


15/17

efficiency four-cylinder reciprocating Solar Stirling Engine,using an internal working fluid that is recycled through theengine. The PCU solar receiver is an external heat exchangerthat absorbs the incoming solar thermal energy. This heatsand pressurizes the internal working fluid in the heat

exchanger tubing and this pressurized gas in turn powers theSolar Stirling Engine.

Todays SES SunCatcher is the result of over a decade ofinnovative engineering and validation testing, with hundredsof thousands of hours of on-sun testing on each major sub-system, and on-sun testing for the complete system.

The SunCatcher Electric Power System

The SunCatcher is a rare combination of breakthrough engineering and proven technology that can del

in even the most demanding environments. The SunCatcher generates 55,000 - 60,000 kWh of utility-quality electricity per year by concentrating the suns energy by a factor of 1,100 times and holds the wofor highest sun-to-grid solar efficiency, converting it into clean, renewable power. The SunCatcher is menough to deliver todays grid quality electricity at 1.5MW and scale easily to 1000MW, as needed to mtomorrows growing power needs.

Public-Private Partnerships | 30 Years of Collaboration

In 1978, engineers at Ford Motor Company began developing designs of a solar-powered Stirling enginethe years, companies like McDonnell-Douglas, Lockheed Martin and Boeing all worked to improve on thtechnology and design. In 1996, SES, our sister company, based in Scottsdale, Arizona USA, was formethis technology and has worked in a cooperative public-private partnership relationship with Sandia NatiLaboratories and US Department of Energy, to bring the SunCatcher to market. Following the NTR $1investment in May 2008, the design and technology has been further optimized and perfected and readiedcost, high-volume production and deployment.


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Optimized for Performance, Modularity & Cost

The SunCatcher is the most efficient solar to grid quality electric system. The power conversion proceno water, as is required by other solar thermal generating platforms. The only water consumed by the Suis for washing the mirrors. Several SunCatchers constitute a single power plant, making projects modu

scalable. During the construction phase, installed units will start producing power while the remainder ofis completed. Maintenance will be undertaken on individual units while the vast majority of the units remthe result is high overall availability.

The high-volume manufacturing production model provides the following competitive advantage:

SOLAR COST LEADERLow Cost Solar Power Solution.

HIGHEST SOLAR-TO-GRID ELECTRIC EFFICIENCYRecord-setting 31.25% Sun-to-Grid Electricity Conversion.

LOWEST WATER USEA Fraction vs Competition. Critical Cost, Siting and Regulatory Advantages.

MODULAR DESIGNFlexible plant sizes from 25MW to 1,000MW+.

PRODUCTION READYLow-Cost Production.

MINIMAL LAND DISTURBANCEUp to 10 % Slope Tolerance. No Excavation. Minimal Grading. Limited Roads.

PROVEN ENGINE TECHNOLOGYUnrivaled Testing & Validation

HIGHEST ON-SUN AVAILABILITYBuilt in redundancy with modular design, therefore no single point of failure.

NO FUEL PRICE VOLATILITYEconomic Stability.


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PEAK POWER OUTPUT

Predictable Power Production When Needed Most.

stirling energy by solar

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