Search NASA⌕ Search

SEARCH · Search NASA

Results for “PCM energy storage”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Evaluation of Phase Change Plaster/Paste Composites for Building Envelopes

Thermal energy storage (TES) materials increase a building’s thermal mass and provide the flexibility to shave and time-shift energy use. These materials are needed to enable grid-interactive efficient buildings, allowing building occupants to lower costs by leveraging free ambient heating/cooling as well as shifting consumption to cheaper electricity periods. Phase change materials (PCMs) that store heat through a solid-liquid/solid-solid transformation are of particular interest for TES because of their ability to store large amounts of energy across a constant temperature or very small temperature range. Furthermore, previous studies on PCM building envelopes evaluated products that may only be incorporated as part of new construction and are not easily applicable to existing, energy-intensive buildings. In this work, we leverage laboratory PCM characterization and whole-building energy simulation to study the energy and cost savings of PCM plaster/paste coatings, which can be applied post construction to both new builds and retrofits of existing buildings (about 40% of residential buildings in the United States fall into the retrofit category). We evaluated the energy impact of PCM plaster/paste composites for a single-family residential building in the United States, including layer design (location and thickness), composite properties (phase change temperature, energy density, and shape of the enthalpy curve), and U.S. climate zone. The enthalpy curve shape of PCM shows that phase change temperature and energy density are not the only two parameters that must be considered for PCM selection. Maximizing the energy density amid the effective TES zone is key to boosting energy savings. We also studied PCM price targets with the aim of achieving reasonable payback periods based on both block and time-of-use electricity rates. Moreover, we developed an empirical equation to provide a rough estimate of the energy savings potential of incorporating PCM without the need to perform detailed simulations. These results will help guide the selection and design of PCM plaster/paste composite elements for residential building envelopes.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
DOE OSTI2022

Micro-Environmental Control System (Final Report)

This project developed an innovative micro-environmental control system (µX) that enables office buildings to reduce energy used for heating and cooling by 15% or more. The µX is a compact, quiet, and ergonomic device that is designed to be installed under an office workstation; it is designed to maintain occupant comfort when room thermostat setpoints are incremented by 4°F or more (warmer in the summer and cooler in the winter) to save energy. When ambient room temperatures are outside of the usual comfort range, the µX maintains occupant comfort by delivering personalized cooling or heating locally to each office worker. The µX provides personalized cooling using a micro vapor compression system that includes a new high-performance micro-scroll compressor and a novel thermal storage unit. The vapor compression system operates at night to freeze a phase-change material (PCM). During the workday, the cooling stored in the PCM is released as a cool breeze of air to make occupants more comfortable. The micro-scroll compressor was developed specifically for this application; it is smaller than any of its type, minimizing the amount of power needed. In heating mode, the µX maintains occupant comfort using a foot heating mat with an infrared reflective box. The µX R&D project was conducted by Syracuse University in collaboration with United Technologies Research Center, Air Innovations, Bush Technical, and Cornell University. Over the course of the initial three-year project, the team developed and evaluated four versions of the unit, advancing the concept to Technology Readiness Level 6. The capabilities of individual proof-of-concept prototypes were verified in tests that were conducted with: 1) units in psychrometric chambers, 2) an instrumented manikin in a laboratory, and 3) human subjects in laboratories that simulate office environments. The tests verified that the µX prototypes met or exceeded all performance targets required to enable office buildings to reduce energy used for heating and cooling by 15% or more by maintaining occupant comfort when thermostat setpoints are incremented by 4°F or more.

25 ENERGY STORAGE↗
DOE OSTI2026

Radiative Cooling Paints: Application on Warehouses and Integration with Phase Change Materials

Despite extensive research on radiative cooling (RC), researchers are still working to understand its best implementation strategy and potential benefits. Understanding this could be an instrumental part of reducing building energy costs and combating climate change. In this work, we introduce two concepts to achieve this goal and broaden the application of RC paints. While building energy simulations for RC are common, most studies focus on single-layer paints in residential settings. Limited research exists on warehouses, and no literature has conducted multi-climate zone analyses or included RC technologies with >90% reflectance. As RC technology advances in efficiency, versatility, and affordability, large-scale simulations across diverse climates are crucial, particularly for warehouses as a passive indoor temperature control solution. Here, a TRNSYS-modeled single-story warehouse assesses the energy impact of BaSO4-based RC paints. Another under-explored RC application is its integration with phase change materials (PCMs), which provide thermal regulation via latent heat storage. Though RC and PCMs have been combined by placing PCMs atop, beneath, or within RC layers, studies focus on either experiments or modeling, with no validation between the two. Here, we develop a simple RC+PCM experimental and modeling setup, placing RC paint atop an aluminum cell filled with a Rubitherm PCM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Nature-inspired lotus-shaped fins combined with hybrid nanoparticles and metal foam for high-performance latent heat thermal energy storage

Latent heat thermal energy storage (LHTES) systems play a critical role in renewable energy integration by providing high energy density and nearly isothermal operation during phase transitions. However, their performance is often limited by slow melting/charging rates, which motivates the search for enhanced heat transfer designs. This study investigates the melting behavior of RT-82 phase change material (PCM) using novel lotus-shaped fins combined with copper metal foam and conductive graphene nanoparticles and carbon nanotubes. A two-dimensional enthalpy-porosity model in ANSYS Fluent was developed to simulate the charging/melting process, capturing non-thermal equilibrium between the foam and PCM/nano-PCM. In this study, effects of fin geometry, nanoparticle concentration, and foam porosity on melting dynamics and cost-performance trade-offs were investigated. Results showed that natural convection accelerated melting by ~12% compared to conduction-only scenarios. Optimized lotus-shaped fins with higher fin density (T3F4 and T3F10) achieved up to 63% faster melting relative to sparse configurations. Graphene nanoparticles improved thermal conductivity, with a 6% volume fraction, by reducing melting time by ~6.9%, while their combination with 75% porosity foam achieved a maximum reduction in the melting time of ~51% compared to pure PCM. Cost-performance analysis identified T3F4 as the most balanced design, offering rapid thermal response without excessive material costs, while moderate-density designs like T3S6 provided economical alternatives with acceptable performance. These results highlight the performance enhancement that can be achieved by integrating bio-inspired fins, nanoparticles, and foams, into compact and efficient LHTES for solar heating, building thermal management, and industrial waste-heat recovery applications.

25 ENERGY STORAGE↗
DOE OSTI2021

Thermal management of a high temperature sodium sulphur battery stack

The sodium sulfur battery is an advanced secondary battery with high potential for grid-level storage due to their high energy density, low cost of the reactants, and high open-circuit voltage. However, as the operating temperature of the battery is high (about 300 °C), effective thermal management is required to prevent thermal runaway under high current density operation. Here, to develop efficient thermal management strategies, a detailed, thermo-electrochemical, non-isothermal, distributed dynamic model of a sodium-sulfur battery stack is developed. Models of three thermal management strategies are developed and analyzed in this work: active cooling, passive cooling, and hybrid cooling. The active cooling strategy uses air as the cooling medium whereas, the passive cooling strategy uses a phase change material. In the hybrid cooling strategy, both active and passive cooling strategies are used. Due to the high operating temperature of the sodium sulfur batteries, the rejected heat can be utilized effectively and consequently a high variability in the heat rejection rate may not be acceptable. Performance of these strategies is analyzed under high current density operation by evaluating the variability in the cell temperature during charge/discharge cycles, temperature difference between the cells based on their locations, and variability in the heat rejection rate. The phase change-based hybrid thermal management strategy with an embedded controller maintained the temperature variation within ±/- 2.8 °C. Considering the tradeoff between the capital cost for PCM, fan power requirement, and variability in the heat rejection rate, the optimal quantity of the PCM and the maximum air velocity for the maximum current density of 260 mA/cm 2 (0.55 C-rate) were found be 0.74 g/Wh and 3 m/s, respectively.

25 ENERGY STORAGE↗
DOE OSTI2022

Experimental and numerical study on the impacts of various long carbon fiber inserts on the thermal performance of phase change materials

In thermal energy storage systems, phase change materials (PCMs) are widely used to provide efficient storing and extraction of thermal energy. However, most PCMs have low thermal conductivities, which limit the heat transfer of the latent energy inward/outward. In this study, the impacts of various fiber inserts on the solidification and melting processes with PCM were investigated by experiments and simulations. It was found that long anisotropic carbon fibers with high thermal conductivities can not only increase the heat transfer within PCM by enlarging hot-cold interface areas, but also act as crystallization nuclei and increase the solidification of PCM during the charging process. Recalescence of PCM during solidification was observed. COMSOL models were used to understand the thermal transfer mechanisms. COMSOL Multiphysics models of a single carbon fiber filament in PCM showed that the anisotropy in thermal conductivities controlled the radial and axial heat transfer ratios along its fiber axis and can enhance both the solidification and melting processes.

Zhou, Xinzhang↗
DOE OSTI2021

Parametric study of solid-solid translucent phase change materials in building windows

Thermal energy storage and solar radiation management are crucial to improve the sustainability and energy efficiency of buildings. Compared with the implementation of phase change materials (PCMs) in opaque components, the energy saving potential of incorporating PCMs in transparent glazing windows is much less studied and not well understood. Here we present a comprehensive parametric study of novel PCM windows for building energy saving with a focus on optimizing and quantitatively distinguishing the contributions from the optical and thermal properties of the PCM, which is particularly useful for the design of solid-solid PCM windows. We investigate a reference commercial office building using EnergyPlus by developing an equivalent model of our PCM window that is compatible with EnergyPlus's modeling capabilities. Compared with a clear-clear double-pane window, the integration of 3 mm solid-solid PCMs with optimal properties in warm, mixed, and cold climates can respectively save up to 17.2%, 14.0%, and 5.8% energy for the HVAC (heating, ventilation, and air conditioning) system, and 9.4%, 6.7%, and 3.2% energy for the whole building. We also demonstrate that these energy savings are most sensitive to the solar absorptance of PCMs for all three climates. The optimal transition temperature varies with climate and is related to the climate and solar radiation heat gain. Other issues are also briefly discussed, such as hysteresis, window orientations, and the effect of interior lighting. Finally, although the optimal PCM windows show energy saving performance comparable with low-emissivity windows, the PCM windows provide a unique advantage in terms of shifting HVAC loads which can provide benefits to the electrical grid.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Preliminary Design of Critical Experiments Involving Commercially Available B 4 C Neutron Absorber Plates with Low-Enriched UO 2 Fuel

The International Criticality Safety Benchmark Evaluation Project (ICSBEP) is an initiative to provide high-quality benchmark data in a standardized format for criticality safety analysts to use to validate calculational tools and nuclear data. In the last released 2022 version, the ICSBEP handbook contains over 5,000 critical experiment descriptions, results, and associated models. This paper describes the critical configurations proposed and calculations performed as part of the conceptual design phase of Integral Experiment Request (IER) 554 (IER-554). The goal of IER-554 is to add to the benchmark experiments available to the criticality safety community by designing critical experiments that can analyze how adding commercially available Boralcan plates to an assembly of low-enriched UO2 fuel rods affects the effective neutron multiplication factor (k eff ). Boralcan, a neutron absorber product developed by Rio Tinto, is made of B4C in an Al 1100 matrix and is commonly used for criticality suppression in fuel storage pools. In the current version of the ICSBEP handbook, only a few dated critical experiments involve B4C materials, and none involve Boralcan in a thin plate shape. The experiments designed as part of IER-554 are intended to be performed at the Sandia Pulsed Reactor Facility/Critical Experiments (SPRF/CX) apparatus at Sandia National Laboratories. SPRF/CX is a well-characterized assembly considered trustworthy by the benchmarking community because of the numerous high-quality evaluations with very low experimental uncertainties included in the ICSBEP handbook. Figure 1 illustrates the assembly for a particular configuration from LCT-078, one of the published benchmarks in the ICSBEP handbook. The experiments will be moderated and reflected by light water at ambient atmospheric pressure. Before the plates are inserted in the critical assembly, they will be characterized with x-ray computed tomography (XCT) to identify the sizes and distribution of the B 4 C powder particles inside the plates. The preliminary design calculations were performed with SCALE 6.3.0 using the KENO V.a sequence for the criticality calculations, the CE-TSUNAMI-3D sequence for the sensitivity and uncertainty studies, and the ENDF/B-VII.1 Continuous Energy cross section library. All the calculation results presented have 10 pcm statistical uncertainties. A set of critical experiments with Boralcan plates could increase the confidence of the criticality safety community in its modeling methods when using this type of neutron absorber material. Experiments would also help validate k eff calculations, and the industry could use these validations to change the B loading credit limits from the US Nuclear Regulatory Commission standard review plan for dry cask storage of spent nuclear fuel. This paper summarizes only part of the analysis documented in the preliminary design report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Chemically Stable Polyarylether-Based Metallophthalocyanine Frameworks with High Carrier Mobilities for Capacitive Energy Storage

Covalent organic frameworks (COFs) with efficient charge transport and exceptional chemical stability are emerging as an import class of semiconducting materials for opto-/electronic devices and energy-related applications. However, the limited synthetic chemistry to access such materials and the lack of mechanistic understanding of carrier mobility greatly hinder their practical applications. Herein, we report the synthesis of three chemically stable polyarylether-based metallophthalocyanine COFs (PAE-PcM, M = Cu, Ni, and Co) and facile in situ growth of their thin films on various substrates (i.e., SiO 2 /Si, ITO, quartz) under solvothermal conditions. We show that PAE-PcM COFs thin films with van der Waals layered structures exhibit p -type semiconducting properties with the intrinsic mobility up to ~19.4 cm 2 V -1 s -1 and 4 orders of magnitude of increase in conductivity for PAE-PcCu film (0.2 S m -1 ) after iodine doping. Density functional theory calculations reveal that the carrier transport in the framework is anisotropic, with the out-of-plane hole transport along columnar stacked phthalocyanine more favorable. Furthermore, PAE-PcCo shows the redox behavior maximumly contributes ~88.5% of its capacitance performance, giving rise to a high surface area normalized capacitance of ~19 μF cm -2 . Overall, this work not only offers fundamental understandings of electronic properties of polyarylether-based 2D COFs but also paves the way for their energy-related applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Preliminary Assessment for the Electric Load Shifting Potential of Integrating Thermal Energy Storage with Heat Pumps in Residential Buildings in Texas of United States

The widespread adoption of electric-driven heat pumps for heating and cooling is expected to significantly increase electric demand. Cooling electric demand will result in an increase in peak hours electric loads, placing additional strain on the grid during peak hours. This challenge, combined with the current rapidly increasing demand from data centers, exacerbates the electric demand duck curve problem. Integrating thermal energy storage (TES) with heat pump can shift electric use for heating and cooling from peak to off-peak hours of the electric grid, which can help flatten the daily electric demand profile of a building. This paper presents a novel design that integrates heat pump with TES (HP-TES), which uses phase change materials (PCM). Heat pump charges TES by melting or freezing PCM during off-peak hours when there is no thermal demand from the building. TES is then discharged (i.e., by freezing or melting PCM) during peak hours to provide a more favorable heat source or heat sink for the heat pump to meet the thermal demand of the building with lower electricity use than conventional air-source heat pumps. Computer simulations were developed to predict the performance of HP-TES applied to a typical single-family house in the US. The building-level simulation results were scaled up to preliminarily assess the aggregated impacts of deploying HP-TES across all single-family houses in Texas of the United States, including reduction of peak demand of the electric grid.

Anees, Fady [ORNL]↗
DOE OSTI2024

Predictive model using artificial neural network to design phase change material-based ocean thermal energy harvesting systems for powering uncrewed underwater vehicles

Uncrewed Underwater Vehicles (UUVs) are a major beneficiary of the phase change material (PCM)-based ocean thermal energy harvesting technology for their mission needs. However, this technology relies on different parameters and energy conversion steps that could be critical to the general energy generation efficiency. Sea trials showed that the design performed lower than their laboratory design specifications. This underperformance results from different factors, mainly the UUV’s trajectory, travel time, underwater ocean currents, temperature fluctuations, and biofouling on the heat exchanger due to long term underwater operations. Therefore, there exists a need to continuously monitor the ambient energy harvesting system and predict system performance, for mission planning purposes. Two major parameters influencing the energy harvesting system include the final pressure inside the hydraulic energy storage vessel or accumulator, and the electrical load value. Here, this work focuses on the hydraulic to electric energy conversion system. Therefore, a combination of numerical model and experimental testing is used to develop a predictive model using artificial neural network using MATLAB. After validation with experimental testing, 1000 data samples obtained from the numerical model are used to train the ANN. Compared to the experimental results, the developed ANN model can predict in less than a second the designed benchtop system’s total efficiency with less than 15 percent maximum error range. This predictive model development represents a cost-effective way for optimization and a computational energy efficient mode aboard UUVs for mission planning for deployed UUVs using PCM-based ocean thermal energy harvesting technology.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Advanced blade-shaped thermal energy storage device: Development and application

Thermal energy storage (TES) using phase change materials (PCMs) is a promising approach for capturing and reusing excess thermal energy, yet widespread adoption is limited by low thermal conductivity, bulky configurations, and inadequate scalability. Here, this study presents a modular, blade-shaped TES prototype designed to address these challenges. The device integrates a lightweight aluminum shell, an embedded serpentine coil for active or passive heat exchange, and a cost-effective corrugated metal mesh for enhanced PCM thermal conductivity. With thickness-to-length and thickness-to-width ratios of 0.03 and 0.08, respectively, the blade-shaped TES achieves a compact, modular form factor suitable for space-constrained applications. Experimental testing demonstrated the efficient charge and discharge behavior of blade-shaped TES, capturing PCM superheating, phase-change transitions, and subcooling dynamics, with charging and discharging efficiencies of 94.9% and 94.6%, respectively. Also, the system can potentially achieve higher energy density than that of conventional TES designs. When integrated into a household refrigerator during the study, three blade-shaped TES modules successfully shifted 100% of peak-time compressor operation to off-peak hours, reducing energy consumption while maintaining more stable compartment temperatures. The blade-shaped TES's thin geometry, modularity, and enhanced thermal performance support scalable deployment across residential, commercial, and industrial applications, providing a versatile, cost-effective solution for high-efficiency, demand-flexible thermal energy management.

Blade-shaped↗
DOE OSTI2024

Recharge Demand Mitigation for Latent Heat Thermal Energy Storage at Off-peak Hours

The utilization of integrated heat pump thermal energy storage (HP-TES) systems for space conditioning applications can reduce electrical power demand and achieve utility savings resulting from peak shaving and load shifting. However, issues arise when the energy required to recharge the TES exceeds the shifted energy demand, especially in extreme climates where high-temperature lifts between the outdoor air conditions and phase-change materials (PCMs) during recharging may occur. In this work, a single room-temperature (22°C) PCM-TES is integrated into a single-speed heat pump system using a secondary hydronic loop where the TES is recharged using the outdoor unit during off-peak hours. Three recharge strategies were investigated as potential pathways to reduce recharging power demand: (i) considering different heat source/sink temperatures, (ii) using a variable-speed compressor, and (iii) using a variable-speed pump. Simulations were conducted using Modelica for HP-TES recharging at different heat source/sink temperatures from -30 – 20℃ in heating mode and 0 – 30℃ in cooling mode. Results show that the most effective recharge demand reduction strategy is an HP-TES system using a single-speed compressor with a variable-speed pump for the hydronic loop run at preferable heat source/sink temperatures when the temperature lifts were reduced. Utilizing a variable-speed compressor for the HP-TES system reduced recharge time in extreme cases at the cost of additional compressor power input. The findings motivate potential control strategies that minimize recharge energy and maximize peak energy savings, hence reducing overall operating costs and annual energy consumption for HP-TES systems for space conditioning applications.

25 ENERGY STORAGE↗
DOE OSTI2023

Multiscale Electricity Modeling for Evaluating Carbon Capture and Sequestration Technologies (Final Report)

Carbon capture and sequestration (CCS) technologies that can operate with a high degree of operating flexibility could provide necessary electric grid flexibility in a system with high shares of variable renewables. This project examines the deployment and dispatch potential of twelve unique flexible CCS (FLECCS) technologies that encompass post-combustion carbon dioxide (CO 2 ) capture designs, concepts using a storage media to enable energy arbitrage, and hybrid processes that integrate CCS with direct air capture (DAC) for flexibility with net zero or negative CO 2 emissions. FLECCS technology potential is explored with a multi-model, multi-scale framework including the Regional Energy Deployment System (ReEDS) electric sector capacity expansion model (CEM) and the PLEXOS production cost model (PCM). Innovative methods were developed to represent FLECCS technology operating modes, performance, and cost in the two models. ReEDS was then used to simulate nine scenarios for each FLECCS technology, three CO 2 emissions price futures reaching $\$$150, $\$$225, and $\$$300/tCO 2 in 2050; and three scenarios for FLECCS technology deployment favorability relative to competing technologies. For each CO 2 price and reference FLECCS favorability, the 2050 infrastructures from ReEDS model are downscaled and implemented in PLEXOS to examine hourly dispatch under detailed operational constraints that are not included in ReEDS. FLECCS technologies exhibited a wide range of deployment potential ranging from none to several hundred gigawatts of capacity, with outcomes highly sensitive to input cost and performance parameters that are inherently highly uncertain. When deployed, FLECCS tended to displace a combination of wind, solar, and natural gas-based technologies rather than supporting increased renewable deployment. As a result, CO 2 emissions reductions facilitated by FLECCS deployment tended to come with higher overall system costs and electricity prices. When economically competitive, FLECCS technologies can contribute significant flexible generation and firm capacity to the grid, but continued technology development and an expanded analytical scope are necessary to fully understand FLECCS deployment potential its impact on the electric power sector. Follow-on analysis incorporating captured CO 2 tax credit value from the Inflation Reduction Act (IRA) and other potential policy scenarios could be particularly valuable, as this policy can substantially change the relative competitiveness of FLECCS technologies.

03 NATURAL GAS↗
DOE OSTI2021

A Study on Computational Cost Reduction of Simulations of Phase-Change Material (PCM) Embedded Heat Exchangers

Thermal storage can be implemented using Phase-Change Materials (PCM), which absorb significant latent heat with a relatively small temperature change. PCM phase-change processes are transient and are driven by thermal diffusion and natural convection – the latter, especially for melting process. Modeling and simulation of PCM heat exchangers (HX’s) is typically computationally intensive due to the relatively complex time-dependent physics. Most of the PCM modeling work in the literature uses high-order modeling tools such as Computational Fluid Dynamics (CFD) and Lattice-Boltzmann Method (LBM). For design purposes, the existing PCM modeling approaches are not practical, limiting researchers in their ability to investigate new ideas and different PCM’s with faster turnarounds. This paper presents a study investigating the reduction of computational cost of PCM embedded HX’s CFD models by evaluating the feasibility of spatial reduction without losing accuracy. The analysis consists of comparing full and partial domain under full melting conditions. The subject of this study is a single straight tube with circular transverse fins in the vertical orientation, using PCM’s with 35oC nominal melting temperature. Different tube and fin dimensions are investigated. Results indicate that the reduced domain reproduces - in half the run time - the same behavior as the full domain since the buoyancy effects are localized and patterned. The outputs from the partial domain simulation were used to build a non-general correlation for the PCM heat transfer characteristics and demonstrated how it can be implemented in a Finite Control Volume Reduced Order Model (ROM). The ROM can accurately reproduce the CFD simulations at 4 to 5 orders of magnitude faster.

25 ENERGY STORAGE↗
DOE OSTI2021

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗
DOE OSTI2020

Ceramic encapsulated metal phase change material for high temperature thermal energy storage

Thermal energy storage (TES) is a broad-based technology for reducing CO₂ emissions and advancing concentrating solar, fossil, and nuclear power through improvements in efficiency and economics. Phase change materials (PCMs) are of interest as TES media because of their ability to store large amounts of heat in relatively small volumes. The volume expansion during a phase change, typically between a solid and liquid, can cause breakage of protective coatings. This paper reports on the fabrication of a ceramic encapsulated metal (CEM) high temperature TES technology using a rotary calcining furnace and a fluidized bed chemical vapor deposition coating technique. Aluminum beads were chosen as the PCM because Al has a high melting point (660 °C), low cost, high heat of fusion, and an ability to form a thin, strong alumina layer capable of supporting the Al melt for subsequent processing. Quite remarkably, this study shows that 1 mm diameter Al can be fluidized up to at least 1500 °C in an appropriate atmosphere while maintaining a spheroid geometry. This allowed for producing a first of a kind CEM whereby Al particles were encapsulated in pyro-carbon (PyC) and high purity, dense chemical vapor deposited SiC. The CEM with a PyC only coating was exposed to thermal cycling to test the performance with a differential scanning calorimeter; the melting point and latent heat were measured to be 648.4 ± 2.8 °C and 293.3 ± 6.2 J/g respectively. It was demonstrated that the CEM design is possible to produce, laying the foundation for manufacturing of high temperature, tunable, TES media.

25 ENERGY STORAGE↗
NASA NTRS1980

Active heat exchange system development for latent heat thermal energy storage

Five tasks to select, design, fabricate, test and evaluate candidate active heat exchanger modules for future applications to solar and conventional utility power plants were discussed. Alternative mechanizations of active heat exchange concepts were analyzed for use with heat of fusion phase change materials (PCMs) in the temperature range of 250 to 350 C. Twenty-six heat exchange concepts were reviewed, and eight were selected for detailed assessment. Two candidates were selected for small-scale experimentation: a coated tube and shell heat exchanger and a direct contact reflux boiler. A dilute eutectic mixture of sodium nitrate and sodium hydroxide was selected as the PCM from over 50 candidate inorganic salt mixtures. Based on a salt screening process, eight major component salts were selected initially for further evaluation. The most attractive major components in the temperature range of 250 to 350 C appeared to be NaNO3, NaNO2, and NaOH. Sketches of the two active heat exchange concepts selected for test are given.

Lefrois, R. T.↗