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DOE OSTI2021

Energy-efficient sorption-based gas clothes dryer systems

Standard electric resistance and fuel-driven dehydration technologies exhibit a maximum coefficient of performance of well below 1 mainly due to enthalpy losses associated with the air leaving the dehydration system. To improve energy efficiency, condensing dryer systems condense the moisture captured from a product in a closed-loop air circulation cycle. Existing condensing dehydration systems including heat pump dryers, however, need to significantly cool the air to achieve dehumidification. The added cooling and subsequent heating to return the air to a desired drying temperature consume substantial energy and thus reduce drying performance. Here, an innovative sorption-based gas dehydration system is proposed to overcome barriers deteriorating energy efficiency in existing gas, electric, or heat pump dryer systems. Decoupling latent and sensible loads, the system employs a liquid-desiccant solution to directly capture air humidity, thereby allowing circulation of the air in a closed loop to achieve high drying energy efficiency. In other words, the system captures waste latent heat from the moisture produced during the dehydration process and reuses it to improve energy efficiency. This study focuses on a comprehensive quasi-steady-state thermodynamic modeling of the proposed sorption-based dehydration concept employed for a gas clothes dryer application to predict transient response and overall drying performance (i.e., time and energy metrics). The analysis indicates the proposed sorption-based gas clothes dryer system can deliver a specific moisture extraction rate of 1.71 kg of water per kWh (i.e., a combined energy factor of 3.167 kg (6.98 lbm) of dry cloth per kWh) with a drying time of 44 min. This is a 112% energy improvement compared with state-of-the-art gas clothes dryers exhibiting a combined energy factor of 1.50 kg (3.3 lbm) of dry cloth per kWh. The technology pursued here can potentially be employed as a platform for many fuel-driven equipment to take advantage of available waste thermal energy in the environment instead of simply burning a fuel.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

On the validity and limitations of 1D model for heat and mass transfer performance evaluation in a multilayer binder-free desiccant dehumidifier: isothermal dehumidification with internal cooling

Efficient humidity control is essential for maintaining indoor thermal comfort, yet conventional vapor-compression-based dehumidifiers are energy-intensive. Employing separate sensible and latent cooling through desiccant-coated heat exchangers (DCHEs) combined with evaporative coolers offers energy savings of up to 80 % compared to conventional systems. However, the dehumidification performance of DCHEs remains limited due to the use of polymer binders for coating desiccant materials onto heat exchange surfaces. In our previous study, we developed a multilayer fixed-bed binder-free desiccant dehumidifier (MFBDD) that demonstrated high dehumidification capacity and low pressure drop compared to rotary desiccant wheels. Nevertheless, its potential for further enhancement through internal cooling and the use of step-shaped adsorption isotherms has not been explored. In this study, a physics-based one-dimensional (1D) transient model is developed and validated to capture the coupled heat and mass transfer processes in the MFBDD and extended to simulate internal cooling using a high-capacity composite metal–organic framework, MIL-101/GO-6 (water uptake ≈1.6 g/g within 35–47 % RH). The model enables detailed analysis of local air and bed temperature dynamics and quantifies how internal cooling affects the dehumidification performance under a wide range of operating conditions. Results show that integrating internal cooling and using MIL-101/GO-6 enhance mass adsorbed, moisture removal capacity, and dehumidification effectiveness by 50 %–99 % compared with the M.S. Gel baseline. The study further reveals that achieving near-isothermal operation requires simultaneous enhancement of the convective heat transfer coefficient and heat exchange surface area. In conclusion, this work provides the first detailed physical insight into the interplay between internal cooling and step-shaped isotherms in a binder-free desiccant device and establishes a validated modeling framework for scaling up and system-level performance evaluation of next-generation energy-efficient dehumidification systems.

Heat and mass transfer↗

DOE OSTI2022

Review of liquid desiccant air dehumidification systems coupled with heat pump: System configurations, component design, and performance

Vapor Compression Systems (VCS) are the most common air conditioning technology. VCS cool the air to its dew point temperature (overcooling) to remove water vapor in the air through condensation and then reheats the air back to the comfort temperature for direct use. The VCS process is inefficient due to overcooling and reheating. Liquid Desiccant Dehumidification (LDD) is a potentially energy-efficient air conditioning. LDD removes water vapor in the process air using liquid desiccant’s high-water affinity. It hybrids with sensible cooling to control temperature and humidity separately. The LD in the LDD becomes weak after dehumidification. The LDD needs additional heating to regenerate the weak Liquid Desiccant (LD) to a high concentration for dehumidification. Earlier versions of the LDD systems use highly concentrated liquid desiccant (large water removal capability) to dehumidify the air by only dealing with latent load. It leads to highly elevated temperatures above 60 °C of heat sources (combustion or electric resistance-based heating) for regeneration. The energy needed for the elevated temperature heat resource significantly reduces or demolishes the benefit of LDD systems. In the recent two decades, researchers have investigated a new configured LDD system that couples an LDD with a heat pump at both dehumidification and regeneration sides for better efficiency. The heat pump provides cooling (from the evaporator) for both dehumidification and sensible cooling and simultaneous heating from the condenser for regeneration. The highly integrated system (HP-LDD) with improved efficiency enables the LDD to operate at lower concentrations and temperatures in dehumidification and regeneration. This paper depicts the working principle behind HP-LDD and its heating and cooling requirements. It reviews the comparison between the HP-LDD systems and the conventional LDD systems regarding system configurations, component design, energy efficiency, and dehumidification performance characteristics. The main findings from the review include the preferred use of packed bed over membrane-based dehumidifiers, the use of internally cooled dehumidifiers enabled by the HP cooling capacity, the high dispersion of HP operation conditions, and the dependence of dehumidification performance on various dehumidifiers. Finally, an outlook for future research on HP-LDD strategies is presented based on the reviewed works and their limitations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Next-Generation Desiccant-Based Gas Clothes Dryer Systems

The goal of the project is to develop an advanced gas clothes dryer system demonstrating significant improvements in fuel efficiency and drying performance compared to current gas clothes dryer technologies. The new system decouples latent and sensible loads to effectively utilize the latent heat associated with laundry moisture as an advantageous energy source. In other words, the system captures the waste latent heat from moisture produced during the fabric-drying process and reuses it to improve drying efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Geothermal-integrated thermally anisotropic building envelope for energy and peak-demand reduction

Buildings consume large amounts of energy for heating and cooling, while peak electricity demand places significant stress on the power grid. This paper presents a reduced-order co-simulation framework and load-oriented supervisory control strategy for a geothermal-integrated thermally anisotropic building envelope with a ground loop (TABE+GL). In TABE+GL, a hydronic loop embedded in the building envelope is directly coupled with a geothermal ground loop, allowing for bidirectional heat exchange between the envelope, the ground, and the indoor environment. A hybrid co-simulation framework was established by coupling a reduced-order resistor–capacitor (RC) thermal network model with EnergyPlus augmented with GHEDesigner modules. The RC model generated feasible heat flux options under three operating modes, and EnergyPlus predicted sensible loads, energy use, and pump energy demand. At each simulation step, a supervisory control algorithm selected the optimal loop configuration and duty factor that maximizes useful TABE geothermal utilization without exceeding the predicted sensible load, thereby avoiding overheating or cooling. Case studies were conducted for Los Angeles, California, Charleston, South Carolina, and Denver, Colorado. Results showed that the proposed framework reduced HVAC electricity consumption by 43%–67%, natural gas use for space heating by 11%–38%, and peak electricity demand by 43%–88%. These results highlight the potential of combining reduced-order envelope modeling, direct geothermal coupling, and load-oriented supervisory control to improve whole building energy performance and reduce peak demand across diverse weather conditions.

Howard, Daniel [Southern Adventist University]↗

DOE OSTI2026

Coupled heat and mass transfer in internally cooled silica gel-coated aluminum foam heat exchangers for dehumidification

Solid desiccant dehumidifiers offer significant potential to improve humidity control in buildings due to their ability to independently regulate latent (humidity) and sensible (temperature) loads. However, adsorption of water vapor by desiccants is an exothermic process; the resulting heat of adsorption increases both the desiccant bed temperature and the temperature of the air flowing over the bed, thereby limiting the performance of desiccant dehumidifiers. To address this problem, desiccant-coated heat exchanger prototypes were developed by coating silica gel onto aluminum foam substrates and integrated with chilled water circulation for effective removal of the heat of adsorption. Prototype heat exchangers with two different pore densities (10 and 20 pores per inch (PPI)) and two different desiccant loadings (∼10.36% and ∼17.80%) were fabricated. Experiments were conducted by varying the inlet air face velocity, chilled water inlet temperature, and chilled water flow rate to investigate the coupled heat and mass transfer characteristics of the prototype heat exchangers over a wide range of operating conditions. The underlying transport mechanisms were analyzed using transient desiccant bed temperature, outlet air temperature, and outlet humidity profiles. The results demonstrate that internal cooling significantly enhances dehumidification performance by maintaining more favorable thermodynamic conditions for water vapor adsorption. Under identical operating conditions, a 20 PPI heat exchanger coated with 25.05 g of silica gel achieved 98.98% higher cumulative water uptake and 97.75% higher moisture removal capacity than the corresponding non-cooled case after 5 min of adsorption. This substantial enhancement was further supported by a validated one-dimensional coupled heat and mass transfer model developed in the present study. To date, this is one of the first experimental studies to systematically investigate the combined effects of internal cooling, foam pore density, and desiccant loading on the performance of silica-gel-coated metal foam heat exchangers under HVAC-relevant operating conditions.

42 ENGINEERING↗

DOE OSTI2023

Analysis of Frost Prevention for Heat Recovery Ventilation in an Arctic Facility

Sub-Arctic environments present a unique challenge for the continuous operation of mechanical ventilation systems in occupied buildings where cold temperatures create complications for maintaining adequate air quality, efficiency, and system operability. Heat recovery ventilation is most difficult at the coldest temperatures, when there is the greatest availability to transfer heat between airstreams, due to the potential for frost accumulation in the exhaust airstream. Frost limits heat transfer and creates the potential for subsequent blockage of airflow. A successful frost prevention strategy is necessary to ensure that recovery ventilation systems function in locations with a large amount of annual heating degree days. Commonly, this is achieved by preheating outdoor air above freezing temperatures via airflow through a glycol-water mix hydronic coil before heat exchange occurs. Preheating the outdoor air proactively inhibits frost formation but is associated with a penalty to recovery efficiency. A commercial-scale heat recovery ventilator in a facility in Fairbanks, Alaska was analyzed for sensible recovery effectiveness and exhaust temperature at different winter conditions. The system utilized the common defrost strategy of preheating the air above-freezing with a static temperature control scheme. The heat transfer efficiency of the recovery ventilator was observed to be poor at various winter conditions with elevated exhaust temperatures indicating lost heat recovery effectiveness. Using prior findings on strategies for sub-freezing temperatures along with observed field conditions it was determined that a dynamic relationship between the coil and the exterior conditions would reduce the energy required to preheat the air and allow the heat exchanger to maximize effectiveness due to temperate difference. This reduction in preheated temperature of the air is achieved by modulating the temperature of the coil to keep the discharge air stream above a certain dewpoint temperature threshold, likely leading to energy savings for other sub-Arctic facilities using this frost control strategy.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

DOE OSTI2022

Electrohydrodynamic Enabled Electrochemical Membrane Dehumidifier for Separate Sensible and Latent Cooling

In hot and humid parts of the world, air conditioning is a necessity for an adequate standard of living. Cooling and heating represent one-third of building energy consumption. When cooling humid air, a substantial amount of the cooling energy is absorbed by water vapor condensation. The dehumidification cooling load is referred to as the latent cooling load and the dry bulb cooling load is referred to as the sensible cooling load. In most residential applications, the total cooling load is processed by a vapor compression cycle. Processing the latent load separately would not only reduce energy consumption. It would also reduce the required refrigeration capacity. Refrigerants often have adverse ecological impacts, contributing to the greenhouse effect and depletion of the ozone layer. Reduction of the cooling capacity in a system could reduce the amount of refrigerant charge required.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Hygroscopic Metal-Complex Coated Metal Foam for Moisture Management

Moisture management for improving indoor air quality is critical for health and thermal comfort. Recently, the use of desiccant-coated heat exchangers (HXs) has emerged as a promising dehumidification approach to reduce energy consumption as compared with conventional vapor compression-based air dehumidification. The desiccant material is a key component of dehumidification performance. However, currently used desiccant materials have a low moisture uptake capability and require a high temperature for regeneration. The current study investigated the dehumidification performance of a metal-complex-based hygroscopic desiccant-coated metal foam HX. Furthermore, the results revealed that the desiccant-coated foams display increased hydrophilicity compared with the uncoated metal surfaces. Additionally, the desiccant coating had superior moisture absorption capability of more than 2 g/g desiccant , which is much higher than commonly used zeolite and silica gels. Wind tunnel experiments showed that the coating absorbs moisture from humid air and can be effectively regenerated at low temperatures. Additionally, the coating did not increase the pressure drop of the HX. Overall, the results of this study suggest that this desiccant-coated metal form can potentially be used for moisture management in the building sector.

Atmospheric chemistry↗

DOE OSTI2025

Investigation of ventilation-coupled high energy density sensible thermal energy storage

Low-cost energy storage will play an important role in supporting the decarbonization of the energy sector. Here, a novel approach to thermal energy storage for buildings is proposed, in which a tank of antifreeze liquid can be used to heat outdoor air in mechanical ventilation systems. If heated to a high enough temperature, the fluid can potentially undergo temperature swings of nearly 100°C during discharge in cold climates. Because the energy density of sensible storage systems scales proportionally to the system temperature change, this concept has the potential to offer higher energy densities than other liquid-based sensible storage devices used in building applications. A one-dimensional numerical model of the storage system was developed and experimentally validated using 30 wt% (wt%) potassium acetate as an aqueous antifreeze solution. Using a commercial hot water tank, energy densities of 47.0 kW-hour per cubic meter (kWh/m 3 ) were demonstrated in a laboratory setting. Material energy densities of approximately 74.7 (kWh/m 3 ) were measured. Design improvements may boost this energy storage density even further. Because of the system's relative simplicity, ventilation-coupled sensible storage has the potential to be an easily deployable, low-cost energy storage solution for building systems.

25 ENERGY STORAGE↗

DOE OSTI2025

Benchmarking thermal energy storage cost for industrial process heat

Process heat accounts for roughly half of industrial energy demand, and currently 95% of process heat is derived from the combustion of natural gas, oil, and coal. Electrification of industrial heating could be an alternative, potentially expanding locations suitable for manufacturing; however, industrial facility owners may desire energy storage to stabilize energy costs. In this work, the economic benefits of pairing thermal storage with electrified process heat to reduce the average price paid for energy are analyzed. Cost savings focus on energy arbitrage, or leveraging flexible energy pricing schemes, alone. The cost of natural gas combustion across decades (2019-2060) is compared to the costs of electricity and thermal energy storage in four United States Independent System Operator (ISO) regions. Systems installed today may not yield positive net present value (NPV) compared to the use of natural gas. However, using estimated electricity prices, systems installed in 2030 using arbitrage alone could be profitable when compared to natural gas in some regions of the U.S. Furthermore, if capital expenditures could be reduced by 50% for sensible thermal storage systems by 2030, profitable systems are found across all regions. This implies that electrification of industrial process heat, when paired with inexpensive thermal energy storage systems, could be less expensive than brownfield natural gas systems, using arbitrage as the only source of revenue and without a dependency on any future policy drivers such as pricing externalities that could further incentivize the electrification of industrial process heat.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Research and Development of a Ventilation-Integrated Comfort System

From an indoor air quality perspective, the best residential ventilation strategies include filtering outdoor air and distributing that air to all occupied parts of a home. From an energy standpoint, it is desirable that energy be transferred from the exhaust air to the incoming outdoor air to limit heating and cooling impacts. Heat or energy recovery ventilators (HRVs or ERVs) can provide these functions, but researchers have seen many poor installations related to design, installation, and operation and maintenance. More robust ventilation systems may involve an ERV with a dedicated duct distribution system and controls. Such a duct system can be costly to install, and many builders reduce these costs by connecting an ERV to a central heating and cooling duct system. Although this can sometimes be done effectively, researchers have seen consistent challenges with low, inconsistent, or imbalanced flow rates; high electricity consumption; and—of greatest concern—outdoor air short-circuiting or not being delivered to occupied spaces at all. Most ERVs are designed to operate with their own duct system; they are not designed as an add-on to much larger heating, ventilating, and air-conditioning (HVAC) systems. The ventilation-integrated comfort system (VICS) is expressly designed to integrate with low-capacity, efficient, ducted heating and cooling systems. Overall, the latest VICS prototype consumed 40–75 watts (W), including the air handler power, to deliver 50–120 cfm of whole-dwelling ventilation. The large, cross-flow ERV core performed to match manufacturer values (73% winter sensible effectiveness, 64% summer total effectiveness), but further improvements are possible. The VICS system researched and tested during this project will provide efficient, controllable, balanced energy recovery ventilation that is integrated with heating and cooling systems. The integration reduces space and ductwork needed for separate ventilation systems, and there are no compromises to heating, cooling, or ventilation performance. The integrated nature of the device also reduces risks for improper installation and commissioning. Even when using the air handler blower to distribute outdoor air, the total power consumption is lower than that of most available ERV products in the same airflow range. This system has the potential to offer very high-performance ventilation with much smoother and simpler installation than conventional systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Sustainable Energy Solutions for Thermal Load in Buildings—Role of Heat Pumps, Solar Thermal, and Hydrogen-Based Cogeneration Systems

Economic and population growth is leading to increased energy demand across all sectors—buildings, transportation, and industry. Adoption of new energy consumers such as electric vehicles could further increase this growth. Sensible utilization of clean renewable energy resources is necessary to sustain this growth. Thermal needs in a building pose a significant challenge to the energy infrastructure. Potential technological solutions to address growing energy demand while simultaneously lowering the carbon footprint and enhancing the grid flexibility are presented in this study. Performance assessment of heat pumps, solar thermal collectors, nonfossil fuel-based cogeneration systems, and their hybrid configurations is reported in this study. The impact of design configuration, coefficient of performance (COP), electric grid’s primary energy efficiency on the key attributes of total carbon footprint, life cycle costs, operational energy savings, and site-specific primary energy efficiency are analyzed and discussed in detail. In conclusion, heat pumps and hydrogen-fueled solid oxide fuel cells (SOFCs) are highly effective building energy resources compared to traditional approaches; however, the carbon intensity of electrical energy and hydrogen production are keys to the overall environmental benefit.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Separating the Influences of Low-Latitude Warming and Sea Ice Loss on Northern Hemisphere Climate Change

Abstract Analyzing a multimodel ensemble of coupled climate model simulations forced with Arctic sea ice loss using a two-parameter pattern-scaling technique to remove the cross-coupling between low- and high-latitude responses, the sensitivity to high-latitude sea ice loss is isolated and contrasted to the sensitivity to low-latitude warming. Despite some differences in experimental design, the Northern Hemisphere near-surface atmospheric sensitivity to sea ice loss is found to be robust across models in the cold season; however, a larger intermodel spread is found at the surface in boreal summer, and in the free tropospheric circulation. In contrast, the sensitivity to low-latitude warming is most robust in the free troposphere and in the warm season, with more intermodel spread in the surface ocean and surface heat flux over the Northern Hemisphere. The robust signals associated with sea ice loss include upward turbulent and longwave heat fluxes where sea ice is lost, warming and freshening of the Arctic Ocean, warming of the eastern North Pacific Ocean relative to the western North Pacific with upward turbulent heat fluxes in the Kuroshio Extension, and salinification of the shallow shelf seas of the Arctic Ocean alongside freshening in the subpolar North Atlantic Ocean. In contrast, the robust signals associated with low-latitude warming include intensified ocean warming and upward latent heat fluxes near the western boundary currents, freshening of the Pacific Ocean, salinification of the North Atlantic, and downward sensible and longwave fluxes over the ocean.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Open-source simulation platform for air source heat pump integrated with thermal energy storage

Here, this article introduces a modular simulation platform for assessing thermal energy storage (TES) integrated with air source heat pumps (ASHP). The Python platform is an open-source library that includes classes for modeling air-air and air-water heat pumps, TES devices, and the heating load of residential buildings. To validate the ASHP model, the study utilized experimental data obtained from a commercial heat pump evaluated at the National Renewable Energy Laboratory (NREL). The results indicate a mean deviation of 0.7% for COP across the operating range, with a maximum relative deviation of 12.6%. In terms of system heating capacity, the model had an average deviation of 4.3% compared to experimental results, with a maximum deviation of 8.2%. Three classes were implemented for modeling distinct types of TES devices: a generic TES based on energy balances, a sensible isothermal water tank, and a stratified water tank. Details of the mathematical models are provided, along with their respective strengths and limitations. An example is provided showcasing the integration of a residential 10 kWh thermal storage unit with an ASHP operating in Denver, CO. The comparison of two different discharge criteria for the TES unit highlights the importance of control strategies in the system performance.

25 ENERGY STORAGE↗

DOE OSTI2022

Design of a Compact Dry Cooler With an Aluminum Heat Exchanger Core for a Supercritical CO2 Power Cycle Is Evaluated for a Concentrating Solar Power Application

Abstract As the supercritical CO2 power cycle develops and the component technologies mature, there is still a need to reduce the associated capital and operating costs to maintain a competitive levelized cost of electricity (LCOE) in order to enter the market. When considering concentrating solar power (CSP) coupled with an sCO2 power block and sensible thermal storage, the technology presents a clean source for utility-scale power generation to support baseload or peak-load electrical demand. However, the LCOE of the technology is still considered higher than the competing technologies and should be reduced to better compete in the market; 2030 targets for dispatchable solar plants are 5¢/kWh for baseload CSP and 10¢/kWh for peaker plants, as set by the United States Department of Energy. In response to this need, this study is targeting improvements in the power cycle precooler to reduce power block contribution to LCOE. This study considers a dry cooler, as CSP plants are sensitive to water consumption because many installations are slated for remote or arid locations where solar irradiance is very high, but water is scarce. Furthermore, the power block footprint for an sCO2 system is quite compact, especially as compared to a steam cycle. Therefore, there is interest in installing a more compact dry cooler that is proportional to the reduced footprint sCO2 power block, while conventional dry coolers are an order of magnitude larger. The competing goals of size, performance, and cost were considered in this study to develop a compact dry cooler that can easily be packaged with the power block, significantly reducing the installation and transport cost compared to the current state of the art, while maintaining or improving upon the heat transfer performance and impact on plant LCOE. This paper details the high-level findings of a large dry cooler sensitivity study for design point selection, design of the compact dry cooler, expected year-round performance for the dry cooler and the power cycle, and the predicted LCOE for a 30-year plant life. It was found that an aluminum heat exchanger core can be suitably designed to meet the pressure and temperature requirements for a precooler in an sCO2 recompression Brayton cycle. The dry cooler assembly was found to have improved heat transfer performance, allowing for increased cycle efficiencies and a reduced plant LCOE. When coupled with a centrifugal blower and compact transition duct, the dry cooler assembly was able to reduce the installation footprint by over 50%.

14 SOLAR ENERGY↗

DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage

Industrial process heating (IPH) accounts for approximately 70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately 1500 TWht (approximately 60%) of IPH demand is in the temperature range of 100-300. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. TES development has historically been dominated by technologies suitable for deployment with concentrating solar power (CSP). State-of-the-art thermal storage deployed commercially with power tower CSP plants uses a 60%/40% NaNO3/KNO3 molten salt and operates between temperatures of approximately 280 degrees Celsius and 570 degrees Celsius using a two-tank configuration. However, these nitrate salts are unsuitable for operation outside of this temperature range due to a high freezing point of approximately 220 degrees Celsius, and limits on high-temperature salt stability and corrosion resistance of containment alloys. Other materials being investigated for TES include those based on: (1) sensible energy storage (various molten salt compositions, inert solid particles, rocks or pebble beds, sulfur, water, concrete, graphite, etc.), (2) latent energy storage in materials that undergo solid-liquid phase change at relevant temperatures (organic materials for low-temperature applications, inorganic salts and/or metals for high-temperature applications), or (3) thermochemical energy storage (hydrides, hydroxides, carbonates, metal oxides, etc.). The application temperature and challenges pertaining to storage material and/or containment cost, energy density, long-term thermal and cyclic stability, and charge/discharge heat transfer effectiveness drive material selection for a given IPH or electricity generation application. Sulfur is a cheap commodity at $80/ton compared to $1100 - 1300/ton for conventional salts. When using a metric of storage cost per kWh, sulfur costs around 2-3 $/kWh. Previous sulfur TES development focused on high temperature (>600 degrees) concentrated solar power applications with sulfur encapsulated in pipes and flow of gaseous HTF (air) in the shell side. However, for lower-temperature IPH applications in the range of approximately 100-300 degrees Celsius Element 16 adopted a compact and scalable TES design with molten sulfur in the shell and HTF pipes submerged in the molten sulfur bath. The low-cost molten sulfur TES for dispatchable IPH has deployment potential for broad applications. The spatial and temporal evolution of the HTF and sulfur temperature is critical to the TES system performance, and thus detailed modeling can improve understanding of the performance and facilitate design improvements. Using high performance computing and computational fluid dynamics (CFD) a low-cost molten sulfur thermal energy storage (TES) system for industrial process heating (IPH) applications was developed. The unique challenges in CFD modeling of sulfur TES are the sharp property changes of sulfur relevant to the working temperatures. Above 159, liquid sulfur undergoes polymerization, and the viscosity of sulfur rapidly increases by several orders of magnitude between 159 degrees Celsius and 188 degrees Celsius, followed by a decrease in viscosity beyond 188 degrees Celsius due to thermal bound dissociation. In addition, various concentrations of H2S impurities can also modify sulfur viscosity. This numerical challenge is especially relevant to transient simulation of the sulfur TES charging and discharging processes as the extreme property variations limit the applicability of traditional heat transfer correlations. Transient CFD simulations including the temperature-dependent sulfur properties and geometric complexity of the TES design were used to predict the effect of natural convection during charging and discharging on the heat transfer process, sulfur temperature uniformity, charge/discharge rates, and performance of the storage devices. The CFD model was validated with experimental results for a full charge and discharge cycle. The work will show 3D and 2D simulation comparisons aimed to facilitate rapid design iterations and a machine learning based design optimization approach.

CFD↗

DOE OSTI2020

High temperature synthesis for power production and storage

Thermochemical energy storage (TCES) for concentrating solar power (CSP) systems provides higher energy density than sensible energy storage systems. An ammonia-based TCES system dissociates endothermically into hydrogen and nitrogen. The stored energy is released when supercritical hydrogen and nitrogen react exothermically to synthesize ammonia. Prior ammonia synthesis systems are unable to produce temperatures consistent with modern power blocks requiring a working fluid, for example steam or carbon dioxide, to be heated to greater than 600° C., for example about 650° C. An ammonia synthesis system heats steam from, for example 350° C. to 650° C. under pressure of about 26 MPa. The hydrogen and nitrogen are preheated with a flow of supercritical fluid prior to the synthesis step to provide reaction rates sufficient to heat power block working fluid to the desired temperature.

14 SOLAR ENERGY↗