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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.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Supercritical CO2 Heat Pumps and Power Cycles for Concentrating Solar Power

Pumped Thermal Energy Storage (PTES) is a promising technology for electricity storage applications. An electrically driven heat pump moves energy from a cold space to a hot space, thereby creating hot and cold thermal storage. The temperature difference between the hot and cold storage is later used to drive a heat engine and return electricity to the grid. In this article, supercritical carbon dioxide (sCO2) is chosen as the working fluid for PTES, and results are compared to 'conventional' systems that use nitrogen. Molten salts are used for the hot storage which means that a CSP plant with thermal storage and an sCO2 power cycle could potentially be hybridized with PTES by the addition of a heat pump. This article describes some of the benefits of this combined system which can provide renewable power generation and energy management services. Two methods by which an sCO2 heat pump can be combined with an sCO2 power cycle for CSP are described and techno-economic results are presented. Results indicate that these systems can achieve reasonable technical performance, but that costs are currently high.

carnot battery↗
DOE OSTI2026

Design of a SiC-Si moving packed-bed particle-to-sCO 2 heat exchanger for high temperature concentrating solar power applications

Particle-based concentrating solar power systems integrated with sCO 2 power cycles offer high thermal efficiencies but require durable heat exchangers to transfer heat from high-temperature particles to the sCO 2 working fluid. Here, this study presents the design and optimization of a silicon carbide-silicon moving packed-bed heat exchanger for fabrication via binder jetting additive manufacturing. The heat exchanger was designed to withstand a 20 MPa sCO 2 pressure and operate at particle inlet temperatures up to 750 °C. The final design features 152 sCO 2 channels distributed across 19 plates, with elliptical corners and a minimum wall thickness of 3 mm. Flow restrictors at the sCO 2 channel inlets significantly improved flow uniformity, reducing thermal stresses and achieving a structural reliability of 99 % under representative operating conditions. The heat exchanger delivers a thermal duty of 9 kW and a volumetric power density of approximately 1 MW/m 3 in the channel region. Sensitivity studies confirmed the heat exchanger’s robustness under varying operating conditions, demonstrating its viability as a high-performance alternative to metallic heat exchangers for particle-based high-temperature concentrating solar power applications.

Barua, Bipul [Argonne National Laboratory (ANL), A↗
DOE OSTI2022

Cast Components for High Temperature Concentrated Solar Power Thermal Systems

Concentrating Solar-Thermal Power (CSP) components such as piping, valves fittings are required for use at temperatures up to 800°C. These are anticipated to be made using Nickel-based alloys such as Haynes ® 230 ® , Haynes ® 282 ® , or IN ® 740H ® and can contribute significantly to the cost of a CSP Gen 3 plant. Thus, there is a significant motivation to lower the cost of materials and components so that the capital costs can be minimized. In all these cases, the cost of the component has two contributions: 1. Materials cost, and 2. Manufacturing cost. Both materials cost and manufacturing costs must be kept low to attain the lowest possible cost. Materials cost can be lowered by using materials that have the ideal combination of properties at the lowest cost. Another avenue to lower cost is chose a manufacturing process that has the potential to lower the cost. Traditionally tubes are made from billets through a wrought process and can be expensive. An alternative process to consider is the centrifugal casting process where the tube is directly fabricated from molten metal. In this case, the molten metal is poured inside a cylindrical metallic mold with an insulating layer and is spun rapidly. A wide range of sizes (diameter, wall thickness, and length) can be cast using this process. The objective of this project was to develop the process for fabricating pipes and related components using a centrifugal casting process and to measure the properties of alloys fabricated using this process.

14 SOLAR ENERGY↗
DOE OSTI2022

Real-time dispatch optimization for concentrating solar power with thermal energy storage

Concentrating solar power (CSP) plants present a promising path towards utility-scale renewable energy. The power tower, or central receiver, configuration can achieve higher operating temperatures than other forms of CSP, and, like all forms of CSP, naturally pairs with comparatively inexpensive thermal energy storage, which allows CSP plants to dispatch electricity according to market price incentives and outside the hours of solar resource availability. Currently, CSP plants commonly include a steam Rankine power cycle and several heat exchange components to generate high-pressure steam using stored thermal energy. The efficiency of the steam Rankine cycle depends on the temperature of the plant's operating fluid, and so is a main concern of plant operators. However, the variable nature of the solar resource and the conservatism with which the receiver is operated prevent perfect control over the receiver outlet temperature. Therefore, during periods of solar variability, collection occurs at lower-than-design temperature. To support operator decisions in a real-time setting, we develop a revenue-maximizing non-convex mixed-integer, quadradically-constrained program which determines a dispatch schedule with sub-hourly time fidelity and considers temperature-dependent power cycle efficiency. The exact nonlinear formulation proves intractable for real-time decision support. Here we present exact and inexact techniques to improve problem tractability that include a hybrid nonlinear and linear formulation. Our approach admits solutions within approximately 3% of optimality, on average, within a five-minute time limit, demonstrating its usability for decision support in a real-time setting.

14 SOLAR ENERGY↗
DOE OSTI2020

Off-design performance of molten salt-driven Rankine cycles and its impact on the optimal dispatch of concentrating solar power systems

This paper presents a model for improving off-design performance predictions for molten salt-driven Rankine power cycles, such as in concentrating solar power tower applications. The model predicts cycle off-design performance under various boundary conditions, including molten salt inlet temperature, mass flow rate, and ambient temperature. The model is validated using industry performance data and benchmarked with results from the literature. A complete concentrating solar power plant, inclusive of solar heliostat field and receiver, is then considered, by implementing the Rankine cycle off-design performance results into the National Renewable Energy Laboratory’s System Advisor Model software, which includes a tool that determines optimal power production schedules. The work improves upon the current System Advisor Model by updating off-design performance characteristics. A case study demonstrates the impact of cycle off-design behavior on annual performance for a stand-alone concentrating solar power system and a concentrating solar power-photovoltaic hybrid system. In addition, we demonstrate how cycle off-design performance influences optimal operator dispatch decisions and, thereby, overall system design and economics. We conclude that off-design cycle performance impacts “optimal” sub-system sizing, especially for a concentrating solar power-photovoltaic hybrid configuration in which concentrating solar power must dispatch in conjunction with photovoltaic generation.

14 SOLAR ENERGY↗
DOE OSTI2021

Efficient prediction of concentrating solar power plant productivity using data clustering

Concentrating solar power (CSP) plants convert solar energy to electricity and can be deployed with a thermal storage capability to shift electricity generation from time periods with available solar resource to those with high electricity demand or electricity price. Rigorous optimization of plant design and operational strategies can improve the market-competitiveness and commercial viability; however, such optimization may require hundreds of annual performance simulations, each of which can be computationally expensive when including considerations such as optimization of dispatch scheduling, sub-hourly time resolution, and stochastic effects due to uncertain weather or electricity price forecasts. This paper proposes a methodology to reduce the computational burden associated with simulation of electricity yield and revenue for CSP plants over a single- or multi-year period. Data-clustering techniques are employed to select a small number of limited-duration time blocks for simulation that, when appropriately weighted, can reproduce generation and revenue over a single year or within each year of a multi-year period. After selection of appropriate data features and weighting factors defining similarity between time-series profiles, the methodology captured annual revenue within 2.3%, 1.7%, or 1.2% using simulation of 10, 30, or 50 three-day exemplar time blocks, respectively, for each of three single-year location/weather/market scenarios and five plant configurations ranging from low to high solar multiple and storage capacity. When applied to multi-year datasets, the proposed methodology can capture inter-year variability that is unavailable from typical meteorological year (TMY) datasets while simultaneously requiring simulation of less than a single year of data.

14 SOLAR ENERGY↗
DOE OSTI2023

Characterization of solid particle candidates for application in thermal energy storage and concentrating solar power systems

Thermal energy storage (TES) enables concentrating solar power to remain competitive in the renewable energy mix by firming up intermittent solar resource and providing grid services such as load shifting. Free from siting constraints, stand-alone TES systems show promise as a low-cost alternative to traditional pumped-storage hydropower or compressed air energy storage. At the core of all TES technologies is a storage medium, the selection of which governs many aspects of system design and operation. Although the majority of commercial installations utilize molten salts, solid particles can demonstrate stability over wider temperature ranges. This amounts to increased energy storage densities and corresponding reductions in system cost which is essential in achieving low-cost energy storage. In this work, eight solid particle candidates are systematically identified and screened for application in a specific particle-TES system. The five most promising candidates (CARBO CP and HSP, calcined flint clay (CFC), brown fused alumina (BFA), and silica sand) are further characterized by size and morphology for fluidization suitability, flowability for particle transport, and thermal stability. Calcined flint clay and brown fused alumina are eventually down-selected due to thermal instability at the target operational temperature of 1200 °C. Although the physical characteristics of CARBO outperform silica sand in all categories examined, the marginal performance gains are considered insufficient to justify the additional media cost so silica sand is selected as the leading candidate. Within the silica sand (α-quartz) space, the high end of Geldart Group B particles is identified to satisfy the target fluidization regime for the application of interest without compromising particle flowability. Here, in focused testing, Silica 460 is shown to exhibit sufficient stability through long-duration (500-hour) thermal and cyclic testing (1200 °C), 10-hour testing at 1400 °C, and in contact with candidate refractory containment materials. Finally, an average heat capacity of 1.1 J/g∙ °C is measured over 300-1200 °C with a quartz inversion enthalpy (ΔH α-β ) of 10.7J/g.

14 SOLAR ENERGY↗
DOE OSTI2020

Concentrating Solar Power Best Practices Study

The primary objective of this Concentrating Solar Power Best Practices Study is to publish best practices and lessons learned from the engineering, construction, commissioning, operations, and maintenance of existing concentrating solar power (CSP) parabolic trough and power tower systems. To accomplish this objective, information was solicited from many owners, operators, and engineering, procurement, and construction (EPC) contractors, independent engineers, and other stakeholders of parabolic trough and central receiver plants (also commonly referred to as power towers). Information was gathered through in-person or online meetings, site visits, and questionnaires sent to participants. The project team held about 50 information-gathering sessions with participants over the course this effort; and in the process, it collected information from participants representing nearly 80% of CSP plants operating worldwide.

14 SOLAR ENERGY↗
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

Analysis of thermal and mechanical properties with inventory level of the molten salt storage tank in central receiver concentrating solar power plants

Molten salt thermal energy storage (TES) tanks ensure steady power output of concentrating solar power (CSP) plants; however, recent tank failures have highlighted the need for further analysis. Current studies primarily focus on analyzing the molten salt flow, heat transfer, and thermal efficiency. Additionally, research on the latest tank structures is limited and lacks newest experimental validation. This study measures temperature and molten salt inventory levels in the high-temperature tank at a 50 MW central receiver CSP plant, connected to the power grid in 2019. A multi-physics model was developed to evaluate thermal and mechanical properties of TES tanks by combining computational fluid dynamics and finite element modeling using real plant data. Heat loss, temperature, displacement, and stress distribution of the tank at different inventory levels were investigated. Results show that ambient air velocity near the tank roof reaches 2.14 m/s, much higher than 0.2 m/s near the wall. The temperatures of inventory fluid and tank are close, varying slightly at different levels due to thermal conduction and radiation. Because the heat loss strongly depends on temperature, the total tank loss remains nearly constant across inventory levels. Larger temperature gradients and thermal stresses are primarily localized along the tank floor edge and the air-salt interface. Notably, the maximum thermal stress at the tank edge is three times higher than that at the interface. The magnitude of total stress changes by less than 5 MPa with and without thermal load, indicating that high temperatures exert only a minor impact on tank stress. In contrast, thermal load significantly affects tank deformation, particularly at the roof edge, where values exceed 150 mm. Despite the large variation in molten salt levels, tank wall temperatures and displacements present a minor change, suggesting a weak correlation with inventory levels. In conclusion, the findings obtained in this study provide important insights on the TES tank that could be used to optimize tank design and operation strategies.

14 SOLAR ENERGY↗
DOE OSTI2024

Vascular Carbon/Carbon composites for concentrated solar power

Due to their exceptional mechanical and thermal properties under high temperature conditions, for the first time, a novel vascular (embedded channels) Carbon/Carbon (C/C) composite was developed for use as a modular concentrated solar power (CSP) gas receiver. The fabrication process involves the combination of the vaporization of sacrificial component (VaSC) technique with conventional methods to produce C/C composites with well preserved channels. Different heat treatments were evaluated together with X-ray diffraction (XRD) analysis to determine optimal fabrication conditions that maintains the material and channel’s integrity. Mechanical testing confirms that structural integrity is maintained, with statistical analyses indicating no compromise in flexural strength or modulus. Furthermore, this research introduces an innovative pathway for efficient CSP gas receivers, which can bridge the gap towards improved energy generation efficiency in next-gen CSP plants through higher operating temperatures with the use of C/C composites.

14 SOLAR ENERGY↗
DOE OSTI2023

Multi-Objective Optimization of a Bi-Metal High-Temperature Recuperator for Application in Concentrating Solar Power

Supercritical CO 2 closed Brayton cycles are a major candidate for future power cycle designs in concentrating solar power applications, with high-temperature recuperators playing an essential role in realizing their high thermal efficiency. Here, printed circuit heat exchangers (PCHEs) are often chosen for this role due to their thermal-hydraulic and mechanical performance at high temperatures and pressures, all while remaining compact. However, PCHEs can be costly because of the high-performance materials demanded in these applications, and the heat exchanger internal geometry is restricted by their manufacturing process. Additively manufactured heat exchangers can address both of these shortcomings. This work proposes a modular bi-metal high-temperature recuperator with integrated headers to be produced with additive manufacturing. Beginning with existing PCHE channel geometries, a 1D heat exchanger model is developed. Then, multi-objective optimization is used to maximize the heat transfer effectiveness of a lab-scale device while limiting its size. Two distinct channel geometries emerge from the optimization. Optimal designs achieve up to 88% effectiveness with negligible pressure drop. Deterioration of effectiveness due to axial conduction of heat in the heat exchanger walls is found to be a notable problem for lab-scale PCHEs, and the optimal designs obtained here minimize its detrimental effects. A sensitivity analysis reveals that the effectiveness of the recuperator is much less sensitive to variation in mass flowrate in off-design operation when axial conduction is significant, while increasing the length of the device easily increases effectiveness.

14 SOLAR ENERGY↗
DOE OSTI2021

Effects of Particle Size and Concentration of Magnesium Oxide on the Lubricating Performance of a Chloride Molten Salt for Concentrating Solar Power

One engineering challenge for the next-generation concentrating solar power (CSP) is to identify appropriate heat transfer and thermal energy storage media. A chloride salt mixture (20 wt % NaCl + 40 wt % MgCl 2 + 40 wt % KCl) in a molten phase is proposed as a potential fluid for carrying the heat as well as lubricating the CSP pump bearings. Due to the hygroscopic nature of MgCl 2 , the presence of magnesium oxide (MgO) particles is inevitable. In order to understand the impact of MgO particles, this study investigated the tribological behavior of the molten chloride salt mixture containing MgO of various particle sizes and concentrations. Tests were conducted at 750 °C in a dry Ar environment using a zirconia ball sliding against a Haynes 244 alloy disc lubricated by the molten salt. There was a clear trend of the increased friction coefficient and wear loss for a larger particle size and/or a higher concentration of MgO. Distinct wear mechanisms were identified for the ceramic ball and alloy disc. Results provide fundamental insights for this new research avenue of molten salt lubrication for CSP.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Using concentrating-solar-power plants as economic carbon-free capacity resources

Deep decarbonization of electricity systems raises concerns about the need for generating capacity that can maintain reliable energy supply. Given this concern, we explore the ability of concentrating-solar-power plants with thermal energy storage to provide a carbon-free source of such capacity. We develop an approach to assessing the capacity contribution of concentrating-solar-power plants that considers future systems. Such considerations are important, because of potential differences in net-load patterns compared to today (e.g., due to higher renewable-energy penetrations). Using historical data spanning an 18-year period, we demonstrate that concentrating-solar-power plants with thermal energy storage can provide this necessary capacity with little impact on their financial viability. We examine the impact of myopic decisions and imperfect foresight of future system conditions on the operation of concentrating-solar-power plants and the resultant impact on their capacity contributions. We find that imperfect foresight can have limited impacts on such a use of concentrating-solar-power plants, so long as proper forecasting techniques are developed and used. Overall, our work shows that concentrating-solar-power plants with thermal energy storage may have a role to play in delivering reliable electricity supply in a decarbonized energy system.

14 SOLAR ENERGY↗
DOE OSTI2023

Assessing the Optical Performance Impact of Tracking Error in an Operational Concentrated Solar Power Plant Using Monte Carlo Ray-Tracing Simulation

Concentrating Solar Power (CSP) provides firm and dispatchable electricity due to its thermal storage and hybridization capabilities, which supports the decarbonization of our energy supply. Of the various CSP technologies, parabolic trough collectors are the most mature, with over 500 MW operating worldwide. The optical performance of parabolic trough systems is sensitive to tracking error, which is defined as the angular offset of a collector away from the sun position in the transversal plane. Tracking error commonly occurs due to non-continuous adjustment of the trough angle to point toward the sun, but other factors such as gravity, heating, and wind loading can also contribute to tracking error. Researchers have explored the impact of tracking error on optical performance both numerically and experimentally, but existing studies do not include measurements from operational utility-scale power plants. Tilt angle measurements of parabolic troughs at operational utility-scale power plants illustrate spatial variations in optical performance and include various sources of tracking error such as gravity, heating, and wind loading. To fully characterize wind driven loads on parabolic troughs, we are conducting a long-term field measurement campaign at the Nevada Solar One CSP plant located in Boulder City, NV, which has a nominal capacity of 72 MW and 0.5 hours of full-load storage. We record load measurements on four outer trough rows, collecting support structure bending moments, drive torque moments, dynamic accelerations of the spaceframe, mirror displacement, and tilt angles. Using the tilt measurements acquired at 20 Hz frequency, we calculate the deviation between the nominal sun position and the tracker angle. Using a Monte-Carlo ray-tracing simulation software, we assess the impact of the tracker angle deviation on optical performance throughout the diurnal cycle at various spatial locations within the CSP plant. In our view, this first-of-a-kind study will provide important guidance for future trough designs that reduce the impact of various sources of tracking error on performance.

concentrating solar power↗
DOE OSTI2020

Steady-state off-design modeling of the supercritical carbon dioxide recompression cycle for concentrating solar power applications with two-tank sensible-heat storage

Concentrating solar power researchers are evaluating the potential of the supercritical carbon dioxide recompression cycle to improve the thermal efficiency and decrease the capital costs of next-generation systems. This analysis investigates the steady-state off-design performance of a recompression cycle integrated with two-tank sensible-heat thermal energy storage as the ambient temperature and heat-transfer fluid (HTF) inlet conditions to the cycle change. This paper presents off-design component models and then cycle convergence and control models to maximize net cycle power output while constraining the high-side pressure and air-cooler fan power to their respective design values and fixing the cycle HTF outlet temperature to its design value. Results show that inventory control and air-cooler fan power are important control parameters that can be optimized to maximize off-design power output as the ambient temperature and HTF mass flow rate diverge from design. The high-side pressure and fan power constraints cause the cycle net power to degrade when the ambient temperature is warmer than the design value, and this study calculates a maximum mass flow rate for hot days above which the cycle cannot achieve the design HTF outlet temperature. Finally, the analysis shows that optimizing compressor shaft speeds can improve cold-day performance by around 1.5 percentage points and part-load performance by up to 2.5 percentage points versus a baseline case with no active compressor control.

14 SOLAR ENERGY↗
DOE OSTI2024

Analysis and Optimization of the Recompression Cycle with High Temperature Recuperator Bypass for Concentrating Solar Power Applications

This work analyzes the sCO2 recompression with high temperature recuperator (HTR) bypass power cycle for use in concentrating solar power (CSP) systems. CSP operation differs from other thermal power plants in that CSP must balance between maximizing the heat transfer fluid (HTF) temperature difference and maximizing the cycle thermal efficiency, which typically are inversely related. Large HTF temperature differences reduce the size and cost of thermal energy storage (TES), improve the solar receiver efficiency, and require lower mass flow rates that reduce pumping power required to elevate the HTF to the receiver. The recompression cycle with HTR bypass potentially offers improved thermal efficiency with larger HTF temperature differences as compared to the recompression cycle, and it has fewer turbomachinery components than the partial cooling cycle. The recompression with HTR bypass cycle adds a second lower temperature primary heat exchanger which transfers heat from the HTF to the fraction of sCO2 flow that bypasses the HTR. We developed a model to compare the recompression with HTR bypass cycle to the recompression and partial cooling cycles. A sweep of design parameters including bypass fraction, recompression fraction, recuperator conductance, and pressure ratio is used to form a pareto-optimal front with the cycle thermal efficiency and HTF temperature difference as objectives. An optimization routine has also been developed to find optimal design point parameters for a target HTF temperature difference. The performance of the recompression with HTR bypass cycle is compared with recompression and partial cooling cycles.

concentrating solar power↗
DOE OSTI2024

UHTC-TPMS Heat Exchangers for Concentrating Solar Power Applications with Thermal Energy Storage in Molten Chlorides

Concentrating solar power (CSP) plants convert energy from sunlight into electricity. Generally, a heliostat field is used to reflect sunlight and concentrate it onto a receiver, which heats the receiver and/or the media flowing through it. A flow loop transports the media through the system to a heat exchanger before returning the media back to the receiver to be reheated. The heat extracted by the heat exchanger is then converted into electricity using a conventional heat engine.

14 SOLAR ENERGY↗