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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 OSTI2023

Progress and opportunities in corrosion mitigation in heat transfer fluids for next-generation concentrating solar power

Concentrating solar power (CSP) systems have gained considerable eminence in converting solar thermal energy into electrical power in recent years. According to the U.S. Department of Energy's Gen3 roadmap, the CSP system should operate > 700 °C, as its efficiency depends directly on the operating temperature of the heat transfer fluids (HTFs). A significant challenge, however, is the corrosion of containment materials by the HTFs that is exacerbated at the higher temperatures. A comprehensive review of the high temperature stable HTFs, their properties, corrosion mechanisms on different alloys, and corrosion mitigation measures is of much importance for directing a concerted research and development in the field, which forms the motivation for this compendium. First, molten salt HTFs and their thermophysical properties, along with liquid metals, are introduced. Corrosion of structural materials in different HTFs including molten salts, liquid metals, and supercritical carbon-di-oxide at various temperatures and the corrosion mechanisms are comprehensively reviewed. In addition, several corrosion mitigation methods are discussed. Finally, future directions for HTFs and corrosion mitigation methods in molten salts are proposed. As a result, the holistic review presented here will serve as the foundation for further research addressing relevant challenges and enabling the promise of achieving cost-competitive CSP.

14 SOLAR ENERGY↗
DOE OSTI2021

Multielectrode Array Sensors to Enable Long-Duration Corrosion Monitoring and Control of Concentrating Solar Power Systems

Molten mixtures of MgCl2-KCl-NaCl are promising heat transfer fluid (HTF) candidates for the next generation of concentrating solar power systems (Gen3 CSP), because of their low cost, high decomposition temperature, and favorable heat transfer characteristics. However, if the chemistry of the salts is not properly controlled, molten chlorides can cause corrosion of high-temperature metal alloys, such as Inconel (R), in CSP systems. Here we demonstrate a corrosion monitoring system that can be used to monitor the health of the structural alloys over long durations. The monitoring system includes a multielectrode array voltammetry sensor that measures the redox potential of molten MgCl2-KCl-NaCl mixture as well as the presence of corrosion products and impurities. The sensors have been successfully operated in static molten salt environments for long durations, and are capable of detecting corrosion products, such as Cr2+ and Fe2+, quantitatively at low concentrations (i.e., approximately 100 ppm) with less than 4% error.

Concentrated solar power↗
NASA NTRS2000

A High-Efficiency Refractive Secondary Solar Concentrator for High Temperature Solar Thermal Applications

A refractive secondary solar concentrator is a non-imaging optical device that accepts focused solar energy from a primary concentrator and redirects that light, by means of refraction and total internal reflection (TIR) into a cavity where the solar energy is used for power and/or propulsion applications. This concept offers a variety of advantages compared to typical reflective secondary concentrators (or the use of no secondary at all): higher optical efficiency, minimal secondary cooling requirements, a smaller cavity aperture, a reduction of outgassing from the cavity and flux tailoring of the solar energy within the heat receiver. During the past 2 years, NASA Lewis has been aggressively developing this concept in support of the NASA Marshall Shooting Star Flight Experiment. This paper provides a brief overview of the advantages and technical challenges associated with the development of a refractive secondary concentrator and the fabrication of a working unit in support of the flight demonstration program.

Piszczor, Michael F., Jr.↗
NASA NTRS2026

Prototype Demonstration of an Integrated Solar Concentrator System and Carbothermal Reactor Using Solar Energy to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Oxygen from Regolith↗
DOE OSTI2020

High-efficiency, air-stable manganese–iron oxide nanoparticle-pigmented solar selective absorber coatings toward concentrating solar power systems operating at 750 °C

Solar selective absorber coating with long-term thermal stability at high temperatures ≥750 °C in air is an important component to reduce the levelized cost of energy (LCOE) of concentrating solar power (CSP) systems toward 50% power efficiency and dispatchable solar electricity. Conventionally, solar spectral selectivity requires multilayer-interference coatings implemented by stringently controlled vacuum deposition, and these coatings degrade significantly at >700 °C in air. Herein, we established a quantitative design approach and demonstrated a proof-of-concept air-stable, manganese–iron oxide nanoparticle (NP)-pigmented solar selective coatings with a high solar absorptance of ~93%, a relatively low thermal emittance of ~52%, and an optical-to-thermal energy conversion efficiency >89% under 1,000× solar concentration at 750 °C toward Generation 3 CSP systems. These coatings demonstrate spectral selectivity using cost-effective spray coating approach, a notable improvement over conventional vacuum-deposited, multilayer solar selective coatings for low-cost, high-efficiency solar thermal receivers. In contrast to the thermal degradation of spectrally non-selective benchmark Pyromark 2500 coatings at 750 °C in air, the solar absorptance of the MnFe 2 O 4 -pigmented coatings on stainless steel 310 (SS 310) substrates is increased to ~92.9% and the optical-to-thermal energy conversion efficiency is improved to 89.7% after serving at 750 °C in air for 700 h. X-ray diffraction results reveal that this improvement is due to the transformation of MnFe 2 O 4 NPs into more thermodynamically stable, non-stoichiometric manganese-rich manganese ferrite and iron-rich manganese–iron oxide phases after 500 h aging at 750 °C. For >1,000 h-endurance testing at 750 °C in air and the subsequent 19 day-night thermal cycling between 750 °C (12 h/cycle) and 25 °C (12 h/cycle) on SS 310 substrates, the thermal degradation is mainly due to the CrO x microflake formation from SS 310 substrates rather than the coatings, which can be suppressed by preoxidizing the surface of SS 310. With lower emittance matrix material and further optimization of pigment NP stoichiometry, concentration, and coating thickness, it is promising to achieve an optimized thermal efficiency ≥92.5% with long-term thermal stability at 750 °C for Generation 3 CSP systems.

14 SOLAR ENERGY↗
DOE OSTI2020

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems

Concentrating Solar Power (CSP) plants with Thermal Energy Storage (TES), require compressors capable of circulating supercritical carbon dioxide (sCO2) heat transfer fluids (HTFs) at temperatures from 500 to 700+°C and pressures from 8 to 25 MPa (80 to 250 Bar or 1160 to 3626 psia) in order to achieve thermal-to-electric efficiencies >50%. A review of papers relating to SCO2 compressors reveals that in almost every case the conditions being considered either allow for cooling of the SCO2 working fluid or are considering operating conditions close to the critical point at a temperature and pressure of approximately 31°C and 1070 psi). While the technology reported in these papers is relevant to most turbomachinery, the current CSP gas pathway circulator operating pressures are well above the CO2 critical point and do not allow for cooling of the main HTF flow. The purpose of this paper was to describe the key system issues affecting the design of a HTF circulator that could be scaled from a small size research and proof of concept circulator compressor to sizes supporting power plants producint upwards of 100 to 300 Mega Watts of electrical power. Due to the high temperatures and pressures the research scale HTF circulator was designed to be hermetically sealed to prevent leakage of the super critical carbon dioxide to the environment. In order to achieve hermetic sealing the drive motor and centrifugal impeller were fully integrated in a single shaft system configuration. From a preliminary assessment of compression power as a function of operating speed and impeller diameter it was determined that a smaller, higher speed impeller would result in a more efficient circulator. However, due to the high pressure and corresponding density of the sCO2 coupled with high operating speeds, large windage losses (i.e., viscous drag on the high speed rotating shaft) would occur which could result in a substantial reduction in efficiency of the system. Therefore tradoff studies were complerted to identify the operating speeds and system component sizes to achieve high efficiency. Based on the trade studies, the final design was a 55 mm diamter compressor impeller operating at speeds to 85,000 rpm. The unit will be built and tested in the future. Key Words: Super Critical Carbon Dioxide, Heat Transfer Fluid, Turbomachinery, Compressor, Circulator, Critical Point, Concentrating Solar Power, Solar Energy

Super Critical Carbon Dioxide, Heat Transfer Fluid↗
NASA NTRS1991

Offset truss hex solar concentrator

A solar energy concentrator system comprises an offset reflector structure made up of a plurality of solar energy reflector panel sections interconnected with one another to form a piecewise approximation of a portion of a (parabolic) surface of revolution rotated about a prescribed focal axis. Each panel section is comprised of a plurality of reflector facets whose reflective surfaces effectively focus reflected light to preselected surface portions of the interior sidewall of a cylindrically shaped solar energy receiver. The longitudinal axis of the receiver is tilted at an acute angle with respect to the optical axis such that the distribution of focussed solar energy over the interior surface of the solar engine is optimized for dynamic solar energy conversion. Each reflector panel section comprises a flat, hexagonally shaped truss support framework and a plurality of beam members interconnecting diametrically opposed corners of the hexagonal framework recessed within which a plurality of (spherically) contoured reflector facets is disposed. The depth of the framework and the beam members is greater than the thickness of a reflector facet such that a reflector facet may be tilted (for controlling the effective focus of its reflected light through the receiver aperture) without protruding from the panel section.

White, John E.↗
DOE OSTI2025

Impact of molten salt inflow on the temperature distribution in thermal energy storage tanks at startup for central receiver concentrating solar power plants

Concentrating Solar Power (CSP) systems with molten salt thermal energy storage (TES) tanks are one of the most promising, renewable-based energy conversion technologies for larger-scale power generation. The TES tank is one of the most critical components in CSP plants due to its high-temperature operation (up to 565 °C), daily thermal cycling, and intermittent solar radiation conditions. The plant startup is one of the most challenging operation conditions that could lead to damaging thermal gradients due to low salt inventory levels. In this study an analytical model for the sparger ring was developed and integrated with a detailed computational fluid dynamics model of a commercial-scaled molten salt tank. The integrated model allows an accurate representation of the tank operation to evaluate the effect of molten salt inflow on the mixing process. The tank filling process during plant startup was analyzed considering sparger rings with variations in design features, including inlet orifice configurations, number of orifices, direction of the inlets, and orifice diameter. The results demonstrated that higher temperature gradients are obtained in the tank floor during the plant startup. A sparger ring configuration with a predetermined orifice inlet inclination (30°, 45° and 60°) leads to significant temperature differences in the floor, between 57 °C and 62 °C, but better homogeneity in the temperature of the salt inventory. Lower salt inflow velocities result in a more homogeneous floor temperature, with maximum temperature differences under 38 °C. The sparger ring configuration with 52 orifices of 1-in. diameter and vertical flow showed better homogeneity in the temperature differences as a function of the salt level and lower temperature gradients in the tank floor. Because large temperature gradients in the tank's floor have been identified as one of the main factors contributing to tank failures, assessing various sparger ring design features is fundamental to determining proper inflow conditions that lead to low-temperature gradients and reducing failure susceptibility.

14 SOLAR ENERGY↗
DOE OSTI2020

Analysis of a Fluidized-Bed Particle/Supercritical-CO2 Heat Exchanger in a Concentrating Solar Power System

Concentrating solar power (CSP) development has focused on increasing the energy conversion efficiency and lowering the capital cost. To improve performance, CSP research is moving to high-temperature and high-efficiency designs. One technology approach is to use inexpensive, high-temperature heat transfer fluids and storage, integrated with a high-efficiency power cycle such as the supercritical carbon dioxide (sCO 2 ) Brayton power cycle. The sCO 2 Brayton power cycle has strong potential to achieve performance targets of 50% thermal-to-electric efficiency and dry cooling at an ambient temperature of up to 40 °C and to reduce the cost of power generation. Solid particles have been proposed as a possible high-temperature heat transfer or storage medium that is inexpensive and stable at high temperatures above 1000 °C. The particle/sCO 2 heat exchanger (HX) provides a connection between the particles and sCO 2 fluid in emerging sCO 2 power cycles. This article presents heat transfer modeling to analyze the particle/sCO 2 HX design and assess design tradeoffs including the HX cost. The heat transfer process was modeled based on a particle/sCO 2 counterflow configuration, and empirical heat transfer correlations for the fluidized bed and sCO 2 were used to calculate heat transfer area and estimate the HX cost. A computational fluid dynamics simulation was applied to characterize particle distribution and fluidization. This article shows a path to achieve the cost and performance objectives for a particle/sCO 2 HX design by using fluidized-bed technology.

14 SOLAR ENERGY↗
NASA NTRS2005

Measurement and Characterization of Concentrator Solar Cells II

Concentrator solar cells are continuing to get more consideration for use in power systems. This interest is because concentrator systems can have a net lower cost per watt in solar cell materials plus ongoing improvements in sun-tracking technology. Quantitatively measuring the efficiency of solar cells under concentration is difficult. Traditionally, the light concentration on solar cells has been determined by using a ratio of the measured solar cell s short circuit current to that at one sun, this assumes that current changes proportionally with light intensity. This works well with low to moderate (<20 suns) concentration levels on "well-behaved" linear cells but does not apply when cells respond superlinearly, current increases faster than intensity, or sublinearly, current increases more slowly than intensity. This paper continues work on using view factors to determine the concentration level and linearity of the solar cell with mathematical view factor analysis and experimental results [1].

Scheiman, Dave↗
DOE OSTI2026

Characterizing the Impact of Heliostat Size, Focus Method, and Optical Error on Concentrating Solar Tower Systems

Concentrating Solar Power (CSP) tower systems use heliostat fields to direct solar energy to a central receiver. The efficiency of the heliostat field is crucial for achieving thermal generation targets and is also the largest cost component, making up 30-40% of total project costs. Developers face a tradeoff: reducing heliostat costs may decrease optical performance and increase land use, while improving performance could raise manufacturing costs (through higher precision). The optimal design depends on land, labor, and manufacturing costs. Additionally, inherent performance limitations exist - optical errors result in larger solar images as heliostats move farther from the receiver, increasing spillage and attenuation losses. Ultimately, there exists a point where receiver design power can no longer be achieved at design conditions for a given solar field area. This point depends on key heliostat field design parameters including field layout, heliostats size, focus method, and heliostat optical error. In this work, we explore and characterize the performance trade-offs between heliostat size, focus method, and optical error using Monte Carlo ray-tracing simulations using NREL's high performance computing resources. The goal of this fundamental investigation is to understand practical heliostat design performance impacts that can be used to produce more cost-effective heliostat fields while still achieving plant thermal generation targets.

14 SOLAR ENERGY↗
NASA NTRS2013

A Comparison Of A Solar Power Satellite Concept To A Concentrating Solar Power System

A comparison is made of a Solar Power Satellite concept in geostationary Earth orbit to a Concentrating Solar Power system on the ground to analyze overall efficiencies of each infrastructure from solar radiance at 1 AU to conversion and transmission of electrical energy into the power grid on the Earth's surface. Each system is sized for a 1-gigawatt output to the power grid and then further analyzed to determine primary collector infrastructure areas. Findings indicate that even though the Solar Power Satellite concept has a higher end-to-end efficiency, that the combined space and ground collector infrastructure is still about the same size as a comparable Concentrating Solar Power system on the ground.

Smitherman, David V.↗
NASA NTRS2012

Cassegrain Solar Concentrator System for ISRU Material Processing

A 0.5 m diameter Cassegrain concentrator was constructed as a means of providing highly concentrated sunlight for the demonstration processing of lunar simulated regolith and other NASA In-Situ Resource Utilization Project (ISRU) reaction processes. The concentrator is constructed of aluminum with a concentration ratio of approximately 3000 to 1. The concentrator focuses solar energy into a movable tray located behind the concentrator. This tray can hold simulated regolith or any other material and or device to be tested with concentrated solar energy. The tray is movable in one axis. A 2-axis extended optical system was also designed and fabricated. The extended optical system is added to the back of the primary concentrator in place of the moveable test tray and associated apparatus. With this optical system the focused sunlight can be extended from the back of the primary concentrator toward the ground with the added advantage of moving the focal point axially and laterally relative to the ground. This allows holding the focal point at a fixed position on the ground as the primary concentrator tracks the sun. Also, by design, the focal point size was reduced via the extended optics by a factor of 2 and results in a concentration ratio for the system of approximately 6,000 to 1.The designs of both optical systems are discussed. The results from simulated regolith melting tests are presented as well as the operational experience of utilizing the Cassegrain concentrator system.

Colozza, Anthony J.↗
DOE OSTI2024

Fractal Nanostructured Solar Selective Surfaces for Next Gen Concentrating Solar Power (Final Report)

This project reports a novel coating with enhanced solar absorptance and reduced thermal emittance with high efficiency at elevated temperature for next-generation concentrated solar power (CSP) plants, with targeted operating temperatures around 750°C. Highly textured single and multimetallic oxide coatings were electrodeposited onto Inconel substrate by systematically varying the composition and process parameters. The optimized coating exhibited micro-to-nano structures designed to match the wavelengths in the visible region of the solar spectrum. These structures facilitate resonant absorption of solar radiation, significantly boosting solar absorption and accommodating thermal stress during high temperature exposure. A high solar absorptance exceeding 0.985 and a low thermal emittance below 0.5, yielding a thermal efficiency near 95%, was achieved for the optimized coatings without any anti-reflective overcoat, that remained robust after 750 h of isothermal exposure to 750°C in air. The coatings are also robust to severe mechanical and environmental stressors. The innovative approach presented in this study demonstrates the potential for tailoring air-stable solar absorber coatings to achieve high absorption, low emittance, and excellent high-temperature endurance, meeting the rigorous demands of next-generation CSP systems. A technoeconomic analysis reveals the economic advantage of the coatings for Gen3 CSP installations in different geographical zones globally.

14 SOLAR ENERGY↗
NASA NTRS1989

Concentration of off-axis radiation by solar concentrators for space power

Off-axis radiation is radiation from any direction not parallel to the axis of the solar concentrator. It will be reflected to regions other than the focus of the parabolic concentrator and possibly concentrated there. Four types of off-axis radiation are discussed. These are: (1) small off-axis angles during walk-off; (2) large off-axis angles; (3) an extended off-axis source such as Earth albedo; and (4) miscellaneous off-axis sources including radio frequency sources and local point sources. A previous analytical study used a computer code named PIXEL to predict concentration of off-axis radiation and a previous experimental study used an 11-m diameter multifaceted dish concentrator to validate the PIXEL analysis. The PIXEL code was limited in that it represented concentration by an ideal parabolic reflector of light from a point source. Another code named OFFSET has been developed to represent the solar concentrator being developed for Space Station Freedom. It is a detailed, ray tracing model which represents 50 ray originating points on the Sun and reflections from 10 points on each of the 456 concentrator facets. Results of this code are generally similar to the PIXEL results although there are small differences due to the more detailed representations of the Sun and concentrator that were used in the OFFSET code.

Jefferies, Kent S.↗