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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Solar Receiver with Integrated Thermal Storage for a Supercritical Carbon Dioxide Power Cycle

This project endeavors to design and demonstrate an integrated CSP system that meets the Department of Energy’s 6¢/kW-hr LCOE goal [1]. This design is based on the 10 MWe Supercritical Transformational Electric Power (STEP) engine specifications, but adaptable to any sCO 2 power module up to 10 MW e . The enabling technology to be tested is a new class of metal hydride based thermal energy storage materials which can store thermal energy in the hydrogen bonds between the metal hydride and hydrogen. This thermochemical energy storage solution provides a much greater energy density than sensible and latent energy storage enabling an integrated system design that closely linked the metal hydride to the power block. This allows the entire system to be mounted up tower to provide cost reductions. A novel metal hydride, capable of operating above 760 °C, was developed during the course of this project and thoroughly tested at a lab scale. The material’s hydrogen capacity, reaction enthalpy, thermal conductivity, and cyclic stability were measured. A demonstration test article was built that can store 2kWh of thermal energy and was coupled to Brayton Energy’s CO 2 loop where the performance of the metal hydride under commercial conditions was measured. An integrated model was created that uses the inputs from all the different sub-models in order to return an overall system LCOE using SAM. This project greatly advanced metal hydride based thermochemical energy storage technology and demonstrated its use. Previously there were no metal hydrides which were capable of operating at the proposed temperature limits (760°C), there is now a high temperature metal hydride with documented performance/stability and a path for low-cost production. Additionally, the metal hydride was tested at a scale >650x larger than what had previously been done in the lab. While not at commercial scale, it was an excellent demonstration of the technology and provided knowledge that can be leveraged for other applications.

08 HYDROGEN↗
DOE OSTI2022

SMART: Simplified Melting And Rotation-joint Technology

Oil based parabolic trough solar power plants are the most commercially mature CSP technology. However, the upper limit of about 400°C of the current organic heat transfer fluid(HTF)significantly limits the future potential of the technology. Advances in parabolic trough receiver and collector technology have enabled higher operating temperatures of potentially 500°C or above. The search for an improved higher temperature HTF has identified inorganic molten salts, specifically the mix referred to as Solar Salt, a 60:40 mix of sodium nitrate and potassium nitrate salt. However, Solar Salt starts to freeze at about 240°C. This poses a significant challenge for large parabolic trough plants that could have many kilometers of header piping and hundreds of kilometers of receiver piping all filled with molten salt. Plants using molten salt need to be designed to minimize the risk of freezing and to be able to recover from freeze events. Studies and field experiments have shown that this appears to be feasible and the approach appears to have strong economic advantages over conventional trough plants. However, some technical challenges remain related to the use of molten salt in trough solar fields, the cost of the freeze recovery system is significant, and many still question whether the risk of using molten salt is worth the economic upside. In our view, the potential economic upside justifies the continued look at molten salt HTF in parabolic trough plants. The objective of this project was to address the key technical issue remaining, look for opportunities to reduce the cost of the freeze recovery system, and improve the general information and tools available for assessing the design, performance and economics of trough plants using molten salt HTF.

14 SOLAR ENERGY↗
DOE OSTI2024

MODELING AND METHOD FOR OPTICAL PERFORMANCE OF A RECEIVER COATING AND ITS DEGRADATION DUE TO OPERATION

The optical properties of the coating used on a concentrated solar power (CSP)’s receiver directly impact the performance of the power plant. Receiver coatings are designed to absorb as much heat as possible and transfer it to the circulating fluid. Over time, the absorptivity of the receiver coating degrades due to environmental and operational conditions. This project aims to (1) create a test apparatus that allows coatings to undergo accelerated lifetime testing under conditions that mimic what the coating will experience on-tower; and (2) develop a mathematical model that based on the test data predicts absorptivity over time. To create the mathematical model, samples of BrightSource Energy’s Gen1 and Gen2 coatings were tested first looking at individual failure modes (such as high temperature cycling) and then for combined failure modes in the newly developed apparatus. In addition to taking optical measurements, the samples were destroyed to allow for metalogical evaluation to understand what was happening on a microscopic level. Pre-existing models from the literature that describe accelerated testing as well as individual phenomena observed in the coating were then combined to create the model. Additionally, the Gen2 and Gen3 coatings are being testing at the Plataforma Solar de Almería (PSA) facility in Almeria, Spain to confirm that the apparatus test results are similar to those received on-sun. (PSA’s facility closely mimics on-tower conditions). The goal is to enable industry players to test coatings using the new apparatus, gather absorptivity measurements (without needing to destroy samples), and input the information into the model to determine how the coating will perform over time, thus allowing the optical performance of coatings to be compared even before they are used on-tower. The model will be publicly available by the end of the project (currently projected as December 2024).

14 SOLAR ENERGY↗
DOE OSTI2024

A Novel Concentrating Solar Weathering Apparatus for Experimental Validation of Multi-Modal Degradation Models

High-performance coatings for Concentrating Solar Power (CSP) receivers are subjected to remarkable environmental stressors during normal operations. Applied to the receiver tubes, these coatings serve to maximize the solar absorptivity of the receiver, transferring as much heat as possible from the solar collectors into the heat-transfer fluid (HTF). The lifecycle of these coatings is not well-defined, and the harsh operational conditions make them difficult to test. NREL has designed, built, and tested an apparatus to expose these samples to design levels of environmental stress and well beyond, into accelerated and destructive conditions. The chamber is actively cooled, monitored, and has the capability to supply humidification for cycling tests, allowing us to test multi-modal degradation and failure conditions at high temperature, high flux, and high humidity conditions. These conditions can catalyze high-temperature oxidation, mechanical degradation, and other modes of absorptivity loss seen in selective solar receiver coatings. The experimental data can feed lifecycle models for expensive and necessarily resilient materials, offering insights to aid maintenance schedules, technoeconomic analysis, and material industry performance benchmarks. This presentation will demonstrate the apparatus design and performance, as well as initial results for aging on a selective receiver coating.

14 SOLAR ENERGY↗
DOE OSTI2024

Thermo-Mechanical Modeling and Evaluation of the Cracking Response of Additively Manufactured Monolithic SiC Lattice Structures Subjected to Laser Heating

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. The state-of-the-art SiC volumetric concentrating solar air receivers such as honeycomb design have been demonstrated in field tests to achieve exit air temperatures approaching 800oC. However, successful application of CST systems for decarbonization requires significant increase in temperature capability of SiC receiver technology. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Research in collaboration with Heliogen Holdings Inc, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and to demonstrate a techno-economically viable SiC air receiver technology to achieve exit air temperature of 1100oC for CST applications. This report summarizes the learnings of a computational study on additively manufactured SiC lattice structures subjected to laser heating. The results from this study aim to help guide the design of a SiC receiver through a better understanding of lattice structure geometric parameters and their implications on the cracking response of the structure. In the study, a heat flux was applied to the surface of a 2”-diameter cylindrical lattice structure to simulate a 4kW CO2 laser. The resulting temperature distribution was applied to a structural model to approximate the stress distribution within the lattice structure and a Weibull analysis was performed to gain insight into the probability of failure and to evaluate the cracking response of the structure. With this approach, the influence of lattice density on temperature, stress, and probability of failure was explored for two different lattice beam spacings. A discussion on modeling assumptions, a comparison with experimental results, and an evaluation of the lattice cracking response is provided.

14 SOLAR ENERGY↗
DOE OSTI2025

Design, Fabrication and On-Sun Performance Evaluation of SiC Receiver Feature Specimens for CST Applications Using Additively Manufactured SiC Materials

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Successful development of CST systems to generate heat for industrial applications requires significant increase in temperature capability and techno-economically viability of the receiver systems. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Aerospace Research in collaboration with Heliogen Holdings Inc and Sandia National Lab, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to demonstrate SiC receiver with air exit temperatures up to 1100 oC and high thermal efficiencies. We report design, fabrication and on-sun test results of SiC components of a prototype 50kW (thermal) HOTSSTAR module. The receiver module architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around a SiC center absorber. The SiC components are fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the reliability and to minimize the risk of cracking damage of SiC test articles in thermal gradient and thermal shock environment of the application, the components were laminated with GE’s MI SiC-SiC CMC. Following extensive design and lab test analyses, selected SiC component designs are tested at Heliogen Lancaster Solar field under highly concentrated solar fluxes around 2000 suns to assess the thermal performance characteristics under realistic field conditions. We report on the test results and compare the thermal performances of different HOTSSTAR SiC absorbers. Finally, we discuss fabrication and initial assembly of a 50kW prototype test module in preparation of on-sun field tests to assess the performance of our final design.

CST, CSP, high temperature, air receiver, SiC, add↗
DOE OSTI2024

Evaluation of Additively Manufactured Monolithic SiC and SiC-Matrix Ceramic Matrix Composites for Concentrating Solar Receiver Applications - Fabrication and Testing of Receiver Design Feature Specimens in a Simulating Lab Test via Laser Heating

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. We report the results of our study of the effective heat transfer characteristics of several candidate SiC structure motifs, or feature geometries, which are fabricated via additive manufacturing. The SiC structure motifs studied include different permutations of three-dimensional periodic lattices and defined shapes. A solar-thermal simulating laboratory test setup is constructed using a 4kW CO2 laser system with beam shaping optics to apply concurrent radiative heating power on one face of 2”-diameter cylindrical feature specimens, representing the structure motifs of interest for receiver element design, while flowing through the sample as heat transfer fluid. Using the test setup, simulative test conditions representative of a concentrated solar flux of up to ~2000 suns could be achieved in the lab tests under varying air flow through the test structure. A simple 1D numerical analysis scheme is developed to extract an effective or compound heat transfer coefficient representative of the test structure under steady-state heat flow conditions. The test results and their use to guide the selection and optimization of SiC material and structure motifs for the receiver element design fabrication are discussed.

14 SOLAR ENERGY↗
DOE OSTI2021

Utility-Scale Solar, 2021 Edition

Berkeley Labs "Utility-Scale Solar", 2021 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2020, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, and interconnection queue data.

2021↗
DOE OSTI2026

Advancing Concentrating Solar Thermal Modeling Using System Advisor Model (SAM)

Concentrating solar thermal (CST) technologies play a critical role in enabling dispatchable power and high-temperature industrial heat applications. Accurate and flexible modeling tools are essential for evaluating system performance, guiding technology research and development, and informing investment decisions. The National Laboratory of the Rockies's System Advisor Model (SAM) is a widely used techno-economic simulation platform for CST systems, providing detailed performance and financial modeling capabilities for multiple CST system configurations. SAM integrates physics-based performance models with financial analysis to simulate the behavior of complex energy systems under realistic operating conditions. For CST technologies (including tower, parabolic trough, and linear Fresnel), SAM enables hourly simulations using site-specific weather data that ensure feasible operating conditions and convergence of mass and energy between core system components (i.e., solar field, receiver, thermal energy storage, and power cycle). These capabilities allow researchers and developers to evaluate annual energy production, capacity factors, levelized cost of energy (LCOE), and system dispatch strategies. A key advantage of SAM lies in its flexibility for parametric analysis and large-scale computational studies. Users can vary system design parameters such as heliostat field layout, receiver dimensions, thermal energy storage capacity, power block sizing, and installation cost assumptions to investigate their impact on system performance and financial metrics. When combined with automated scripting through LK, SDKTool, or Python interfaces, SAM enables high-throughput simulation workflows that support sensitivity analysis, technology benchmarking, and optimization studies. These approaches are particularly valuable for next-generation CST concepts, where design spaces are large and system interactions are complex. Another important capability of SAM is its support for dispatch optimization and thermal energy storage modeling, which are central to the value proposition of CST technologies. The ability to simulate integrated storage and flexible power generation allows researchers to explore strategies that maximize grid value, improve capacity utilization, and enhance integration with variable resources such as photovoltaic and wind generation. This poster will present an overview of SAM's thermal system modeling capabilities including concentrating solar. Additionally, we will highlight new feature developments including: 1) implementing Google's OR-Tools optimization platform for faster and more robust dispatch optimization, 2) developing a new power load following controller for modeling behind-the-meter applications, 3) enabling direct modeling of CSP-PV hybrid systems with the inclusion of battery storage, and 4) developing a multi-receiver falling particle Gen3 system model.

14 SOLAR ENERGY↗
DOE OSTI2020

Internal Insulation and Corrosion Control of Molten Chloride Storage Tanks

The U.S. Department of Energy Gen3 CSP program aims to develop integrated systems capable of delivering high temperature thermal energy to advanced power cycles [1]. The National Renewable Energy Laboratory (NREL) is leading a multi-national team to validate the potential of a chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl to provide higher temperature thermal energy storage capability (Fig. 1a). The economic viability of this concept is dependent on internally insulating the hot and cold storage tanks to enable the use of low-cost steel shells (Fig. 1b).

14 SOLAR ENERGY↗
DOE OSTI2023

Wind Loading on Parabolic Trough Collectors: Wind and Structural Loads Measurements at an Operational Powerplant

Concentrated Solar Power (CSP) is a promising method for using solar power for electricity generation with thermal energy storage for industrial applications. Solar collectors constitute almost 1/3 of the total cost of the power plant. One of the primary drivers of unrealiability of these collectors is wind-driven loading of mirrors, support structures, and drives. To date, the design of the solar collector structures has relied on data from wind tunnels that do not adequately capture the dynamic effects observed at scale. NREL initiated a field measurement campaign at the operational Nevada Solar One (NSO) parabolic trough powerplant. At this plant, parabolic trough solar collectors track the sun from east to west in the course of a day and face varying wind loads depending on the wind properties and the angle of the troughs. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs, providing insights into structural dynamic response, and generating a comprehensive wind-loading dataset for validating simulations of wind loading on collector structures. The measurements at NSO consist of sonic anemometers on masts at different heights to characterize the incoming flow and conditions at four trough rows at the edge of the trough field. In addition, a Doppler Lidar scans the horizontal plane above the troughs. The wind measurements at NSO have been continuously collecting data since October 2021 and are combined with structural load measurements that started in November 2022. The load measurements were installed on the same four outermost trough rows and include support structure bending moments, drive torque moments, dynamic accelerations of the spaceframe, mirror displacement, and tilt angles. Measurements are planned to continue until May 2023, providing a first-of-a-kind, high-resolution multi-month dataset of combined wind and load measurements. In this presentation, we show first results of the measurement campaign. Based on the measurements, we identified three main factors altering the flow over the parabolic troughs: Wind speed, wind direction, and the angle of the parabolic troughs. Most interactions between incoming wind and the trough field are observed when the wind blows perpendicular to the trough rows. In this case, the first rows experience the highest wind speed and block the downwind rows, creating conditions with decreased wind speed and enhanced turbulence within the trough field. Also, turbulent length scales are smaller after the first row. This leads to the highest static loads (bending and torque moments) at the first row but potentially increased dynamic loads within the field. We illustrate our findings with case studies focused on different wind conditions and will present fatigue analysis to highlight the impact of wind-driven loads on collector structures.

CSP collectors↗
DOE OSTI2023

A Performance Forecasting Framework for Concentrating Solar Power Systems

This presentation will summarize a methodology used to characterize the uncertainty in performance of a contrived CSP project. As well as develop a case study in which we backcast the projected and actual annual performance of an existing plant. Finally will highlight the importance of several assumptions and the use of time series inputs in obtaining realistic estimates.

concentrating solar power↗
DOE OSTI2022

Binder jet additive manufacturing of ceramic heat exchangers for concentrating solar power applications with thermal energy storage in molten chlorides

Triply periodic minimal surface (TPMS) geometries can only be fabricated by additive manufacturing methods and are of interest for heat exchangers. Ceramic TPMS heat exchangers can operate at higher temperatures and pressures with superior performance and increased operating efficiencies compared to metal heat exchangers. The properties of ultra-high temperature ceramic (UHTC) materials are also favorable for heat exchangers and potentially suited to concentrated solar power (CSP) systems, such as those based on a molten chloride salt thermal energy storage (TES) medium used to heat CO 2 in a closed-loop Brayton power cycle. We intended to demonstrate binder jet additive manufacturing feasibility of a UHTC-TPMS structure by printing and sintering a null candidate. We aimed to achieve parts with a relative density ≥ 92 % of theoretical and to provide a TPMS part demonstration. The target density indicates the transition from intermediate to final stage sintering, a requirement to inhibit gas permeability and for sintering complex near net shapes to full density with sinter-HIP technology. The goal of the TPMS part demonstration was to determine if printing and sintering parameters developed from test coupons apply to the complex geometries that will eventually be used in a heat exchanger design. Our objective was to print cubic TPMS parts with a 9 cm 3 volume and sinter it without distorting and cracking. We report we were able to sinter ZrB 2 -MoSi 2 composite parts based on the Schwarz-D TPMS and achieve isotropic shrinkage up to 60 % by volume, resulting in densities ranging from 92 % to 96 % of theoretical.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessing geothermal/solar hybridization – Integrating a solar thermal topping cycle into a geothermal bottoming cycle with energy storage

Geothermal and concentrating solar power (CSP) technologies typically use heat at different temperatures in their commercial deployments. This enables a technically viable hybridization of a solar topping cycle and a geothermal bottoming cycle at locations where both resources are available. In this article, an underperforming geothermal power system based at Burley, Idaho is used as a baseline to investigate the technical and economic potential of such a hybrid cycle. A direct thermal energy storage (TES) system is also integrated to overcome the intermittency of the solar resource. Design and off-design behavior of key components are modelled to simulate the annual performance of the hybrid system on an hourly basis. The sizing of the solar field and thermal storage is investigated and is seen to significantly impact the annual electricity generation and efficiency. Various cost scenarios for the solar field and thermal energy storage are investigated. An economic metric - levelized cost of electricity (LCOE) - is used to optimize the solar field sizing and TES capacity. The hybrid plant converts the additional solar heat input into additional work with an efficiency of 32.9%. Retrofitting a geothermal plant with solar and eight hours of energy storage can achieve an LCOE of 0.136 $/kWhe in current cost scenarios and 0.081 $/kWhe in a future cost reduction scenario. Although the hybrid system cannot directly compete with current PV systems without batteries, it has an LCOE 32% lower than that of a PV-battery system. This paper provides insights into the research and development of the future grid with a high renewable energy penetration and encourages further study of energy hybridization for improved efficiencies and economics.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Time-dependent-bases with local CUR decomposition method for accelerating turbulent combustion simulations

Here, this study presents a novel reduced-order modeling framework, Time-Dependent Bases with Local CUR decomposition (TDB-L-CUR), designed to efficiently and accurately approximate the species transport equations in reacting flow simulations. The method extends the existing TDB-CUR approach for chemically reacting flows (Jung et al. Comput. Methods Appl. Mech. Engrg. 437 (2025) 117758), which leverages matrix decomposition techniques to form a global-in-space, time-dependent low-dimensional manifold. While TDB-CUR performs well in homogeneous systems, it may be less well-suited to spatially heterogeneous systems such as turbulent flames, where higher-rank approximations are typically required. The proposed TDB-L-CUR framework introduces two methodological extensions to the baseline approach. First, it applies unsupervised clustering to partition the physical domain into distinct regions, enabling spatially localized manifold construction, thereby reducing the rank required for the reduced-order representation. Second, it incorporates a computational singular perturbation (CSP)-based scheme for identifying and penalizing fast species, allowing for spatio-temporally adaptive mitigation of chemical stiffness. The proposed framework is validated on a hierarchy of test cases, including a one-dimensional premixed flame, a two-dimensional nonpremixed ignition case with vortex interaction, and a three-dimensional turbulent premixed flame. TDB-L-CUR significantly improves accuracy over TDB-CUR while further reducing computational cost. The fully on-the-fly formulation of TDB-L-CUR (i.e., requiring no offline training or prior knowledge) makes it a robust and scalable tool for reduced-order modeling of reactive flows.

Local manifold↗
DOE OSTI2021

A first principles framework to predict the transient performance of latent heat thermal energy storage

Thermal energy storage (TES) is increasingly recognized as an essential component of efficient Combined Heat and Power (CHP), Concentrated Solar Power (CSP), Heating Ventilation and Air Conditioning (HVAC), and refrigeration as it reduces peak demand while helping to manage intermittent availability of energy (e.g., from solar or wind). Latent Heat Thermal Energy Storage (LHTES) is a viable option because of its high energy storage density. Parametric analysis of LHTES in terms of dimensionless numbers is highly desired as a tool to model LHTES systems. One approach is to develop a model equation so as to minimize the error between the model and data obtained from experiments or simulations. While this approach can produce an accurate correlation applicable within the range of data used for its creation, it does not provide physical understanding of the rate-limiting process controlling the transient behavior of the device. In this paper we present an alternative approach whereby the potential rate-limiting processes are identified from first principles and then the key process is determined as a function of time as a LHTES device is charged. For example, in a simple geometry, the melt-fraction can be expected to vary linearly in time if the heat transfer rate is limited by natural convection of the phase changing material and we show it scales with the PCM Grashof number as $Gr^1_p$ and PCM Prandtl number as $Pr_p^{(1/3)}$. On the other hand, if surface area of solid PCM limits the heat transfer rate, the melt fraction increases asymptotically to reach full melting. The existence of these linear and asymptotic regions and the $Gr^1_pP r^{1/3}_p$ shape of the melt fraction curve is verified using our database of 64 simulations. Of practical importance in designing LHTES devices is the melt fraction at which the heat transfer rate ceases to be limited by convection, after which the heat storage rate deteriorates. For our geometry, this is found to be about 90%. This test case of our methodology shows the value of our approach, that predicting heat storage rate based on the rate-limiting physical phenomenon as a function of time is an effective approach to modeling LHTES devices.

25 ENERGY STORAGE↗
DOE OSTI2020

One piece ceramic heat exchanger for concentrating solar power electric plants

Using additive manufacturing techniques, a ceramic heat exchanger was optimized for a concentrating solar power (CSP) electric power plant with a corrosive molten salt at atmospheric pressure as the solar field heat transfer fluid and supercritical carbon dioxide at 200 bar as the power block fluid. Temperatures ranged from 750 °C to 540 °C. The plant heat exchanger was optimized for heat transfer and stress using 1 m³ modules arranged in parallel. Heat transfer was optimized using COMSOL Multiphysics software resulting in a unique semi-elliptical cross section for the fluid flow channels in a counter-flow configuration. Counter-flow was made possible through additive manufacturing of the fluid headers as part of each modular heat exchanger thus producing the entire module as a single piece and minimizing cost. Using reasonable parametric values, a heat exchanger module was optimized to 0.5 MW/m³, and a section of it was manufactured including the fluid headers. Here, parametric studies showed the potential for a module to reach 3.5 MW/m³.

14 SOLAR ENERGY↗