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DOE OSTI2024

A Nonintrusive Optical Approach to Characterize Heliostats in Utility-Scale Power Tower Plants: Camera Position Sensitivity Analysis

Optics plays a major role in the effectiveness of concentrating solar power (CSP) technologies. The nonintrusive optical (NIO) approach developed by the National Renewable Energy Laboratory uses uncrewed aircraft system (UAS)-based imaging to survey heliostats in a commercial-scale power tower CSP plant and characterize their optical errors. The image processing algorithm uses photogrammetry to calculate the camera position for each image frame, and the accuracy of the estimated optical errors is highly sensitive to the calculated camera position accuracy. In this study, we simulate a series of case studies in python to examine the impact of different parameters of the sensitivity of the camera calculation, including the number of facet corners used as control points for the photogrammetric calculation, precision error in the detected pixel locations of the facet corners in the image, and precision error of the canting and mounting positions of the facets of the heliostat. The case studies consider heliostat geometry based on three commercial designs to serve as representative examples of different possible sizes of heliostats that the NIO method could be applied to. The results show that increasing the number of control points can improve accuracy for heliostats with many facets, pixel precision has a significantly larger impact on camera calculation accuracy than facet canting and mounting errors, and the camera distance and focal length must be chosen to ensure adequate pixel accuracy on the heliostat surface depending on the size of heliostat. In conclusion, based on the results, recommendations for the allowable values of each parameter are provided to achieve the required NIO optical error estimation accuracy depending on the size of heliostat.

14 SOLAR ENERGY↗
DOE OSTI2015

Improved Large Aperture Collector Manufacturing

The parabolic trough is the most established CSP technology and carries a long history of design experimentation dating back to the 1970’s. This has led to relatively standardized collector architectures, a maturing global supply chain, and a fairly uniform cost reduction strategy. Abengoa has deployed more than 1,500MWe of CSP troughs across several countries and has built and tested full-scale prototypes of many R&D concepts. The latest trough R&D efforts involved efforts to internalize non-CSP industry experience including a preliminary DFMA principles review done with Boothroyd Dewhurst, a construction literature review by the Arizona State University School of Construction Management, and two more focused manufacturing engineering subcontracts done by Ricardo Inc. and the nonprofit Edison Welding Institute. The first two studies highlighted strong opportunities in lowering part count, standardizing components and fasteners, developing modular designs to support prefabrication and automation, and devising simple, error-proof manual assembly methods. These principles have delivered major new cost savings in otherwise “mature” products in analogous industries like automotive, truck trailer manufacture, metal building fabrication, and shipbuilding. For this reason, they were core in the design development of the SpaceTube® collector, and arguably key to its early successes. The latter two studies were applied specifically to the first-generation SpaceTube® design and were important in setting the direction of the present SolarMat project. These studies developed a methodology to analyze the costs of manufacture and assembly, and identify new tooling concepts for more efficient manufacture. Among the main opportunities identified in these studies were the automated mirror arm manufacturing concept and the need for a less infrastructure-intensive assembly line, both of which now form central pillars of the SolarMat project strategy. These new designs will be supported by new technology in the area of quality control inspection, in which state of the art photogrammetry and laser CMM inspection methods will be used to qualify parts and assemblies, and in which the recently-developed Absorber Reflection Method will enable in-line quality control inspection of modules produced by the new high-rate production line.

14 SOLAR ENERGY↗
DOE OSTI2015

Advanced Research Projects Agency - Energy Annual Report for FY 2014

This report presents a summary of the activities of the Advanced Research Projects Agency-Energy (ARPA-E) during Fiscal Year 2014 (FY2014). In FY2014, ARPA-E issued funding solicitations and selected projects for three new programs covering a broad array of energy technologies, including: 27 million dollars to develop next-generation power switching devices that improve energy efficiency in a wide range of applications; 30 million dollars for hybrid solar energy beyond current photovoltaic (PV) and concentrated solar power (CSP) technologies; and 33 million dollars for electrochemical technologies to enable low-cost distributed power generation. ARPA-E released three additional funding opportunities in FY2014 with project selections that were ultimately announced in FY2015. These programs include: 30 million dollars for localized heating and cooling devices to expand temperature ranges within buildings reducing energy consumption; 30 million dollars for low-cost, high-sensitivity systems to detect and measure methane emissions; and 30 million dollars for low-cost tools to aid in the future development of fusion power. ARPA-E also continued the use of a rolling open solicitation to quickly support innovative applied energy research that has the potential to lead to new focused programs. In addition to these new programs, ARPA-E hosted the fifth annual Energy Innovation Summit from February 24-26, 2014. The Summit brought together leaders from academia, government, and business to discuss the foremost energy issues, showcase the latest technology innovations, and cultivate relationships to help advance cutting-edge technologies to market. The event drew over 2,100 attendees and featured over 120 speakers and keynote addresses. At the Summit, ARPA-E announced at least 24 ARPA-E project teams that have formed new companies and more than 16 ARPA-E projects, which have partnered with other government agencies for further development. Additionally, 22 ARPA-E projects have attracted more than 625 million dollars in private-sector follow-on funding after ARPA-E’s investment of approximately 95 million dollars. Lastly, ARPA-E continued to focus on providing awardees with practical training and critical business information as part of the Agency’s Technology-to-Market program. This support equips projects with a clear understanding of market needs to guide technical development and help projects succeed the marketplace.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

FY2023 NSTTF Annual Report

The National Solar Thermal Test Facility (NSTTF) is a DOE Core Capability and Technology Deployment Center located in Albuquerque, NM. It is operated by Sandia National Laboratories (Sandia) for the U.S. Department of Energy (DOE). The NSTTF is the only multi-mission, multi-use, multi-story test facility of its type in the United States. The NSTTF was founded in 1978 and began testing with high heat flux that same year. Over the past 45 years, the NSTTF has been at the forefront of the research, design, fabrication, and testing of many of the critical Concentrating Solar Power (CSP) technologies. These technologies have allowed costs to be dramatically reduced from over $\$ $0.40 /kWh to $\$$0.12 /kWh since the conception of this renewable energy technology. The NSTTF has worked to make the Solar Energy Generating Systems (SEGS) parabolic trough plants successful, while also working with the Solar One and Solar Two facilities for successful implementation. Over the four decades since its founding, the mission of the NSTTF has grown to include new receiver technologies, like our generation 3 falling particle system (G3P3 Tower), optical metrology techniques like SOFAST, molten salt testing, thermal energy storage, solar thermal chemistry, and more. We continue to expand our capabilities in pursuit of the DOE SETO mission and the DOE SunShot 2030 goals: unsubsidized LCOE of $\$$0.05/kWh for CSP that includes 12 or more hours of thermal energy storage. To support both the DOE SETO mission and support the CSP sector as a whole, we are working to develop our operations and maintenance framework to provide a world class testing facility in support of our technological achievements. To accomplish both of these missions, the NSTTF draws on the decades of experience and expertise of our staff along with the world-class facilities at Sandia National Laboratories to further the science of concentrated solar thermal technologies in diverse applications. We remain a trusted partner for high-quality and impactful research in both fundamental and applied arenas. We are able to provide our partners with both one-of-a-kind testing platforms as well as world-class analytics.

14 SOLAR ENERGY↗
DOE OSTI2023

Concentrating Solar Power (CSP) Plant Optimization Study for the California Power Market (CalCSP)

In the United States, many states are implementing goals to achieve 100% carbon free power generation by 2050 or sooner. California has one of the more aggressive goals to achieve 100% carbon free generation of its retail power sales by 2045. California has excellent solar resources, but to accomplish this goal, California’s power utilities will need new zero carbon resources that can replace the natural gas units that they currently rely on for suppling power at night. Appropriately configured concentrating solar power plants with thermal energy storage are an option to serve this nighttime load. These plants would be designed to take advantage of CSP’s low-cost thermal energy storage and collect and store energy during the day and then be dispatched to produce power at night. The U.S. Department of Energy has funded a study to identify the design of a CSP plant that optimally meets the evolving CA grid needs. This will be done by taking a fresh look at how CSP technologies can best be designed to meet the emerging nighttime market for carbon free power generation or zero-carbon firm resources. The paper provides an overview of the study and present preliminary findings on the California power market requirements, CSP configurations, technoeconomic analysis, siting opportunities, and key issues for CSP deployment in this market.

Price, Hank (ORCID:0000000267049197)↗
DOE OSTI2025

Durability and Accelerated Aging Test of the Polymeric Mirror-Film Prototype (CRADA Final Report)

The participant is developing a low-cost liquid metal coating for concentrated solar power (CSP) polymeric mirrors. Current CSP technology uses bulky and costly glass mirrors. As a lighter alternative, polymeric mirror film is cheaper than glass mirrors, yet expensive to manufacture. The participant is working to develop a room temperature liquid-metal thin-film deposition technique and CSP polymeric mirror film that will reduce expenditures by 80% and film cost by 50%.

14 SOLAR ENERGY↗
DOE OSTI2024

Failure Analysis for Molten Salt Thermal Energy Storage Tanks for In-Service CSP Plants

Thermal Energy Storage (TES) is a fundamental component in concentrating solar power (CSP) plants to increase the plant's dispatchability, capacity factor, while reducing the levelized cost of electricity. In central receivers CSP plants, nitrate molten salts have been used for several years for operation temperatures of up to 565 degrees C. Despite many efforts to advance nitrate salt to higher operation temperatures (even considering a replacement with molten chloride salts) to achieve higher energy conversion efficiencies, the 565 degrees C temperature is currently considered the state-of-the art. Although molten salt tanks have been broadly deployed in commercial CSP plants worldwide, several failures have been reported in these tanks after a few months or years of operation, causing significant economic loss and mistrust in CSP technologies. Most of these failures are associated with the infancy of the technology and multiple issues related to tank design, fabrication, commissioning, and aggressive operation. A technical standard dedicated to the design and fabrication of molten nitrate TES tanks does not exist today. Current in-service molten salt tanks have been generally designed based on the American Petroleum Institute's (API) 650 and ASME Section II standards. The API 650 code provides guidelines for dimensions and fabrication for oil storage tanks up to 260 degrees C. The ASME standard provides allowable stress values for various materials at a range of temperatures and conditions. Both standards seem to be limited for molten salt TES tanks where high temperatures, thermal cycling, and transient conditions are expected. In 2020, NREL released the Concentrating Solar Power Best Practices Study (NREL/TP-5500-75763) that summarized multiple issues in CSP plants, along with potential alternatives and recommendations to address those issues based on information collected from participants representing about 80% of operating CSP plants in the world. One of the recommendations from this study was the development of accurate and validated models to evaluate the plant's transient operation, capable of capturing the effect of short-term clouds and operator response, while being flexible in being adapted to various spatial and temporal resource data. The "Failure Analysis for Molten Salt Thermal Energy Tanks for In-Service CSP Plants" project was inspired on this recommendation and was focused on (1) the development and validation of a physics-based model for a representative, commercial-scale molten salt tank, (2) performing simulations to evaluate the behavior of the tank as a function of typical plant operation conditions, (3) understanding tank failures mechanisms, (4) determining the residual stress and distortion in the tank floor after welding fabrication and evaluating their impact in the stresses developed in the tank during operation, (5) assessing the impact of key operation parameters on the temperature and stress distribution, (6) conduct a preliminary evaluation of design features to reduce stress and improve tank's reliability, and (7) estimate the tank's service life based on the stress developed under diverse operation scenarios. From the analysis conducted in the project and presented in this report, it was found that maximum stresses surpassing the yield strength point of the stainless steel (SS) 347H are developed on the tank floor near the perimeter. These large stresses are strongly influenced by the initial residual stresses and distortion of the tank floor after welding fabrication. During operation, large stresses are developed in the tank floor at high operation temperatures with large salt inventory levels during transient operation. High stresses are also related to elevated temperature gradients in the tank floor that could be attributed to insufficient mixing within the salt inflow and the salt inventory. Based on the analysis, creep is the predominant failure mechanism. However, the large stress levels could favor the plastic deformation into buckles, and crack formation due to stress relaxation cracking during cycle operation. A lifetime below 3 years was estimated for the typical plant operation conditions and a specific initial residual stress and deformation distribution of the tank floor. The estimated life agrees with the service time to failure reported in several commercial molten salt tanks. Desing and operation guidelines can be extracted from the analysis presented in this report, which could be adopted by tank manufacturers and CSP operators to advance toward an ultimate solution for tank failures by reducing residual and operational stresses to achieve a tank service life of more than 30 years. Addressing failures in molten salt TES tanks is fundamental for the CSP industry's survivability, but it is also important for other industrial and power generation applications using this technology, including nuclear and concentrating solar thermal.

14 SOLAR ENERGY↗
DOE OSTI2023

Summary Paper: An Initial Heliostat Supply Chain Analysis

This paper summarizes the prior analysis, key findings, and recommendations from the published report titled “Initial Heliostat Supply Chain Analysis” [1]. Globally, the growing demand for concentrating solar power (CSP) technologies, primarily for electricity generation plants has been met with supply chains primarily composed of plentiful commodity materials such as steel, aluminum, and glass. Often the commodity materials can be sourced in the domestic market where power plant will be constructed. Although specialty components are required for CSP solar fields —including mirror panels used for heliostat applications—these specialty components constitute about 30-50% of total system installed costs [2]. Only a few companies and countries, including the United States, have developed the capacity to supply such specialty components. The U.S. heliostat supply chain at present is comprised of few companies (e.g., CSP developers), component suppliers, and is its infancy. By 2035, with current and aggressive solar photovoltaic (PV) capacity expansions, there is the potential for 500,000–1,500,000 direct and indirect jobs in the areas of manufacturing, installation and development, and operations and maintenance (O&M) [3]. Utilizing the CSP capacity estimations the recent NREL report [4], the construction of 39 gigawatts (GW) of CSP (assuming mainly power tower) in the U.S. could lead to approximately 195,000 manufacturing, construction, and O&M jobs. This does not include the longer-term jobs and economic impact (e.g., taxes from plant operations staff) from operating the plants once constructed. It is recommended that further CSP component and system supply chain analysis and modelling be undertaken.

Kurup, Parthiv (ORCID:0000000217356703)↗
DOE OSTI2017

Fluidized-Bed Heat Transfer Modeling for the Development of Particle/Supercritical-CO2 Heat Exchanger

Concentrating solar power (CSP) technology is moving toward high-temperature and high-performance design. One technology approach is to explore high-temperature heat-transfer fluids and storage, integrated with a high-efficiency power cycle such as the supercritical carbon dioxide (s-CO2) Brayton power cycle. The s-CO2 Brayton power system has great potential to enable the future CSP system to achieve high solar-to-electricity conversion efficiency and to reduce the cost of power generation. Solid particles have been proposed as a possible high-temperature heat-transfer medium that is inexpensive and stable at high temperatures above 1,000 degrees C. The particle/heat exchanger provides a connection between the particles and s-CO2 fluid in the emerging s-CO2 power cycles in order to meet CSP power-cycle performance targets of 50% thermal-to-electric efficiency, and dry cooling at an ambient temperature of 40 degrees C. The development goals for a particle/s-CO2 heat exchanger are to heat s-CO2 to =720 degrees C and to use direct thermal storage with low-cost, stable solid particles. This paper presents heat-transfer modeling to inform the particle/s-CO2 heat-exchanger design and assess design tradeoffs. The heat-transfer process was modeled based on a particle/s-CO2 counterflow configuration. Empirical heat-transfer correlations for the fluidized bed and s-CO2 were used in calculating the heat-transfer area and optimizing the tube layout. A 2-D computational fluid-dynamics simulation was applied for particle distribution and fluidization characterization. The operating conditions were studied from the heat-transfer analysis, and cost was estimated from the sizing of the heat exchanger. The paper shows the path in achieving the cost and performance objectives for a heat-exchanger design.

14 SOLAR ENERGY↗
DOE OSTI2022

Initial Heliostat Supply Chain Analysis

Globally, the growing demand for concentrating solar power (CSP) technologies, primarily for electricity generation plants has been met with supply chains primarily composed of plentiful commodity materials such as steel, aluminum, and glass. Often the majority of the commodity materials are sourced within the domestic market where generating plants are constructed. Although specialty components are required for CSP solar field components - including mirror panels used for heliostat applications - these specialty components constitute about 30-50% of total system installed costs. Only a few companies and countries, including the United States, have developed the capacity to supply such specialty components. This report is an initial assessment of the global and U.S. heliostat supply chain.

14 SOLAR ENERGY↗
DOE OSTI2024

Design Methods, Tools, and Data for Ceramic Solar Receivers

This report presents the development of tools and methods for evaluating the reliability and performance of ceramic materials in high temperature solar receivers. As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat requirements, current high temperature metallic materials face challenges in maintaining structural integrity. This report explores advanced ceramics as a promising alternative, given their superior high temperature strength and lower thermal expansion, compared to metals. To address the need for effective ceramic receiver design tools, this report integrates statistical failure models of ceramics into the existing srlife tool: an open-source software package designed to estimate the life of high temperature CSP components. These failure models account for the inherent variability and flaw distribution in ceramics, as well as the impact of subcritical crack growth under high temperature cyclic loads. The report also presents experimental data collected for a commercially available ceramic material, SiC, and details the process of estimating reliability model parameters from these data. A comparative design analysis is then performed between ceramic (SiC) and metallic (current nickel-based superalloys A740H and A282) receiver. This comparison demonstrates that SiC receivers can achieve service life exceeding 30 years under high incident heat flux conditions, compared to just a few years for metallic receivers.

14 SOLAR ENERGY↗
DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗
DOE OSTI2017

Evaluation and comparison of an adaptive method technique for improved performance of linear Fresnel secondary designs

As a line-focus concentrating solar power (CSP) technology, linear Fresnel collectors have the potential to become a low-cost solution for electricity production and a variety of thermal energy applications. However, this technology often suffers from relatively low performance. A secondary reflector is a key component used to improve optical performance of a linear Fresnel collector. The shape of a secondary reflector is particularly critical in determining solar power captured by the absorber tube(s), and thus, the collector's optical performance. However, to the authors' knowledge, no well-established process existed to derive the optimal secondary shape prior to the development of a new adaptive method to optimize the secondary reflector shape. The new adaptive method does not assume any pre-defined analytical form; rather, it constitutes an optimum shape through an adaptive process by maximizing the energy collection onto the absorber tube. In this paper, the adaptive method is compared with popular secondary-reflector designs with respect to a collector's optical performance under various scenarios. For the first time, a comprehensive, in-depth comparison was conducted on all popular secondary designs for CSP applications. In conclusion, it is shown that the adaptive design exhibits the best optical performance.

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 OSTI2024

A Planar-Cavity Receiver Configuration for High-Temperature Solar Thermal Processes: Preprint

Next generation concentrating solar thermal power (CSP) and novel solar thermochemical systems using concentrating solar thermal (CST) energy require high operating temperatures exceeding those of traditional nitrate-salt CSP systems. Particle-based systems are attractive for next-generation CSP and CST applications owing to high-temperature stability of inert silica- or alumina-based particulate materials, the lack of low-temperature freezing concerns that limit molten salt and/or molten metal heat transfer media, and cost-effective thermal storage using low-cost particulate and containment materials. Open-cavity falling particle receivers have many potential advantages, but face challenges pertaining to scalability, thermal loss, and particle loss through the open aperture, and are infeasible for chemical processes that require a low-oxygen ambient environment. Enclosed receiver configurations can be scalable, avoid particle loss when heating particles, and have potential for future chemical processes; however, particle-based heat transfer media provide substantially lower heat transfer rates than liquid media, and thus enclosed particle receiver designs require novel configurations to limit surface temperatures under the high incident solar flux concentrations necessary for high receiver thermal efficiency at high temperature. This paper introduces the novel planar-cavity enclosed particle receiver configuration in which arrays of planar surfaces are arranged into sub-vertical cavities. Large angles between the panel surface normal vectors and the aperture surface normal allow the incoming solar beam to distribute along the panel walls. Correspondingly, a high incident solar flux concentration at the cavity aperture produces substantially lower absorbed solar flux concentration on any panel wall. Sets of individual vertical cavities can be arranged to form a scalable receiver configuration.

cavity receiver↗
DOE OSTI2015

Parabolic Trough Collector Cost Update for the System Advisor Model (SAM)

This report updates the baseline cost for parabolic trough solar fields in the United States within NREL's System Advisor Model (SAM). SAM, available at no cost at https://sam.nrel.gov/, is a performance and financial model designed to facilitate decision making for people involved in the renewable energy industry. SAM is the primary tool used by NREL and the U.S. Department of Energy (DOE) for estimating the performance and cost of concentrating solar power (CSP) technologies and projects. The study performed a bottom-up build and cost estimate for two state-of-the-art parabolic trough designs -- the SkyTrough and the Ultimate Trough. The SkyTrough analysis estimated the potential installed cost for a solar field of 1500 SCAs as $170/m 2 +/- $6/m 2 . The investigation found that SkyTrough installed costs were sensitive to factors such as raw aluminum alloy cost and production volume. For example, in the case of the SkyTrough, the installed cost would rise to nearly $210/m 2 if the aluminum alloy cost was $1.70/lb instead of $1.03/lb. Accordingly, one must be aware of fluctuations in the relevant commodities markets to track system cost over time. The estimated installed cost for the Ultimate Trough was only slightly higher at $178/m 2 , which includes an assembly facility of $11.6 million amortized over the required production volume. Considering the size and overall cost of a 700 SCA Ultimate Trough solar field, two parallel production lines in a fully covered assembly facility, each with the specific torque box, module and mirror jigs, would be justified for a full CSP plant.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

Corrosion resistance of alumina forming alloys against molten chlorides for energy production. II: Electrochemical impedance spectroscopy under thermal cycling conditions

Next-generation power systems require higher temperatures to increase the efficiency of electricity production in the power block. Concentrating solar power (CSP) technology is looking for high temperature thermal fluids able to work in the range of 550–750 °C. Molten chlorides containing NaCl, KCl, MgCl 2 , and/or ZnCl 2 are being considered for solar receivers and/or sensible- or latent- thermal energy storage systems. Vapor pressures of chlorides are high enough that in combination with oxygen gaseous compounds will produce a harsh atmosphere that is generally very aggressive to common chromia forming alloys. Corrosion mitigations must consider a solution in which both zones (immersed in fluid and exposed to vapor phase) will be protected. This could easily be obtained using alloy surface modification approaches. Surface passivation, produced after pre-oxidation treatments, of alumina forming alloys (Inconel 702, Haynes 224 and Kanthal APMT) was evaluated in molten 35.59 wt% MgCl2 – 64.41 wt% KCl thermally cycled from 550 °C to 700 °C in flowing Ar and static zero air (ZA) atmospheres. Electrochemical impedance spectroscopy tests and metallographic characterization showed that the best performing alloy was pre-oxidized In702 in ZA at 1050 °C for 4 h due to the formation of protective, dense and continuous alumina layers. The alumina layers were unstable when flowing Ar was used as the inert atmosphere during corrosion evaluations. Corrosion results in static ZA are promising for next-generation CSP applications using molten chlorides because alumina scales were stable after 185 h of immersion in the oxygen-containing atmosphere. Alumina layers in pre-oxidized Al-FA In702 grew from 5 µm (before immersion) to 13 µm (after 185 h of immersion). As a result, the use of these alloys could be commercial feasibility and cost-effective because of the possibility of using oxygen-containing atmospheres instead of keeping enclosed systems with inert atmospheres to protect alloys from corrosion in molten chlorides.

14 SOLAR ENERGY↗
DOE OSTI2018

Basic properties of eutectic chloride salts NaCl-KCl-ZnCl 2 and NaCl-KCl-MgCl 2 as HTFs and thermal storage media measured using simultaneous DSC-TGA

Concentrated solar power (CSP) technologies tend to work at high temperatures for better energy efficiency, which need high temperature heat transfer fluids (HTF) and thermal storage. A good HTF should have low melting point and be thermally stable at high temperatures. A thermal storage medium needs a high heat capacity in order to store more energy in per unit of mass or volume. The objective of this work is to study the basic thermophysical properties of several eutectic molten salts for HTF and thermal storage media, which can work at upper limit temperatures of 850 °C. The eutectic salts are mixtures by NaCl-KCl-ZnCl 2 , and by NaCl-KCl-MgCl 2 , respectively. The heat capacity, melting point, and heat of fusion of the eutectic salts at different temperatures were measured using Differential Scanning Calorimetry (DSC) and Thermal Gravimetric Analysis (TGA) simultaneously. Details of the measurements and obtained experience of operating the equipment are provided in the work. For each of the eutectic salts multiple samples were tested to check repeatability and to minimize random errors. Finally, in theoretical analysis, mixing rules from literature was used to estimate the heat capacity of the new HTFs, which showed good agreement with experimental data.

14 SOLAR ENERGY↗