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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Off-design operation and performance of pumped thermal energy storage

In this article, we describe off-design models and control strategies for a Pumped Thermal Energy Storage (PTES) system that uses liquid thermal energy storage: specifically molten salt for hot storage and methanol for cold storage. Off-design conditions arise when load-following, or due to variations in storage tank temperatures or ambient temperatures. We propose a control strategy that uses inventory control to manage the mass flow rate in the thermodynamic cycles, which facilitates load following. We also propose a control strategy for the storage fluid mass flow rates, which are varied to ensure the molten salt is maintained at its design temperature. This maximizes efficiency and minimizes problems with salt freezing or degradation. The cold storage fluid mass flow rate is varied so that the cold tanks have the same state-of-charge as the hot tanks. This leads to variations in cold fluid temperature, but these variations are shown to be acceptably small (e.g. 7.5% increase), and this control method is shown to be simpler and more efficient than an alternative strategy where tanks become unbalanced. The ambient temperature and storage tank temperatures are moved ±50 °C from the design values and the impact on power, duration, and tank temperatures is quantified. Results demonstrate that the proposed control strategy is stable and self-correcting - that is, storage temperatures converge on stable values after two-to-three charge-discharge cycles. When inputs return to design values, the system returns to its design point after two charge-discharge cycles. We also demonstrate that inventory control enables delivery of the target power output even when off-design conditions exist that would normally reduce the power output.

25 ENERGY STORAGE↗
DOE OSTI2025

Deployment Potential of Concentrating Solar Power Technologies in California

As states within the United States respond to future grid development goals, there is a growing demand for reliable and resilient nighttime generation that can be addressed by low-cost, long-duration energy storage solutions. This report studies the potential of including concentrating solar power (CSP) in the technology mix to support California’s goals as defined in Senate Bill 100. A joint agency report study that determined potential pathways to achieve the renewable portfolio standard set by the bill did not include CSP, and our work provides information that could be used as a follow-up. This study uses a capacity expansion model configured to have nodal spatial fidelity in California and balancing-area fidelity in the Western Interconnection outside of California. The authors discovered that by applying current technology cost projections CSP fulfills nearly 15% of the annual load while representing just 6% of total installed capacity in 2045, replacing approximately 30 GWe of wind, solar PV, and standalone batteries compared to a scenario without CSP included. The deployment of CSP in the results is sensitive to the technology’s cost, which highlights the importance of meeting cost targets in 2030 and beyond to enable the technology’s potential contribution to California’s carbon reduction goals.

14 SOLAR ENERGY↗
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 OSTI2025

CSP Plant Optimization Study for the California Power Market (“CalCSP”) (Final Technical Report)

Concentrating Solar Power (CSP) with thermal energy storage offers a unique and strategic opportunity to support California’s clean energy transition. Unlike photovoltaic (PV) systems, CSP with thermal storage can generate electricity after sunset and during periods of high demand, making it a valuable complement to intermittent renewable resources. CSP also provides synchronous, inertia-contributing generation, long-duration storage, and flexible dispatch—capabilities increasingly important as thermal plants retire. This report summarizes the findings of the CSP Plant Optimization Study for the California Power Market or “CalCSP study,” which evaluated the technical, economic, environmental, and policy factors that influence the deployment of CSP technologies in California. The CalCSP study was conducted to assess how CSP can contribute to California’s long-term decarbonization goals while enhancing grid reliability, supporting local economic development, and making efficient use of land and transmission resources. It draws on detailed modeling of CSP performance and costs, site suitability analysis, policy reviews, and stakeholder engagement across utilities, regulators, developers, and community organizations. The analysis focuses on mature molten-salt tower technology and incorporates lessons learned from the global CSP fleet, distinguishing today’s CSP from earlier first-of-a-kind projects in the U.S. The findings support a more prominent role for CSP in California’s evolving clean energy landscape. With strategic planning, targeted policy support, and continued cost improvements, CSP can complement PV and batteries to deliver reliable, around-the-clock clean electricity—especially in areas with high solar resource and constrained grid capacity.

14 SOLAR ENERGY↗
DOE OSTI2026

The Use of Microelectrodes in Molten Salt Electrochemistry

Molten salts have attracted considerable interest as essential media for advanced high-temperature technologies, including molten salt reactors, thermal energy storage, high-temperature electrolysis, and pyrochemical processing. Their ability to remain stable in liquid form at elevated temperatures, combined with favorable thermophysical properties and wide electrochemical windows, makes them highly suitable for applications involving heat transfer, energy storage, and hightemperature electrochemical processing. However, despite these advantages, molten salts present challenges due to their chemically reactive nature at high-temperatures, especially in the presence of oxidizing impurities. Salt chemistry can fluctuate through interactions with impurities over time, or fuel burnup in the case of molten salt reactors, often leading to the dissolution of metal species. This dynamic environment not only results in complex redox behavior but also promotes corrosion, which is rarely uniform and frequently manifests as localized degradation driven by structural materials’ compositional differences, electrochemical imbalances, and microstructural susceptibilities.

Kim, Changkyu [University of Wisconsin-Madison, WI↗
DOE OSTI2021

Internal insulation and corrosion control of molten chloride thermal energy storage tanks

A chloride-based molten-salt system that uses a ternary blend of MgCl 2 /KCl/NaCl is investigated to provide higher-temperature thermal energy storage capability than conventional nitrate salt-based systems. Despite their high thermal stability and operating temperature, molten chlorides present several challenges, including the design of internal liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the hot face refractory materials for use as internal liners. Furthermore, three down-selected refractory materials were analyzed with respect to permeation of salt through the material as well as chemical stability during high temperature operation. Through the application of X-ray imaging and electron spectroscopy techniques, highly stable secondary surface phases in equilibrium with the molten salt were identified, as well as time-dependent changes in the salt composition itself.

25 ENERGY STORAGE↗
DOE OSTI2022

Techno-Economic Analysis of Recuperated Joule-Brayton Pumped Thermal Energy Storage

This article describes a techno-economic model for pumped thermal energy storage systems based on recuperated Joule-Brayton cycles and two-tank liquid storage. Models have been developed for each component, with particular emphasis on the heat exchangers. Economic metrics such as the power and energy capital costs (i.e., per-kW and per-kWh capacity) and levelized cost of storage are evaluated by gathering numerous cost correlations from the literature, thereby enabling estimates of uncertainty. It is found that the use of heat exchangers with effectivenesses up to 0.95 is economically worthwhile, but higher values lead to rapidly escalating component size and system cost. Several hot storage fluids are considered; those operating at the highest temperatures (chloride salts) improve the round-trip efficiency but the benefit is marginal and may not warrant the additional material costs and risk when compared to lower-temperature nitrate salts. Cost-efficiency trade-offs are explored using a multi-objective optimization algorithm, yielding optimal designs with round-trip efficiencies in the range 59-72% and corresponding levelized storage costs of 0.12 0.03 and 0.38 0.10 $/kWhe. Lifetime costs are competitive with lithium-ion batteries for discharging durations greater than 6 h under current scenarios.

Carnot battery↗
DOE OSTI2026

Understanding failure in austenitic steels: Key considerations for molten salt storage in CSP applications

Owing to their excellent properties, austenitic stainless steels are extensively used in boilers, furnaces, molten salt tanks, and other applications that are subjected to extreme mechanical loads and high-temperature conditions. Their high corrosion and creep resistance make them suitable for high-temperature operating environments. Additionally, good fatigue resistance and favorable mechanical and visual properties are essential. However, the premature failure of several components at elevated temperatures has been previously reported. Although the failure analysis of components in service is complex, processes such as cold work and welding have been identified as contributing factors to the performance degradation of these steels. This study aims to analyze the various documented failure modes and mechanisms in austenitic steels, including creep, cracking, stress relaxation cracking, and fatigue, to better understand the multi-objective design requirements for these alloys as structural materials for high-temperature molten salt tanks in Concentrating Solar Power (CSP) plants. Stabilized austenitic grades, such as AISI 347H, demonstrate superior resistance to creep and corrosion-related degradation when compared to non-stabilized grades like AISI 316L at temperatures relevant to concentrated solar power (CSP) applications. In contrast, nickel-based alloys offer enhanced corrosion resistance, albeit at a higher cost. This review underscores that creep, stress relaxation cracking, and thermo-mechanical fatigue are the predominant long-term failure risks in CSP hot tanks.

14 SOLAR ENERGY↗
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

Thermal conductivity measurement using modulated photothermal radiometry for nitrate and chloride molten salts

Molten salts are being used or explored for thermal energy storage and conversion systems in concentrating solar power and nuclear power plants. Thermal conductivity of molten salts is an important thermophysical property dictating the performance and cost of these systems, but its accurate measurement has been challenging, as evidenced by wide scattering of existing data in literature. The corrosive and conducting nature of these fluids also leads to time consuming sample preparation processes of many contact-based measurements. Here, in this work, we report the measurement of thermal conductivity of molten salts using a modulated photothermal radiometry (MPR) technique, which is a laser-based, non-contact, frequency-domain method adopted for molten salts for the first time. By unitizing the advantages of front side sensing of frequency-domain measurements and the vertical holder orientation, the technique can minimize the natural convection and salt creeping effects, thus yielding accurate molten salt thermal conductivity . The MPR technique is first calibrated using standard molten materials including paraffin wax and sulfur. It is then applied on measuring pure nitrate salts (NaNO 3 and KNO 3 ), solar salt (NaNO 3 –KNO 3 mixture), and chloride salt (NaCl–KCl–MgCl 2 ). The measurement results are compared with data from literature, especially those obtained from laser flash analysis (LFA). Our results demonstrate that the MPR is a convenient and reliable technique of measuring thermal conductivity of molten salts. Accurate thermal conductivity data of molten salts will be valuable in developing the next-generation high-temperature thermal energy storage and conversion systems.

14 SOLAR ENERGY↗
DOE OSTI2022

Novel textured surfaces for superior corrosion mitigation in molten carbonate salts for concentrating solar power

Corrosion of metals in contact with molten salts used for thermal energy storage and heat transport at high temperatures is a serious impediment to the development of next-generation concentrating solar thermal systems. Toward addressing this limitation, novel multiscale fractal-textured Ni coatings on a variety of substrate alloys are presented in this study for exceptional corrosion mitigation in molten carbonate salts at a high temperature. Strongly adherent, durable, single-layer, and double-layer multiscale fractal coatings were fabricated using the electrodeposition method. Corrosion performance of the coatings on SS310, SS316, SS347, and In800H was studied in molten carbonate salt (32% Li 2 CO 3 +33% Na 2 CO 3 +35% K 2 CO 3 ) at 750 °C. Single-layer coatings are stable up to 300 h immersion, whereas double-layer coatings are stable beyond 750 h. The corrosion rate of double-layer Ni coatings on ferrous alloys was reduced by as much as 60% from that of uncoated surfaces and was about 18% below that of higher cost, high Ni content Ha230. The study represents the first-ever report of corrosion characteristics of alloys in carbonate salts at 750 °C and the first demonstration of a means of dramatically reducing corrosion in carbonate salts at a high temperature. The article is significant in that it provides a viable approach for low-cost structural alloys to be corrosion-resistant to molten carbonate heat transfer fluids and storage media in high-temperature concentrating solar thermal applications. Furthermore, the corrosion-resistant coatings provide opportunities for the use of low-cost, ferritic alloys instead of the expensive nickel-based alloys in practice.

14 SOLAR ENERGY↗
DOE OSTI2023

In-situ thermophysical measurement of flowing molten chloride salt using modulated photothermal radiometry

Molten salts are leading candidates for high-temperature heat transfer fluids (HTFs) for thermal energy storage and conversion systems in concentrated solar power (CSP) and nuclear energy power plants. The ability to probe molten salt thermal transport properties in both stationary and flowing status is important for the evaluation of their heat transfer performance under realistic operational conditions, including the temperature range and potential degradation due to corrosion and contamination. However, accurate thermal transport properties are usually challenging to obtain even for stagnant molten salts due to different sources of errors from convection, radiation, and corrosion, let alone at flowing status. To the best of authors’ knowledge, there is no available in-situ technique for measuring flowing molten salt thermal conductivity. Here, we report the first in-situ flowing molten salt thermal conductivity measurement using modulated photothermal radiometry (MPR). We could successfully perform the first in-situ thermal conductivity measurement of flowing molten NaCl-KCl-MgCl 2 in the typical operating temperature (520 and 580 °C) with flow velocities ranging from around 0.3 to 1.0 m s -1 . The relative change of the molten salt thermal conductivity was measured. Gnielinski’s correlation was also used to estimate the heat transfer coefficient h of the flowing NaCl-KCl-MgCl 2 in the given experimental condition. Furthermore, the work showed the potential of the MPR technique serving as an in-situ diagnostics tool to evaluate the heat transfer performance of flowing molten salts and other high-temperature HTFs.

14 SOLAR ENERGY↗
DOE OSTI2025

The role of moisture in MgCl 2 salt: A multiscale approach to TES performance

This study presents a comprehensive multiscale analysis to evaluate the influence of moisture on the thermal performance of thermal energy storage systems using magnesium chloride (MgCl 2 ) as the phase-changing material. The system uses graphite foam with 90% relative density to enhance thermal conductivity. The analysis includes thermal conductivity calculations and specific heat capacity for different hydrate phases of MgCl 2 : Anhydrous, Mono, Di, Tetra, and Hexa. These properties were evaluated for the first time using the phonon density of states from Density Functional Theory simulations. Results showed that thermal conductivity decreased, while specific heat capacity increased by a factor of two as the phase changed from anhydrous to hexahydrate. Meso-scale models were created to account for the anisotropy of graphite foam and property variations of the MgCl 2 hydrate phases. Asymptotic Expansion homogenization simulations determined the anisotropic thermal conductivity for all phases. This unique methodology improved simulation accuracy, which matched experimental data for anhydrous MgCl 2 . A parametric study examined various operating conditions and their effect on TES performance. It revealed that higher charging temperatures did not enhance exergy efficiency, but increased discharge mass flow rates improved it due to better heat transfer. Thermal performance evaluated by the exergy efficiency remained consistent across hydrate systems under the tested conditions. Furthermore, the study suggests that this uniformity is linked to missing key data, particularly latent heat and melting point for different hydrates. Overall, it highlights the importance of multiscale effects and accurate material properties in designing and optimizing TES systems.

Molten salt degradation↗
DOE OSTI2025

The Impact of Europium as a Fission Product Surrogate on Chromium Corrosion in Molten Chloride Salt

The rising interest in molten salts, both as thermal energy storage media and as high-temperature solvents for fissile materials in advanced nuclear reactors, has spurred significant growth in research on structural and functional salt-facing materials. Impurities, such as water, play a significant role in the degradation of materials in molten salt environments. Other impurities, such as fission products, are expected to accumulate in molten salts during normal reactor operation and can affect the properties of the salt and salt-facing materials. During normal reactor operation, rare-earth element species are expected to form as byproducts of fission reactions, potentially degrading or altering the performance of both structural and functional materials exposed to salts. Here, in this work, fission product surrogates, europium metal and EuCl 3 , were added to the KCl-MgCl 2 salt while exposing pure Cr specimens in the melt at 600 and 700 °C for 1000 h. Low reactivity was observed with the baseline salt, while both the Eu and EuCl 3 additions to the salt resulted in increased mass loss of Cr specimens. A capillary electrophoresis technique was developed to enable the detection of low parts-per-million (ppm) concentrations of europium (Eu) in chloride salt both before and after exposure of Cr metal. This technique provides a sensitive and reliable method for monitoring trace levels of Eu, which is critical for understanding the interactions and potential contamination effects in salt-facing materials during reactor operation. This quantification technique can be applied to other cationic and anionic contaminants in halide salts.

chloride salt↗
DOE OSTI2024

Technical and economic evaluation of heat transfer fluids for a TES system integrated to an advanced nuclear reactor

The utilization of thermal energy storage technology has emerged as a potential enhancement for nuclear power plants. Although nuclear energy systems possess the ability to adjust their energy output, prolonged variations in production can impact the plant's overall efficiency and economic viability. However, the nuclear industry can capitalize on thermal energy storage to bolster the power plant's economics by leveraging ancillary services and market hedging strategies. Here this research aims to advance the development of thermal energy storage for advanced nuclear reactors by assessing the thermophysical properties of various heat transfer fluids, including FLiNaK, KCl-MgCl 2 , LiCl-KCl, (LiNaK) 2 CO 3 , NaF-ZrF 4 , and KF-ZrF 4 , at temperatures ranging from 500 to 900oC. The assessment is conducted based on thermophysical correlations established in previous studies and employs figures of merit as a metric to evaluate the heat transfer performance of different salt candidates. Additionally, a cost analysis is conducted to provide an idea of the potential cost associated with each salt candidate.

25 ENERGY STORAGE↗