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Large area transparent refractory aerogels with high solar thermal performance

Application of transparent silica aerogels in low-temperature solar thermal systems has led to major improvements in performance. In high temperature concentrating solar thermal (CST) systems, aerogels have yet to demonstrate the necessary scalability, durability, and performance to support their widespread deployment. Here, large-area transparent refractory aerogel tiles are synthesized and shown to achieve a record-high receiver figure-of-merit (FOM) at high temperatures. The work leverages a scaled-up process for sol–gel synthesis to control the density of the aerogels for improved solar transmittance and adapts a previous atomic layer deposition (ALD) technique with the aid of predictive reaction-transport modeling. After aging for 10 days at 700 °C, the large-area tiles exhibit a solar-weighted transmittance of 95.6 % and a thermal emittance of 0.31, corresponding to a FOM of 80 % at 100 suns and 700 °C. The observed sintering rates at 700 °C are comparably low to earlier one-inch aerogels, suggesting long-term stability under relevant operating conditions. Furthermore, the study indicates that refractory aerogels are scalable materials for efficient photothermal conversion at high temperatures.

Aerogels↗

Investigation of Flux Spreading in a Light-Trapping, Planar-Cavity Receiver for Enclosed Solar Particle Heating

Concentrating solar thermal power (CSP) technology development has recently focused on increasing the operating temperatures to accommodate high efficiency power cycles and thermochemical processes. Inert solid particles as heat transfer media enable solar receivers to operate above 700 degrees Celsius resulting in increased system thermal efficiency compared to the conventional molten salt based CSP system. An open-cavity falling-particle solar receiver that can efficiently heat particles by direct heating from concentrated solar radiation faces challenges with large particle losses from wind and unable to support thermochemical reactions. A light-trapping, planar cavity reiver (LTPCR) where particles are indirectly heated can significantly minimize the particle losses during the operation, support thermochemical reactions, and offer scalability potential. The LTPCR features an array of vertical planar receiver/absorber panels arranged within a cavity configuration. Concentrated solar radiation from heliostats is focused onto the receiver walls, where heat is indirectly transferred to solid particles flowing inside the receiver channels. Heat transfer occurs through direct contact between the receiver panel walls and particles, and can be enhanced by fluidizing particles with air. This fluidization increases particle-wall contact and extends particle residence time, maximizing heat transfer efficiency. The unique vertical planar receiver structure originated from a near-blackbody tubular light absorber, effectively distributing the incoming solar beam spread across the panel walls and trapping light. This flux spreading effect, driven by cosine projection, converts high incident solar flux into a lower, more uniform heat flux on the panel walls. This redistribution enhances heat transfer efficiency between particle-wall or reaction gases-wall, while preventing localized overheating of the receiver panel. Indirect planar cavity solar receivers completely separate solid particles from the ambient environment that can greatly reduce the thermal losses in heated particles resulting in high efficiency at high temperatures above 700 degrees Celsius. This design ensures no particle losses to the environment during the operation while open-cavity designs can experience significant particle losses from wind. An experimental investigation was conducted to observe flux spreading on the receiver panel wall. A lab-scale prototype planar receiver, fabricated using Haynes 230 alloy, was tested under direct concentrated solar radiation using the high-flux solar furnace (HFSF) facility at NREL. The experiment was performed under normal peak radiative heat fluxes ranging from 800 to 1900 kW/m2. A temperature distribution on the panel wall was measured using a thermal imaging camera (FLIR A 6600). To prevent overheating at the receiver front tip, prism-shaped heat shields (Zircar UNIFROM C1) were placed in front of the receiver, and their influence on flux spreading was also studied. Absorbed flux distribution on the panel wall was modeled using SolTrace. The total solar power and flux distributions delivered from HFSF were determined based on the heliostat mirror optical properties, direct normal irradiance (DNI) on the on-sun testing days, peak flux measurement during the on-sun testing, and shutter/attenuator settings Due to the large incident angles of the solar beam on the panel wall, the angular optical properties of Haynes 230 alloy and Zircar heat shields were incorporated into the model. This flux distribution model was then integrated into a computational fluid dynamics (CFD) simulation to predict the receiver panel wall temperature, which was compared with the experimental measurements. Both prediction and measurements identified a temperature hotspot at the backside of the panel, indicating that the incident solar beam can fully reach to the rear of the receiver. The heat shields positioned at the front of the receiver effectively reduced the excessive temperature rise at the receiver front tip. Overall, the temperature was well distributed over the panel wall, with a minor hotspot at the back of the receiver. The model slightly overpredicted the temperature, possibly due to discrepancies in optical properties of the panel and an underprediction of thermal loss in the receiver. The advancement of the particle LTPCR offers a viable alternative to open-cavity receivers by addressing particle loss issues. Additionally, it presents a pathway for enabling solar thermochemical processes, extending CSP technology beyond power generation to fuel and chemical production.

14 SOLAR ENERGY↗

High-Temperature Linear Receiver Enabled by Multicomponent Aerogels

Concentrating solar thermal (CST) technology has significant potential mainly due to its dispatchability and low cost of storage. However, to compete with other sources, including utility-scale solar PV, its final cost (cents/kWh) still needs to be lowered. Cost reduction can be achieved by improving the system level efficiency of the CST plants through the deployment of advanced power cycles, which operate at high temperatures of ~700°C. However, optical, and thermal losses pose a major challenge to the efficiency of such CST systems. The overall aim of this project is to investigate and de-risk a linear solar receiver concept called an Aerogel Insulated Receiver (AIR) that generates high temperatures (up to 700°C) at a low solar concentration ratio (<100) and with a high collection efficiency (optical × receiver). Our prior work has demonstrated the thermal stability1 and optical and heat-insulating properties2,3 of transparent aerogel insulation at a one-inch scale. The focus of this work is on (1) co-optimization of the geometry of the aerogel tile and receiver enclosure to fit a standard parabolic collector (PTC), (2) scale-up of aerogels into 4-inch tiles while preserving key properties, (3) experimental measurement of receiver heat loss (W/m) in a >70-cm test stand and validation of anticipated receiver performance at high temperatures. Regarding (1), appropriate optical and thermal models for a parabolic trough receiver (PTR) are developed and validated. The geometry of the aerogels and the receiver enclosure are co-optimized to maximize the collection efficiency. The model predicts a 54% collection efficiency at 700°C for an AIR design based on flat aerogels. By combining the collection efficiency with the power block efficiency of supercritical CO 2 cycles, we predict >10% improvements in peak plant efficiency relative to existing line-focusing CST systems. The application of curved plasmonic aerogels is predicted to further increase the collection efficiency to 64%. Regarding (2), we demonstrate the successful development of 6-inch-long refractory aerogel tiles with optical, thermal, and stability characteristics consistent with our prior work. This scale-up requires a transition to a larger ALD station and modifying the ALD process variables such as exposure time and the number of precursor doses. Regarding (3), we design and develop an AIR test stand measuring 3 feet in length. Heat loss performance analysis is carried out using the test stand. The results indicate that aerogel insulation can significantly reduce receiver thermal losses at the high operating temperatures required for next-generation PTRs. The experimental results agree with the heat loss performance predicted by our receiver model. Lastly, we conducted preliminary failure mode and effects (FMEA) and techno-economic (TEA) analyses to identify failure mitigation strategies and commercial opportunities, respectively. Overall, this project identifies key opportunities and challenges in deploying aerogel insulating receivers in next-generation line-focusing CST technologies.

14 SOLAR ENERGY↗

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to flexibly dispatch energy. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating solar thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also cascading lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and simulated using SimTech IPSEpro process modeling software. The design configuration depends on the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year; therefore, off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗

Techno-Economic Analysis and Market Potential of Geological Thermal Energy Storage (GeoTES) Charged With Solar Thermal and Heat Pumps

In this project, we developed a techno-economic analysis (TEA) model that can be used to evaluate the viability of a proposed Geological Thermal Energy Storage (GeoTES) design. This MATLAB-based model integrates distinct subsystem models for the reservoir, wells, power cycle, and solar field to capture their distinct characteristics. It applies this approach in simulating GeoTES storage and dispatch operations for durations ranging from hourly to seasonal. Using cases studies based on GeoTES designs provided by industry partners - Premier Resource Management (PRM) and EarthBridge Energy - we validated the TEA model estimations of system performance and costs (such as thermal and electrical power/energy inflow and outflow, capital costs, and levelized costs of energy and storage) for both concentrating solar thermal (CST) and Carnot Battery (CB) pairings with GeoTES (CST-GeoTES and CB-GeoTES). For the CST-GeoTES case, the model was validated against the proposed system designed by PRM. It showed good agreement with PRM's estimations when well and pump costs derived from PRM's estimations were used. When GETEM-based costs were used, there was a slight overprediction due to GETEM's project/site agnostic assumption of these costs. From a sensitivity analysis perspective, the levelized cost of electricity (LCOE) of the CST-GeoTES case was most sensitive to well flow rate and the charging temperature. An optimal design scenario resulted in an LCOE of 0.11 $\$$/kWhe. CST-GeoTES can also provide a source of heat to meet seasonal demands. With 12-hour and 24-hour levelized cost of heat (LCOH) of 0.018 $\$$/kWhth and 0.022 $\$$/kWhth, respectively, CST-GeoTES could be competitive in the California market with an average industrial price of natural gas in California between 0.041-0.047 $\$$/kWhth. The levelized cost of storage (LCOS) for CST-GeoTES depends on the energy storage duration. Although the LCOS is relatively higher for shorter durations (e.g., ~0.50 $\$$/kWhe for 1 hour of storage), it is an order of magnitude lower (0.06 $\$$/kWhe) for longer storage durations and competitive with lithium-ion batteries (beyond 12 hours of storage) and molten-salt thermal energy storage (beyond 32 hours). Energy. Three options were explored and applied to the EarthBridge case study: (1) A Carnot Battery design using R125 working fluid with both hot and cold storage; (2) A Carnot Battery design using R125 working fluid with only hot storage; (3) A Carnot Battery using a commercially available heat pump with carbon dioxide (CO2) working fluid and hot storage only. The CB-GeoTES with cold storage only had a slight (round-trip) efficiency advantage over the system without (43.4% vs. 42.8%). This is because the cold storage is limited by the freezing point of water, so the cold storage is not much colder than the environment. The system using commercially available technologies was the least efficient - partly because different cycles were used in the heat pump (CO2) and heat engine (binary cycle) which leads to some inefficiencies. Using the commercially available design, the levelized cost of energy (LCOS) from the model (0.10 $\$$/kWhe) was higher than that estimated by EarthBridge (0.068 $\$$/kWhe). This is because of the low round-trip (38.7%) efficiency of the commercially available design. Sensitivity analysis reveals that the model is most sensitive to electricity price. Including electricity price in the TEA for CB-GeoTES leads to an increase in LCOS from the base value to 0.25 $\$$/kWhe. To determine storage sites suitable for GeoTES, we gathered and analyzed geological, petrophysical, and geophysical data of oil and gas reservoir and aquifers in California and Texas. We down-selected possible sites based on cut-off values for site characteristics (e.g., reservoir temperature, formation thickness, permeability, porosity, depth, and brine salinity) and preliminary costs. Using this approach, the Carrizo-Wilcox, Yegua-Jackson, and Dockum brackish aquifers in Texas were identified as having the highest suitability. Similarly, in the central California region, the White Wolf, Belridge South Tulare, and Belridge South Reef Ridge were the most suitable. Going further, we assessed the storage potential in the selected sites. To do this we developed distributions of reservoir characteristic data and applied a Monte Carlo-based analysis to account for intrinsic uncertainty in the acquired data. The analysis revealed that the Carrizo-Wilcox aquifer had the highest storage potential with a mean capacity of 554 TWhth (i.e., 63 TWhe). The estimated capacity serves as an upper limit of storage potential given that not all fields in the basin will be developed. We participated in multiple outreach activities including conference presentations, panel session discussions, and the facilitation of a GeoTES workshop at the NREL Golden campus.

15 GEOTHERMAL ENERGY↗

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle: Preprint

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to dispatch energy flexibly. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating Solar Thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also adding lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and is simulated using SimTech IPSEpro process modelling software. The design configuration depends upon the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year, therefore off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗

Semiconductor-dielectric-metal solar absorbers with high spectral selectivity

An ideal solar thermal absorber has a sharp transition between high and low absorptance at the wavelength where the blackbody emissive power begins to exceed the solar irradiance. However, most real selective absorbers have a fairly broad transition, leading to both solar absorption and thermal emission losses. Here, we model, fabricate, and characterize a highly selective semiconductor-dielectric-metal (Ga0.46In0.54As - MgF2 - Ag) solar absorber with an extremely sharp transition from high to low absorptance. The thin semiconductor serves as a selective filter, absorbing photons with wavelengths shorter than the bandgap and transmitting those with longer wavelengths. The highly reflective dielectric-metal rear mirror allows the structure to have very low emittance for longer wavelengths. These characteristics provide the absorber with a measured solar absorptance >91% below the bandgap wavelength and infrared emittance <5% at 100 degrees C above the bandgap wavelength. This transition wavelength can be tuned by modifying the semiconductor composition, and modeling indicates that the absorber's optical properties should be stable at high temperatures, making the structure a good candidate for unconcentrated to highly concentrated solar thermal energy conversion.

14 SOLAR ENERGY↗

System and Component Development of Particle-Based Pumped Thermal Energy Storage

Reliable power supply from variable renewable resources requires energy storage at various scales to overcome resource intermittency. Long-duration energy storage (LDES, 10-100 hours) can improve dispatchability and grid reliability with increasing levels of renewable power supply. Thermal energy storage (TES) has siting flexibility and the ability to store a large capacity of energy, and thus has the potential to meet the LDES need and provide charging and discharging durations beyond the economic capacity of conventional batteries. TES technology has evolved from concentrating solar thermal power (CSP) generation and is recognized as an economic large-scale energy storage method. A standalone electric-thermal energy storage system supporting renewable integration of wind and solar power without CSP solar field can firm renewable generation and boost overall grid resilience and security.

concentrating solar thermal power↗

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↗

Performance Evaluation of an Additively Manufactured ultra-High Operating Temperature SiC Solar-Thermal Air Receiver (HOTSSTAR) Test Module

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal and solar power systems. GE Aerospace Research in collaboration with Heliogen Inc and Sandia National Laboratories (SNL) is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. HOTSSTAR goal is to demonstrate SiC receiver with air exit temperatures up to 1100oC. We discuss fabrication and on-sun test results of a prototype 50kWth test module. The receiver architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around central absorber. These components were fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the thermo-mechanical reliability of SiC test articles in thermal gradient/ shock environment of the application, the components were laminated with GE’s MI SiC CMC. A dedicated test facility was constructed at SNL Solar Tower to evaluate the operational performance of HOTSSTAR module under solar fluxes >200 W/cm2. We report on our final 50kW test module fabrication, integration at the test facility at Sandia, and discuss on-sun test results. We compare the performance of HOTSSTAR module relative to our model predictions.

14 SOLAR ENERGY↗

Prototype Development, Testing, and Modeling for a Solar Light-Trapping Planar-Cavity Particle Receiver (LTPCR)

Many applications for concentrating solar thermal power (CSP) technologies of high efficiency power cycles or thermochemical processes require higher operating temperatures and alternative heat transfer media. Inert solid particles for next-generation CSP and reactive gas and/or solid media for solar thermochemical processes are common options; however, these have significantly lower heat transfer capabilities than thermal oil, molten salt, or molten metal media. Conventional solar receivers operating temperatures >700 degrees Celsius face challenges including thermal performance and thermal-mechanical issues. To overcome these limitations, we have developed a novel light-trapping, planar-cavity receiver (LTPCR) that can heat solid-phase media within an enclosed receiver while maintaining a high aperture solar flux concentration for high efficiency. This paper presents progress on design, fabrication, and testing of a 100 kWt prototype receiver to demonstrate the LTPCR operability and its commercial feasibility.

14 SOLAR ENERGY↗

Prototype Development, Testing, and Modeling for a Solar Light-Trapping Planar-Cavity Particle Receiver

Many applications for concentrating solar thermal power (CSP) technologies of high efficiency power cycles or thermochemical processes require higher operating temperatures and alternative heat transfer media. Inert solid particles for next-generation CSP and reactive gas and/or solid media for solar thermochemical processes are common options; however, these have significantly lower heat transfer capabilities than thermal oil, molten salt, or molten metal media. Conventional solar receivers operating temperatures >700 degrees Celsius face challenges including thermal performance and thermal-mechanical issues. To overcome these limitations, we have developed a novel light-trapping, planar-cavity receiver (LTPCR) that can heat solid-phase media within an enclosed receiver while maintaining a high aperture solar flux concentration for high efficiency. This paper presents progress on design, fabrication, and testing of a 100 kWt prototype receiver to demonstrate the LTPCR operability and its commercial feasibility.

14 SOLAR ENERGY↗

Integration of Concentrating Solar Power with High Temperature Electrolysis for Hydrogen Production: Preprint

Hydrogen (H2) has been identified as a leading sustainable contender to replace fossil fuels in transportation and electricity generation. H2 production can be achieved by concentrating solar thermal power (CSP) systems collecting thermal energy from the sun to various chemical processes for fuel production. Fuel production via solar thermal chemical processes integrated with CSP uses the full spectrum of sunlight compared with photovoltaic power conversion and stores solar energy directly and efficiently [1]. The solar fuel production can be realized by thermochemical processes (e.g., water splitting for H2 production, carbon dioxide reduction, or methane reforming) or thermal electrochemical methods (e.g., integration with solid oxide electrolysis cell). Technology development for CSP-integrated solar fuel production requires broad technological bases from solar energy collection to chemical energy conversion. H2 generated from renewable sources can be an energy carrier for a carbon-free economy. Integrating CSP with high temperature electrolysis (HTE) using solid oxide electrolysis cells (SOEC) provides a renewable path for H2 generation. The CSP-HTE integration approach provides the benefit of thermal energy storage (TES) for continuous operation, improved capacity, and SOEC life. H2 gas has low energy density for transportation, pipeline networks are expensive, and H2 liquefaction is energy intensive. However, an alternative method for H2 distribution is to use carbon dioxide (CO2) capture and liquid hydrocarbon synthesis to convert solar energy into liquid fuels that are compatible with the existing fossil fuel infrastructure.

concentrating solar thermal power↗

Parabolic Trough Collector Cost Update for Industrial Process Heat In The United States

Despite great potential, the worldwide adoption of concentrating solar thermal (CST) collectors for solar industrial process heat (SIPH) is modest. Industrial process heat (IPH) demands for heat and steam are typically below 300 degrees C, where CST collectors can provide the needed heat. Parabolic trough collectors (PTCs) are the most deployed CST technology for SIPH applications. This paper is focused on the United States, and a summary of known operating parabolic trough plants is shown. A previous analysis of a modern PTC in 2016 found that for SIPH applications, the installed solar field cost could be $200/m2 (2016$). Recent advances in PTC design and manufacturing have led to reduced cost per square meter of aperture area, and for a field of 510 solar collector assemblies (SCAs), the installed cost was $120/m2 (2020$). On one hand, the results from this study showed that the solar field cost for large solar fields (510 SCAs or ~804,000 m2) would increase to $184/m2 (2023$) due to post pandemic inflation and increase in metal prices. On the other hand, medium SIPH sized fields (90 SCAs or ~142,000 m2) cost analysis indicated an installed cost could be $197/m2 (2023$). When small SIPH fields (12 SCAs or ~19,000 m2) are considered, this jumps to $297/m2 (2023$). These are cost estimates for the Installed Cost of the solar fields using the United States 2023$ steel prices. When Chinese steel is used for comparison, the installed cost could be between $162 - $210/m2 for the range of SIPH sizes.

concentrating solar thermal↗

Evaluation of Thermal & Mechanical Properties of Additively Manufactured Monolithic SiC for Solar Receiver Applications

Increasing the 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. State-of-the-art SiC volumetric concentrating solar air receivers such as the honeycomb design have successfully demonstrated in field exit air temperatures approaching 800oC. However, a successful application of CST systems for the decarbonization of heat reliant industrial sectors requires significant increases in the 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 an ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and demonstrate a techno-economically viable SiC air receiver technology that can achieve exit air temperatures up to 1100oC for CST applications. We report and discuss the results of our testing and evaluation of thermal and mechanical properties of reaction-bonded SiC fabricated via binder jet printing to support the receiver component design, development, and analyses.

14 SOLAR ENERGY↗