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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Development of an Open-source Alloy Selection and Lifetime Assessment Tool for Structural Components in CSP

Lack of sufficient data on high temperature mechanical and corrosion behavior of structural materials is a huge barrier in the technological maturity of current and future Concentrating Solar Power (CSP) technologies. Rapid development and selection of materials cannot be achieved by expensive and time-consuming acquisition of experimental data. The goal of the proposed work is development of an open-source alloy selection and lifetime prediction tool that will integrate validated physics-based models to describe influence of temperature, alloy composition, environment and component geometry (thickness) on mechanical and corrosion behavior of Ni and Fe-based alloys employed in molten salts/sCO 2 heat exchangers. This one-year project leveraged the extensive dataset on the creep\corrosion behavior of candidate materials generated at ORNL through past projects and input from current collaborations with industrial partners. Based on previous experience and the feedback provided by industry (Brayton Energy and Echogen), three candidate materials of interest, Ni-based alloys 740H, 282 and 625 and application-specific operating conditions (max. temperature of 730 °C and stress of 150 MPa) were identified for the heat exchanger. An extensive corrosion and creep dataset was assimilated for the relevant operating conditions and was supported by detailed characterization of about 100 metallographic cross-sections. The corrosion dataset consisted of scanning electron microscopy images (secondary electron and backscatter electron), measured concentration profiles of alloying elements using energy dispersive X-ray spectroscopy (EDS), widths of denuded zones (dissolution of strengthening phases) and depths of attack in molten KCl-MgCl 2 mixtures using image analyses. The creep dataset comprised of creep rupture data and creep strain curves (for 740H and 282). Coupled thermodynamic-kinetic microstructure-based models were employed to predict the stress-corrosion induced compositional and phase evolutions in the alloy during operation under the identified operating conditions. Reduced order models were developed from advanced physics-based models and were integrated in a user-friendly alloy selection tool. The corrosion model was able to predict the time to a critical Cr concentration at the oxide/alloy interface (chemical lifetime) within ±10% (1 standard deviation) of typical statistical variation in corrosion tests and EDS measurement errors (±0.5 wt%). The initial scope of the project was limited to predict creep rupture times (Larson-Miller parameter). Based on the input provided by industry, the mechanical lifetime of the heat exchanger is governed by accumulated creep strains (2%) rather than creep rupture. To be able to predict the times to specific creep strains, a more extensive creep model development was undertaken largely beyond the initial scope of the project. The continuum damage mechanics creep model was able to predict times to 2% creep strain, t 2% with an accuracy of ±500h. Ultimately, a screening protocol for SiC was generated to demonstrate the pathway for integration of one of the currently immature materials from a commercial adoption standpoint in the current material evaluation tool. The modeling tool developed here is accessible to the science community and stakeholders and lays the foundation for methods that will enable a rapid evaluation of optimum materials for CSP applications and reliable prediction of material degradation thereby considerably reducing operational costs, improving reliability and increasing overhaul intervals. However, the complete potential of such a tool to include a wider range of materials and test conditions can only be realized with a more concentrated combined experimental-characterization-computation effort.

14 SOLAR ENERGY↗
DOE OSTI2024

3D Printing of Inconel 718 with Enhanced Boron Composition as a Novel Solar Absorber Tube Material in the Concentrated Solar Power (CSP) System

The growing demands for elevated efficiency in the solar energy industry led researchers to focus on the development of functional solar absorber tube material in concentrated solar power (CSP) systems, when molten salts are adopted as the heat transfer fluid. In this study, the typical solar absorber tube material, Inconel 718, was enhanced with boron to achieve a higher solar absorptivity in the visible light spectrum. Combined with an additive manufacturing (AM) method, the boron composition exceeded the traditional manufacturing limit of 60 ppm without microstructural defects. The boron-enhanced Inconel 718 exhibited a high solar absorptivity of nearly 90 % while maintaining a high thermal cycle fatigue resistance after thermal cycling treatment between 550°C and 720°C. The boron composition was increased to the manufacturing failure point, and the effects of different boron compositions on mechanical properties, microstructure, and optical properties were studied. The provided microstructure-property map in this study delivers high potentials of functional AM-printed alloy material in CSP applications.

13 HYDRO ENERGY↗
DOE OSTI2025

Final Report for CSP Tower Public Opinion and Education Project

As part of the CSP Plant Optimization Study for the California Power Market (DE-EE0009809) the project wanted to understand the public’s opinion of the technology and and explore the types of community engagement that is needed to support such development. The initial objectives for the public perception activities were twofold. The primary objective was to gather public opinion and feedback from the communities living near the two operating solar power tower plants, Ivanpah and Crescent Dunes, and to distill lessons learned from the community engagement conducted before, during, and after the plants were developed to inform future development. This included outreach to nearby airports. The other objective was to gauge public opinion about large-scale solar, specifically CSP towers, to start educating the public on the benefits and to begin building relationships with communities of interest, initially targeting the Kingman, Arizona area. The objectives shifted after the first exploratory trip to Ivanpah and Kingman, however, as it became apparent that it would be challenging to gather public opinion from the community surrounding Ivanpah that could be useful for other community profiles, and the company wasn’t ready to address the concerns in Kingman. Another area was chosen, therefore, to represent those where future development is possible. The recently published Lawrence Berkeley National Lab Perceptions of Large-Scale Solar Project Neighbors Study exemplified public perception polling based on social science and served as the foundation for the survey questions taken to the field. The intent was to ensure that people knew their input was valued and that the time they spent was valuable for the participant as well. It has been noted in the literature that in-person interaction has greater benefits than activities online or via mail, as well as limits the expense.

14 SOLAR ENERGY↗
DOE OSTI2025

Ground Truth for CSP Mirror Metrology (Full-Length)

The high optical accuracy required for concentrating solar power (CSP) systems in turn requires accurate metrology to assess mirror optical parameters during design, manufacturing, and operation. To meet this need, researchers have developed a variety of CSP optical metrology systems, which include complex calculations and calibration terms. This raises the question: How do we know these methods’ accuracy? One approach is to compare metrology system measurements against a ground truth reference.

14 SOLAR ENERGY↗
DOE OSTI2025

Low-cost and high-performance heat exchangers for CSP

This project aimed to design and manufacture a low-cost and high-performance, particle–to–sCO 2 heat exchanger (HX) for Concentrated Solar Power (CSP) using additive manufacturing (AM). Three enabling technologies will be integrated to achieve the targeted cost and performance. The first technology is the extreme high‐speed laser materials deposition (LMD) AM process known by its German acronym EHLA that was invented at the Fraunhofer Institute for Laser Technology. The EHLA process utilizes a specially designed powder-feeding nozzle that enables a laser to melt the powder particles above the melt pool, in contrast to the conventional LMD process where the powders are melted inside the melt pool. EHLA enables much faster deposition rate than conventional LMD without the need to wait for the powders to melt. The second technology is an innovative double-helical HX geometry that can be easily fabricated using the EHLA process by rotating a rod at a high-speed to take advantage of the high EHLA deposition rate. The double-helical fins separate the hot region (the hot particle side) and the cold region (the sCO 2 side) and provide large heat transfer surface area without a large pressure drop on the sCO 2 side. The particle side will have a larger gap to facilitate the particle flow. The outer rims of the double helixes can be sealed off using the same AM process. After sealing-off, additional double helixes can be built radially on top of the first set to improve HX performance. The HX can be installed vertically for gravity-driven flow of the hot particles if necessary. The third technology is a low-cost high-temperature alumina-forming austenitic (AFA) steel TMA-6350 that has creep and oxidation resistance up to 1100 °C. These technologies together will enable high-performance and low-cost HXs for particle–to–sCO 2 for CSP.

14 SOLAR ENERGY↗
DOE OSTI2023

Informed Feature Selection for Data Clustering of CSP Plant Production

To make concentrating solar power (CSP) more cost competitive, rigourous optimizations must be run to improve plant design and operations. However, these optimizaitons rely on time consuming annual simulations that solve an electricity dispatch scheduling problem to maximize plant revenue. To reduce the runtime of annual dispatch simulations of CSP plants, a data clustering approach is utilized. This approach assumes that like days of revenue and electricity generation can be identified using weather and price data. Although weather and price are important factors for electricity production, this work investigates how thermal energy storage (TES) inventory at the beginning of a day, denoted as Si, can be used as a supplemental feature to group like days. A framework for creating and training a deep neural network to predict Si is proposed. This model is validated and assessed using eleven sets of testing data that were not used during training. Then, the data clustering approach is performed three seperate times with features of weather and price along with either Si from the neural network, Si from the full annual simulation, or no Si. Ultimately, the results suggest that using Si as an additional clustering feature improves the data clustering simulation accuracy by 1.4%.

Tuman, Matthew J. (ORCID:000900038772051X)↗
DOE OSTI2020

Materials Data on CsP(HO)2 by Materials Project

CsP(HO)2 crystallizes in the orthorhombic Pnma space group. The structure is three-dimensional. Cs1+ is bonded in a 7-coordinate geometry to one H1- and six equivalent O2- atoms. The Cs–H bond length is 3.35 Å. There are a spread of Cs–O bond distances ranging from 3.11–3.32 Å. P5+ is bonded in a distorted tetrahedral geometry to two H1- and two equivalent O2- atoms. Both P–H bond lengths are 1.43 Å. Both P–O bond lengths are 1.52 Å. There are two inequivalent H1- sites. In the first H1- site, H1- is bonded in a distorted single-bond geometry to one Cs1+ and one P5+ atom. In the second H1- site, H1- is bonded in a single-bond geometry to one P5+ atom. O2- is bonded in a distorted single-bond geometry to three equivalent Cs1+ and one P5+ atom.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Mechanical Failure Risk Management for In-Service CSP Nitrate Hot Tanks

The hot thermal energy storage tanks in many operating (Gen2) concentrating solar power plants are designed to contain molten nitrate solar salt at 565 Degrees Celsius and are constructed from 347H stainless steel (SS). From previous work, it is known that 347H SS weldments are potentially susceptible to stress-relaxation cracking (SRC), particularly in the heat-affected zone above 540 Degrees Celsius when no post-weld heat-treatment (PWHT) is performed. However, residual stresses can be reduced when weldments receive PWHT, while at the same time a crack-resistant microstructure is being generated. The overarching goal of this project was to optimize cost-effective, thickness-dependent, localized PWHT procedures and to investigate for feasible non-destructive evaluation (NDE) at commercial scale for hot tanks in Gen2 CSP using 347H SS.

14 SOLAR ENERGY↗
DOE OSTI2024

Wind Loading on CSP Collectors

The project significantly enhanced the community's understanding of the fundamental physics drivers underlying the wind-loading experienced by concentrating solar power (CSP) collector structures (i.e., parabolic troughs and heliostats) as well as their support structures. This project had two overarching objectives: (1) detailed measurements to characterize the prevailing wind conditions and resulting operational loads on collector structures, and (2) development and validation of a computationally efficient, high-fidelity modeling tool capable of predicting wind-loading in deep-array installations. Over three years, we conducted comprehensive at-scale field measurements of the atmospheric turbulent wind conditions, and the resulting wind loads on parabolic troughs and heliostats. Two at-scale measurement campaigns yielded first-of-its-kind, high-resolution, long-term datasets that are used to characterize the complex flow field and wind loading on parabolic-troughs and heliostats in operational power plants. The high-resolution measurements collected during these campaigns were used to validate the high-fidelity computational models developed at NREL. These open-source computationally efficient models were shown to be accurate in predicting wind-driven loads on collectors without the need for a large supercomputer.

14 SOLAR ENERGY↗
DOE OSTI2023

Utility-Scale Solar, 2023 Edition: Analysis of Empirical Plant-level Data from U.S. Ground-mounted PV, PV+battery, and CSP Plants (exceeding 5 MWAC)

Berkeley Labs "Utility-Scale Solar", 2023 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2022, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, and interconnection queue data.

analysis↗
DOE OSTI2022

Utility-Scale Solar, 2022 Edition: Analysis of Empirical Plant-level Data from U.S. Ground-mounted PV, PV+battery, and CSP Plants (exceeding 5 MWAC)

Berkeley Labs "Utility-Scale Solar", 2022 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2021, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, and interconnection queue data.

2022↗
DOE OSTI2024

Utility-Scale Solar, 2024 Edition: Analysis of Empirical Plant-level Data from U.S. Ground-mounted PV, PV+battery, and CSP Plants (exceeding 5 MWAC)

Berkeley Labs "Utility-Scale Solar", 2024 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2023, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, net value, and interconnection queue data.

analysis↗
DOE OSTI2024

Demonstrate and De-Risk an Internally Lined Tank Design for Molten-Salt Thermal Energy Storage Benefitting CSP and Nuclear-Energy Sectors

The LIMOSA project extends the Gen3 CSP "Liquid Pathway" project to evaluate 720 degrees C thermal energy storage based on molten chloride salts. While SETO selected the Particle Pathway for Gen3 demonstration, LIMOSA was created to resolve a major risk factor with molten chloride salts - the design of the salt storage tank. The project team designed and assembled a test system leveraging experience from Oak Ridge National Lab and the Liquid Pathway Phases 1 and 2. The key innovation in the project is development of a graphite-foil barrier to protect insulation from salt intrusion and wetting.

chloride salt↗
DOE OSTI2022

Dry cooler contribution to LCOE in a sCO 2 power cycle for CSP

In order to maintain viability as a future power-generating technology, concentrating solar power (CSP) must reduce its levelized cost of electricity (LCOE). One component of solving this problem is reducing the cost of the power block while simultaneously increasing the efficiency of the thermodynamic cycle. One disruptive technology that has the promise to accomplish this is supercritical CO 2 (sCO 2 ) based power cycles. Here, these cycles are conceptually similar to steam cycles; however, they have substantially smaller turbomachinery at equivalent power while also delivering more efficiency at turbine inlet temperatures of 500-700 °C.

14 SOLAR ENERGY↗
DOE OSTI2024

Optical Flow Diagnostics of Counter Fluidization of Gravity-Driven Moving Packed Bed for a CSP Receiver Section Featuring Staggered Array of Cylindrical Pins

Particle fluidized beds have the potential to improve the efficiency of heat transfer in concentrated solar receiver furnace for use in next generation concentrated solar power (CSP) plants. This study presents an experimental investigation on the flow characterization of vertically downward moving packed bed with counter fluidization through an array of jets. To control the bubble size and its distribution in the bubbling fluidized bed, an array of cylindrical pin fins was arranged uniformly across the test article. The flow visualization was performed on the surface of transparent glass coated with electrically conductive materials for electrostatic dissipation purposes. The image acquisition was carried out via high-speed camera at a frequency of ~ 1kHz. The acquired images were analyzed in pairs with the help of a modern optical flow algorithm capable of calculating the movement of dense particle flow in the fluidized bed by tracking the light intensity of each predefined window of the frames. A comparison of fluidized beds with plane and pin-finned channels revealed distinct bubble behavior. Pin-finned channels were found to produce a larger number of small-sized bubbles, while plane channels generated fewer but larger bubbles at any given instant. The presence of pin fins was observed to reduce bubble size by preventing bubble merging and splitting larger bubbles when they encountered a pin.

concentrating solar power↗