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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Multilayered luminescent solar concentrators based on engineered quantum dots

Luminescent solar concentrators (LSCs) based on engineered quantum dots (QDs) are disclosed that include at least one lower band-gap energy LSC layer and at least one higher band-gap energy LSC layer. The higher band-gap energy LSC layer has a higher internal quantum efficiency (IQE) than the lower band-gap energy LSC layer. The lower band-gap energy LSC layer may broadly absorb the remainder of the solar spectrum that is not absorbed by previous layers. An external optical efficiency (EQE) of at least 6%, and in some cases, more than 10%, may be achieved by such LSCs.

Source record↗
NASA NTRS1982

A transmittance-optimized, point-focus Fresnel lens solar concentrator

The development of a point-focus Fresnel lens solar concentrator for high-temperature solar thermal energy system applications is discussed. The concentrator utilizes a transmittance-optimized, short-focal-length, dome-shaped refractive Fresnel lens as the optical element. This concentrator combines both good optical performance and a large tolerance for manufacturing, deflection, and tracking errors. The conceptual design of an 11-meter diameter concentrator which should provide an overall collector efficiency of about 70% at an 815 C (1500 F) receiver operating temperature and a 1500X geometric concentration ratio (lens aperture area/receiver aperture area) was completed. Results of optical and thermal analyses of the collector, a discussion of manufacturing methods for making the large lens, and an update on the current status and future plans of the development program are included.

Oneill, M. J.↗
NASA NTRS1984

A Transmittance-optimized, Point-focus Fresnel Lens Solar Concentrator

The development of a point-focus Fresnel lens solar concentrator for high-temperature solar thermal energy system applications is discussed. The concentrator utilizes a transmittance-optimized, short-focal-length, dome-shaped refractive Fresnel lens as the optical element. This concentrator combines both good optical performance and a large tolerance for manufacturing, deflection, and tracking errors. The conceptual design of an 11-meter diameter concentrator which should provide an overall collector efficiency of about 70% at an 815 C (1500 F) receiver operating temperature and a 1500X geometric concentration ratio (lens aperture area/receiver aperture area) was completed. Results of optical and thermal analyses of the collector, a discussion of manufacturing methods for making the large lens, and an update on the current status and future plans of the development program are included.

Oneill, M. J.↗
NASA NTRS1992

Solar concentrator technology development for space based applications, volume 1

Thermoelectric conversion using a radio-isotope heat source has been used where outer planetary space craft are too far away for absorbing significant solar energy. Solar dynamic power (SDP) conversion is one technology that offers advantages for applications within the inner planet region. Since SDP conversion efficiency can be 2 to 3 times higher than photovoltaic, the collecting surfaces are much reduced in area and therefore lighter. This becomes an advantage in allocating more weight to launched payloads. A second advantage results for low earth orbit applications. The reduced area results in lower drag forces on the spacecraft and requires less reboost propellant to maintain orbit. A third advantage occurs because of the sun-to-shade cycling while in earth orbit. Photovoltaic systems require batteries to store energy for use when in the shade, and battery life for periods of 10 to 15 years is not presently achievable. For these reasons the Solar Dynamics and Thermal Systems Branch at NASA LeRC has funded work in developing SDP systems. The generic SDP system uses a large parabolic solar concentrator to focus solar energy onto a power conversion device. The concentrators are large areas and must therefore be efficient and have low specific weights. Yet these surfaces must be precise and capable of being stowed in a launch vehicle and then deployed and sometimes unfurled in space. There are significant technical challenges in engineering such structures, and considerable investigation has been made to date. This is the first of two volumes reporting on the research done by the Advanced Manufacturing Center at Cleveland State University to assist NASA LeRC in evaluating this technology. The objective of the grant was to restore the solar concentrator development technology of the 1960s while improving it with advances that have occurred since then. This report summarizes the work done from January 1989 through December 1991.

Pintz, A.↗
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↗
NASA NTRS1992

Solar concentrator technology development for space based applications, volume 2

Thermoelectric conversion using a radio-isotope heat source has been used where outer planetary space craft are too far away for absorbing significant solar energy. Solar dynamic power (SDP) conversion is one technology that offers advantages for applications within the inner planet region. Since SDP conversion efficiency can be 2 to 3 times higher than photovoltaic, the collecting surfaces are much reduced in area and therefore lighter. This becomes an advantage in allocating more weight to launched payloads. A second advantage results for low earth orbit applications. The reduced area results in lower drag forces on the spacecraft and requires less reboost propellant to maintain orbit. A third advantage occurs because of the sun-to-shade cycling while in earth orbit. Photovoltaic systems require batteries to store energy for use when in the shade, and battery life for periods of 10 to 15 years is not presently achievable. For these reasons the Solar Dynamics and Thermal Systems Branch at NASA LeRC has funded work in developing SDP systems. The generic SDP system uses a large parabolic solar concentrator to focus solar energy onto a power conversion device. The concentrators are large areas and must therefore be efficient and have low specific weights. Yet these surfaces must be precise and capable of being stowed in a launch vehicle and then deployed and sometimes unfurled in space. There are significant technical challenges in engineering such structures, and considerable investigation has been made to date. This is the second of two volumes reporting on the research done by the Advanced Manufacturing Center at Cleveland State University to assist NASA LeRC in evaluating this technology. This volume includes the appendices of selected data sets, drawings, and procedures. The objective of the grant was to restore the solar concentrator development technology of the 1960s while improving it with advances that have occurred since then. This report summarizes the work done from January 1989 through December 1991.

Pintz, A.↗
DOE OSTI2023

The value of concentrating solar power in ancillary services markets

Ancillary services, such as spinning reserves, can provide grid reliability and contribute to profitability of an energy resource. We exercise an existing dispatch optimization model to estimate the profitability of a concentrating solar power plant by incorporating the sale of spinning reserves in the ancillary service market using the National Renewable Energy Laboratory's System Advisor Model to simulate operations within a 72-h rolling horizon framework. Assuming a price-taker approach with day-ahead energy and spinning reserve prices from both the California Independent System Operator and the Electricity Reliability Council of Texas, we find that selling spinning reserves in addition to electric energy increases plant profitability by up to 7% with perfect knowledge of day-ahead pricing and solar resource availability. Here, this finding suggests that spinning reserve markets provide significant value streams to concentrating solar power plants that can leverage thermal energy storage to offer reliable production in the short-to-medium term.

14 SOLAR ENERGY↗
DOE OSTI2024

Characterizing and improving the performance of molten-salt-steam heat exchangers in concentrating solar power plants

Shell-and-tube heat exchangers (HXs) for steam generation from molten salts in concentrating solar power (CSP) plants experience thermal fatigue due to significant temperature gradients and inherent transient operation. Molten salt-steam HX design lifespans exceed actual lifespans, and, as a consequence, designers overpredict plant profitability and operators neglect appropriate prescriptions to optimize these lifetimes. Here, this study refines HX lifespan estimates with data benchmarked against thermal-fluid mechanical modeling of stress and accumulated fatigue. Reduced-order thermal models of the molten salt-steam, shell-and-tube evaporator and superheater predict transient temperature profiles along the two HXs salt-steam flow paths. The modeled evaporator and superheater temperature profiles enable assessment of cyclic stresses within the HX tubesheets, where molten-salt HX failures are most common. Evaporator and superheater performance data from a current 110 MW elec commercial CSP plant provide a basis for validating the reduced-order HX models. HX life predictions derived from stochastic failure distributions serve as inputs for simulating and optimizing existing plant operations. The impact of the updated lifespans on overall plant revenue depends on operating scenarios. This study suggests that typical ramping rates for a CSP plant with a high-temperature Rankine cycle result in an evaporator and superheater life of approximately 10 and 25 years, respectively, compared to the design target of 30 years. Reduced HX lifespans decrease operational plant revenue on average by 4.6-5.1%. Furthermore, there may be as many as four HX replacements over the 30-year lifetime of the plant; and, purchase agreement loss due to failure to meet contractual production requirements can have ramifications that include the risk of bankruptcy.

14 SOLAR ENERGY↗
DOE OSTI2021

Effects of Particle Size and Concentration of Magnesium Oxide on the Lubricating Performance of a Chloride Molten Salt for Concentrating Solar Power

One engineering challenge for the next-generation concentrating solar power (CSP) is to identify appropriate heat transfer and thermal energy storage media. A chloride salt mixture (20 wt % NaCl + 40 wt % MgCl 2 + 40 wt % KCl) in a molten phase is proposed as a potential fluid for carrying the heat as well as lubricating the CSP pump bearings. Due to the hygroscopic nature of MgCl 2 , the presence of magnesium oxide (MgO) particles is inevitable. In order to understand the impact of MgO particles, this study investigated the tribological behavior of the molten chloride salt mixture containing MgO of various particle sizes and concentrations. Tests were conducted at 750 °C in a dry Ar environment using a zirconia ball sliding against a Haynes 244 alloy disc lubricated by the molten salt. There was a clear trend of the increased friction coefficient and wear loss for a larger particle size and/or a higher concentration of MgO. Distinct wear mechanisms were identified for the ceramic ball and alloy disc. Results provide fundamental insights for this new research avenue of molten salt lubrication for CSP.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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 OSTI2023

Temporal performance indicators for an integrated pilot-scale membrane distillation-concentrated solar power/photovoltaic system

Management of concentrate streams in inland applications has uncertain long-term environmental impacts. This study investigates an intensified solar-energy capture desalination system that integrates membrane distillation (MD) with a hybrid concentrated solar power (CSP)/photovoltaic (PV) collector to realize self-sustained zero-waste discharge for effective management of concentrate streams in inland and off-grid applications. The demonstration-scale CSP/PV system can produce up to 178 kWh of thermal energy and 4 kWh of electrical energy per day. The thermal and electrical energy from the CSP/PV system is directly supplied to the air gap MD (AGMD) pilot-scale system producing up to 288 L of distilled water per day. Experiments were performed on the hybrid AGMD-CSP/PV system to evaluate system performance under various operating conditions including AGMD and CSP flow rates, CSP system pre-heating, and AGMD vacuum pressure. Experimental results indicate that doubling the AGMD flow rate results in a 119% increase in thermal energy utilization and a 71% increase in distillate production. Compared to the winter months, operating the system in summer months when direct normal irradiance (DNI) is highest results in nearly double the distillate production (88 L in winter and 168 L in summer) and nearly three times the amount of thermal energy consumption (15 kWh in winter and 43 kWh in summer). Operating with vacuum resulted in a 34% increase in distillate production and allowing the thermal storage reservoir to preheat in the winter resulted in a 61% increase in distillate production. Altogether, experimental results highlight the tradeoff between distillate production and thermal and electrical energy production and consumption under various environmental conditions and the potential for AGMD-CSP/PV to be a stand-alone desalination system.

14 SOLAR ENERGY↗
NASA NTRS1981

The systems impact of a concentrated solar array on a Jupiter orbiter

Results of a study are presented suggesting that a Galileo Jupiter orbiting mission could be performed with a concentrated solar array power source. A baseline spacecraft design using concentrated arrays is given, and the overall spacecraft implications for attitude control, propulsion, power conditioning and the resultant spacecraft mass are examined. It is noted that while the concentrated array concept still requires extensive development effort, no insurmountable system level barriers preclude the use of a concentrated solar array on this difficult mission, with its stressing radiation environment, its lengthy periods of spacecraft shadowing as it passes behind Jupiter, and, finally, its large delta v burn required for orbital insertion.

Rockey, D. E.↗
NASA NTRS1986

Protective telescoping shield for solar concentrator

An apparatus is described for use with a solar concentrator such as a parabolic dish which concentrates sunlight onto a small opening of a solar receiver, for protecting the receiver in the event of a system failure that could cause concentrated sunlight to damage the receiver. The protective apparatus includes a structure which can be moved to a stowed position where it does not block sunlight, to a deployed position. In this position, the structure forms a tube which substantially completely surrounds an axis connecting the receiver opening to the center of the concentrator at locations between the receiver and the concentrator.

Argoud, M. J.↗
DOE OSTI2021

Tribological behavior of ceramic-alloy bearing contacts in molten salt lubrication for concentrating solar power

Molten salts are considered as candidate heat transfer fluids and thermal energy storage media for next generation concentrating solar power (CSP). A molten salt circulates inside the piping and heat exchanger and also functions as a lubricant for the sleeve bearings of the CSP pump. Furthermore, wear- and corrosion-resistant high-temperature bearing materials are critical for the pump efficiency and durability. This study evaluated the tribological performance of candidate bearing materials in lubrication of a molten chloride salt mixture (20% NaCl + 40% MgCl 2 + 40% KCl) at 750 °C in an inert argon gas (a simulative CSP pump environment). Six ceramic-alloy pairs were tested, zirconia and silicon nitride against Haynes 244, Hastelloy C276, and Tribaloy T900 alloy, and ranked by the friction coefficient and wear loss. Characterization of worn surfaces suggested the wear mechanism as a combination of abrasion, adhesion, and tribocorrosion. Results from this study provide fundamental insight for the development and selection of bearing materials for molten salt powered CSP pumps.

14 SOLAR ENERGY↗
NASA NTRS1987

Solar concentrator advanced development project

A solar dynamic concentrator design developed for use with a solar-thermodynamic power generation module intended for the Space Station is considered. The truss hexagonal panel reflector uses a modular design approach and is flexible in attainable flux profiles and assembly techniques. Preliminary structural, thermal, and optical analysis results are discussed. Accuracy of the surface reflectors should be within 5 mrad rms slope error, resulting in the need for close fabrication tolerances. Significant fabrication issues to be addressed include the facet reflective and protective coating processes and the surface specularity requirements.

Corrigan, Robert D.↗
DOE OSTI2026

Evaluation of thermal energy storage for central receiver concentrating solar power plants under charging cycles through structural assessment

Electricity production by concentrated solar power (CSP) systems has stood out among energy transition alternatives due to their large generation capacity (between 30 MW and 400 MW) and high capacity factor (80%) when incorporating thermal storage systems (TES). Although TES tanks in operation worldwide are made of austenitic steels with remarkable mechanical and anticorrosive properties, operational failures have been reported due to low-cycle fatigue, creep, and the abrupt release of residual stresses generated during tank manufacturing. A critical operation for salt tanks is the initial daily charging operation, given the low fluid level and the thermal gradients between the inventory and the salt entering the tank. This study presents a structural simulation of a 39.6 m-diameter molten salt tank for central receiver CSP plants, accounting for temperature and pressure variations during charging and different sparger ring inlet configurations. The initial pre-stressed condition of the floor, resulting from the manufacture of welded plates, is used as a boundary condition. The fatigue and creep life analyses were performed in accordance with the ASME BPVC and API standards. It was found that the tank's floor is in a less favourable mechanical condition than the wall, due to its initial manufacturing condition and the maximum temperature differences during charging. A critical zone was identified in an area affected by residual stress on the floor and under the sparger ring. The baseline sparger ring configuration, with 52 2-inch-diameter orifices and a flow direction of 90 degrees , results in an average floor stress of approximately 25 MPa and creep damage after 1.2 years of tank operation.

14 SOLAR ENERGY↗