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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 145 records · Page 8
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DOE OSTI2022

Assessment of Molten Eutectic LiF-NaF-KF Density through Experimental Determination and Semiempirical Modeling

Molten salts have favorable material properties for use in high-temperature energy systems, including thermal energy storage systems, concentrating solar power plants, nuclear reactors, and various industrial manufacturing processes. Knowledge of chemical and thermophysical property data is essential for the design and optimization of these systems, yet data are often limited or uncertain for many candidate salts due to the difficulty of thermophysical property measurements at relevant temperatures (e.g., 500–900 °C). Here, the density of molten LiF-NaF-KF eutectic is reassessed through review of previous experimental data, new density measurements from 470 to 800 °C, and semiempirical modeling. Additionally, the density was measured using the displacement technique. Compositional and temperature-dependent density estimates were calculated with a multidimensional Redlich–Kister model. The results of the new experimental measurements agree within 2% of the modeled density of molten eutectic LiF-NaF-KF. The Redlich–Kister model’s prediction shows a near-ideal density behavior for the LiF-NaF-KF system and is promising for the estimation of off-eutectic LiF-NaK-KF densities. Finally, through review of the existing literature and comparison to new measurements, recommendations are made for the density of LiF-NaF-KF.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

New High-Strength Ni-based Alloys for High Temperature Service in Liquid Fluoride Salt Environments

The ever-increasing demand for higher system thermal efficiency necessitates the operation of power generation cycles and heat conversion systems for chemical processes at progressively higher temperatures. As the system operating temperature increases, fewer and fewer materials are available with the required mechanical properties and environmental compatibility. This dearth of materials is particularly acute in structural applications at temperatures above 700°C in liquid Fluoride Salt Cooled High-Temperature Reactors (FHRs) and Concentrated Solar Power (CSP) systems where liquid fluoride and/or liquid chloride salts are used for their high thermal capacity and low thermal conductivity to store and transport heat. It has been shown that fluorides and chlorides can degrade the properties of the material used for storage and transport due to corrosive effects thus affecting the performance and lifetime characteristics. Thus, materials used for storage and transport for fluoride/chloride-salt must at the minimum have good compatibility with the salt by exhibiting low corrosion rates at the required temperatures. In addition, since many of the components will be subject to stresses in service, they need to have sufficient strength to resist plastic deformation, and the resistance to time dependent creep deformation at these temperatures, and stress levels. Achieving the combination of these properties required for higher temperatures is particularly challenging considering traditionally, the expected lifetime of some of the components used in these systems are from 30 years (CSP) to 80 years (FHRs). Although 316 stainless steel and associated redox corrosion reduction techniques are being considered for use in the first generational systems, use of 316SS is limited to operating temperatures up to ~ 650°C, thereby resulting in lower reactor efficiencies. Hastelloy ® N, developed at ORNL in the 1950s-60s for molten salt service is currently the leading candidate FHR structural alloy but has inadequate creep properties at high temperatures. Using a computationally-guided approach, Oak Ridge National Laboratory had developed new high strength alloys strengthened by γ’ precipitates (about 2X the strength of Hastelloy ® N) in small laboratory-scale heats that show good resistance to corrosion by fluorides and improved creep rupture life at temperatures up to 850°C (U.S. Patent Application No. 13/833,357 entitled “High Strength Alloys for High Temperature Service in Liquid-Salt Cooled Energy Systems”- granted U. S. Patent No. 9,540,714).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Binderjet Additive Manufacturing for Complex Heat Exchanger Geometries

Concentrated Solar Power (CSP) systems play a role in the worlds development of renewable energy. Mirrors are used to concentrate sunlight that is converted into electricity or other forms of useful energy. CSP impact depends significantly on its overall economics. The U.S. Department of Energy’s (DOE’s) Solar Energy Technology Office (SETO) cost goals for 2030include $0.05/kWh levelized cost of electricity (LCOE) for a baseload plant [1]. The power cycle cost goal is $900/kWe [1]. The envisioned recompression supercritical carbondioxide (sCO2) power cycle includes four heat exchangers, which together are at least ¾ of the total power cycle cost. Meeting the cost target requires reducing the heat exchanger cost. The 260 bar and 588 °C heat exchanger requirements are challenging. Shell and tube heat exchangers can meet the requirements, but the size and cost are prohibitive. State-of-the-art diffusion bonded printed circuit heat exchanger designs are 3 m3 or larger and expensive to manufacture. Additive manufacturing enables novel heat exchanger geometries that can reduce heat exchanger size and mass [2]. Binderjet technology is an additive manufacturing modality. It selectively deposits binder material onto the powder bed to form a solid part one layer at a time. Once applied, the binder is cured, the remaining powder removed, and the part heat treated in steps to remove the binder, sinter the metal powder, and densify the part. The Binderjet printing process is more than 10x faster than the best-known metal additive modality, direct metal laser melting (DMLM), thus enabling 10x the part through-put rate [3]. The high throughput rate results in a low-cost manufacturing process capable of creating complex heat exchanger geometries. This paper introduces a complex heat exchanger geometry and methods of Binderjet processing to fabricate the geometry.

Barua, Ananda↗
DOE OSTI2024

Thermo-Mechanical Modeling and Evaluation of the Cracking Response of Additively Manufactured Monolithic SiC Lattice Structures Subjected to 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. The state-of-the-art SiC volumetric concentrating solar air receivers such as honeycomb design have been demonstrated in field tests to achieve exit air temperatures approaching 800oC. However, successful application of CST systems for decarbonization requires significant increase in 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 ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and to demonstrate a techno-economically viable SiC air receiver technology to achieve exit air temperature of 1100oC for CST applications. This report summarizes the learnings of a computational study on additively manufactured SiC lattice structures subjected to laser heating. The results from this study aim to help guide the design of a SiC receiver through a better understanding of lattice structure geometric parameters and their implications on the cracking response of the structure. In the study, a heat flux was applied to the surface of a 2”-diameter cylindrical lattice structure to simulate a 4kW CO2 laser. The resulting temperature distribution was applied to a structural model to approximate the stress distribution within the lattice structure and a Weibull analysis was performed to gain insight into the probability of failure and to evaluate the cracking response of the structure. With this approach, the influence of lattice density on temperature, stress, and probability of failure was explored for two different lattice beam spacings. A discussion on modeling assumptions, a comparison with experimental results, and an evaluation of the lattice cracking response is provided.

14 SOLAR ENERGY↗
DOE OSTI2024

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↗
DOE OSTI2020

Guidelines for Phase Change Material Selection Based on a Holistic System Model

Concentrating solar power (CSP) has potential to increase the amount of renewable energy on electric grids and reduce global carbon emissions, in particular because of its capability to incorporate inexpensive thermal energy storage. To realize this potential, development of latent heat storage with phase change materials (PCMs) is attractive because of its high energy density and low material cost. Research in this area has identified many promising materials, and has developed effective storage system designs that could be used to deploy PCMs. However, the field has lacked a rigorous methodology to select the optimal material for a particular CSP system. To address this need, here we present a holistic model that evaluates all important influences of PCM properties on the performance and cost of an entire CSP plant. We apply this model to over 100 of the most widely considered candidate materials, including both salts and metals. We quantify the relative value of each PCM property, and identify leading materials for application in CSP systems. This method and our results may aid future efforts to develop latent heat storage by providing a more informed view of how material selection impacts an entire CSP system.

14 SOLAR ENERGY↗
DOE OSTI2021

Managing Solar Photovoltaic Integration in the Western United States Appendix: Reference and High Solar Photovoltaic Scenarios for Three Regions [Slides]

This slide deck is an appendix to a paper series that examines potential challenges related to planning future power systems with higher solar photovoltaic (PV) penetrations. The series uses the western U.S. power system for these investigations because it is a region the authors and their colleagues have already extensively studied. We are therefore well-suited to analyze even higher PV penetrations and then examine the results in multiple models to determine whether our current approaches are missing key details that only emerge at higher PV penetrations. This deck details the systems underlying those analyses and how they were modeled using the Resource Planning Model (RPM), a capacity expansion modeling tool. We examine both Western Interconnection-wide and regional results for three regions in the Western U.S. with significantly different existing power systems and connections to neighboring regions; this provides a more balanced picture as to how power systems with high PV penetration might emerge in different contexts and what the resulting grid challenges, if any, might be.

14 SOLAR ENERGY↗
DOE OSTI2020

A Cost-Performance Analysis of a Sodium Heat Engine for Distributed Concentrating Solar Power

We present that a sodium thermal electrochemical converter (Na-TEC) generates electricity directly from heat through isothermal expansion of sodium ions across a beta"-alumina solid-electrolyte. This heat engine has been considered for use with conventional concentrating solar power (CSP) systems before. However, unlike previous single-stage devices, the improved design uses two stages with an interstage reheat, allowing more economical and efficient conversion up to 29% at a hot side temperature of 850 °C. Herein, a cost-performance analysis for this improved design assesses opportunities for distributed-CSP in the context of micro-combined heat and power systems. A high-level techno-economic analysis (TEA) is presented that explores four scenarios where a Na-TEC is used as the heat engine for a distributed-CSP system. Overnight capital cost and levelized cost of electricity (LCOE) are estimated for a system lifetime of 30 years, revealing that overnight capital costs in a range from $3.57 to $17.71 per W e are feasible, which equate to LCOEs from 6.9 to 17.2 cents kWh e -1 . This analysis makes a significant contribution by concurrently quantifying the efficiency and unit costs for a range of multistage configurations, and demonstrating that a Na-TEC may be a promising alternative to Stirling engines for distributed-CSP systems at residential scale of 1–5 kW e .

14 SOLAR ENERGY↗
DOE OSTI2025

Design, Fabrication and On-Sun Performance Evaluation of SiC Receiver Feature Specimens for CST Applications Using Additively Manufactured SiC Materials

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Successful development of CST systems to generate heat for industrial applications requires significant increase in temperature capability and techno-economically viability of the receiver systems. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Aerospace Research in collaboration with Heliogen Holdings Inc and Sandia National Lab, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to demonstrate SiC receiver with air exit temperatures up to 1100 oC and high thermal efficiencies. We report design, fabrication and on-sun test results of SiC components of a prototype 50kW (thermal) HOTSSTAR module. The receiver module architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around a SiC center absorber. The SiC components are fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the reliability and to minimize the risk of cracking damage of SiC test articles in thermal gradient and thermal shock environment of the application, the components were laminated with GE’s MI SiC-SiC CMC. Following extensive design and lab test analyses, selected SiC component designs are tested at Heliogen Lancaster Solar field under highly concentrated solar fluxes around 2000 suns to assess the thermal performance characteristics under realistic field conditions. We report on the test results and compare the thermal performances of different HOTSSTAR SiC absorbers. Finally, we discuss fabrication and initial assembly of a 50kW prototype test module in preparation of on-sun field tests to assess the performance of our final design.

CST, CSP, high temperature, air receiver, SiC, add↗
DOE OSTI2024

Malcolm Deployment Guide for Solar Power Generation Plants

This guide provides detailed instructions for deploying Malcolm in Solar Power Generation systems. It covers the deployment process, from understanding the network architecture of these systems to configuring network switches and Switched Port Analyzer (SPAN) ports or mirror ports or TAPs. The guide also includes best practices for deploying Hedgehog sensors, another critical component in these systems. Following this guide, users can enhance network visibility, improve their system’s security, and effectively troubleshoot common issues.

14 SOLAR ENERGY↗
DOE OSTI2022

Experimental Study of Eutectic Molten Salts NaCl/KCl/ZnCl2 Heat Transfer Inside a Smooth Tube for High-Temperature Application

Abstract Eutectic salts NaCl-KCl-ZnCl2 and NaCl-KCl-MgCl2 are two of the chloride salt systems that are promising for being used as high-temperature heat transfer fluid (HTF) and thermal energy storage (TES) materials in a wide range of temperatures from 230 °C to 750 °C in concentrated solar thermal power systems. To conduct measurement of the heat transfer coefficient of the molten salt at high temperatures, a circulation system and instrumentation of flow and heat transfer was constructed. Experimental measurement of the convective heat transfer coefficients of NaCl-KCl-ZnCl2 (molar fraction: 13.8–41.9–44.3%) inside tubes has been accomplished to find the most suitable heat transfer correlations. Experience of salt processing and operation of the high-temperature heat transfer test system was obtained. Two correlations, Dittus-Boelter equation and Gnielinski’s correlation for Nusselt number against Reynolds number and Prandtl number, are evaluated using the test results, and the latter correlation is recommended due to its better agreement of prediction against tested data.

Energy & Fuels↗
DOE OSTI2023

Hawaiian Electric Company (HECO) Grid Optimization with Solar (Cooperative Research and Development Final Report)

The purpose of this project is to provide a software platform that gives utility companies the capability to seamlessly dispatch legacy devices (at both the distribution and subtransmission levels) and distributed energy resources (DERs) to achieve system-wide performance and reliability targets–such as minimizing loss, reducing voltage violation, and corresponding imbalance–for extreme solar futures with well over 100% (capacity) penetrations.

14 SOLAR ENERGY↗
DOE OSTI2020

Redox-active oxide materials for thermal energy storage

Thermochemical storage materials having the general formula A x A′ 1-x B y B′ 1-y O 3-δ , where A=La, Sr, K, Ca, Ba, Y and B=Mn, Fe, Co, Ti, Ni, Cu, Zr, Al, Y, Cr, V, Nb, Mo, are disclosed. These materials have improved thermal storage energy density and reaction kinetics compared to previous materials. Concentrating solar power thermochemical systems and methods capable of storing heat energy by using these thermochemical storage materials are also disclosed.

14 SOLAR ENERGY↗
DOE OSTI2020

Redox-active oxide materials for thermal energy storage

Thermochemical storage materials having the general formula AxA′1-xByB′1-yO3-δ, where A=La, Sr, K, Ca, Ba, Y and B=Mn, Fe, Co, Ti, Ni, Cu, Zr, Al, Y, Cr, V, Nb, Mo, are disclosed. These materials have improved thermal storage energy density and reaction kinetics compared to previous materials. Concentrating solar power thermochemical systems and methods capable of storing heat energy by using these thermochemical storage materials are also disclosed.

14 SOLAR ENERGY↗
DOE OSTI2021

Optimized AC/DC Dual Active Bridge Converter using Monolithic SiC Bidirectional FET (BiDFET) for Solar PV Applications

Grid interface power conversion systems for commercial, industrial and residential solar power generation are becoming ubiquitous due to the competitive cost of solar energy. The AC/DC dual active bridge (DAB) converter is an upcoming topology in industrial PV energy and energy storage applications, providing bidirectional power transfer and galvanic isolation. In this paper, the properties of a DAB-type converter are leveraged to propose a design optimization process. It can optimize the high-frequency RMS current, size of magnetic elements and zero-voltage-switching (ZVS) region of the converter. The resulting design is compared against that derived from a conventional approach. In addition, an algorithm to compute the harmonic currents at the DC and line frequency AC ports of the system is proposed, and the respective filter designs are presented. The optimized design of the AC/DC DAB converter is implemented using the newly developed, 1200 V, 46 mΩ, four quadrant, SiC-based monolithic bidirectional FETs (BiDFET). Experimental results from the 2.3 kW, 400V/277VRMS hardware prototype are finally presented to verify the design process.

Bidirectional isolated AC-DC conversion, solar ene↗
DOE OSTI2020

Thermal Energy Storage Using Solid Particles for Long-Duration Energy Storage

The rapid growth of renewable energy increases the importance of economically firming the electricity supply from variable solar photovoltaic- and wind-power generators. Energy storage will be the key to manage variability and to bridge the generation gap over time scales of hours or days for high renewable grid integration. The integration of renewable power and storage of excess electricity has several significant and positive impacts including: 1) expanding the renewable energy portion of total electricity generation, 2) improving the peak-load response, and 3) coordinating the electricity supply and demand over the grid. Long-duration energy storage can potentially complement the reduction of fossil-fuel baseload generation that otherwise would risk grid security when a large portion of grid power comes from variable renewable sources. Several energy storage methods are deployed or under development, including mechanical, chemical or electrochemical, and thermal energy storage (TES). Comparing their economic potential for different scales and applications helps identify suitable technology to support high renewable grid integration. Despite the progress of TES technologies developed and deployed with concentrating solar power (CSP) systems, TES has been undervalued for its potential role in electric energy storage. This paper introduces TES methods applicable to grid energy storage and particularly focuses on solid-particle-based TES to serve the purpose of long-duration energy storage (LDES). The objective of this paper is to present a standalone particle-based TES system for electric storage and to show the potential of TES systems for LDES applications over other energy storage methods such as batteries, compressed-air energy storage, or pumped-storage hydropower.

27 ARPA - Advanced Research Projects Agency-Energy↗
DOE OSTI2021

Redesigning capacity market to include flexibility via ramp constraints in high-renewable penetrated system

Capacity markets can co-exist alongside the energy and ancillary markets to ensure the medium-term and long-term supply adequacy by remunerating the generation resources for their availability. With the substantially increasing deployment of renewable generation, the system needs more flexibility to quickly mitigate the variability and uncertainty caused by the renewable generation. However, the present capacity market model does not differentiate the flexibility of generating units, so it might not give appropriate pricing signals to more flexible units that are usually more expensive. This is particularly important considering the increasing penetration levels of renewable generation on the electric grid, which increases the need for flexible units. This paper proposes a novel capacity market model considering flexibility requirement (FR) under the high penetration levels of renewable generation. Therefore, the proposed model can give the market-clearing price (MCP) for not only peak load generation capacity but also flexibility requirement. Thus, flexible units will tend to receive more economic incentives than non-flexible units. In the case studies, the profitability of different generation resources under the proposed capacity market model is analyzed and compared to the present capacity market model. The results show that the proposed method can maintain system reliability with regard to both peak load and flexibility requirement efficiently.

24 POWER TRANSMISSION AND DISTRIBUTION↗