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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
All sourcesNASA NTRSDOE OSTI
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 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 OSTI2022

NCSU Industrial Assessment Center

Renewable energy technologies are becoming more attractive and gaining more attention as the world becomes increasingly aware of the negative impacts of global warming and greenhouse gas (GHG) emissions. Two such emerging technologies are geothermal heat pumps (GHP) and solar thermal heating which can be used for heating and cooling of buildings. GHP systems are a well-studied technology that have been proven to be more efficient than traditional air-source heat pumps for space conditioning of buildings. Solar thermal heating has become more common as a way to heat domestic hot water (DHW) in homes, but the two technologies are not often combined. This study presents the findings of combining an open-loop GHP with 100 ft2 of flat plate solar thermal panels and a 5,655-gallon sensible water storage tank for space heating and DHW heating needs of a residential home in Bozeman, MT, USA. The goal of this system was to use energy from the solar panels and storage tank first to decrease pumping energy from the GHP well. The open loop system was designed to be a backup system to the solar thermal panels and sensible storage tank. An actual home was modeled to determine potential energy and cost savings of such a system compared to a traditional propane boiler. Then, a case study was performed on the installed system from January to June 2021. Results obtained from April 2nd to June 5th, 2021 indicated that the combination system supplied all necessary heat, and that heat was supplied from the thermal storage tank 55% of the time. This represents a savings of 330 kWh of energy and $36 compared to operating just the open loop geothermal system. From April 2nd to June 5th the combination system consumed a total of 2,510 kWh of energy and cost $274 to operate. Based on data obtained, there is significant potential for energy savings compared to a propane boiler, however only small potential for cost savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Solar Thermochemical Ammonia Production (STAP) (Final Report)

Ammonia (NH 3 ) is an energy-dense chemical and a vital component of fertilizer. In addition, it is a carbon-neutral liquid fuel and a potential candidate for thermochemical energy storage for high-temperature concentrating solar power (CSP). Currently, NH 3 synthesis occurs via the Haber-Bosch process, which requires high pressures (15-25 MPa) and medium to high temperatures (400-500 °C). N 2 and H 2 are essential feedstocks for this NH 3 production process. H 2 is generally derived from methane via steam reforming; N 2 is sourced from air, after oxygen removal via combustion of hydrocarbons. Both processes consume hydrocarbons, resulting in the release of CO 2 . In addition, hydrocarbon fuels are burned to produce the heat and mechanical energy required to perform the NH 3 reaction, further increasing CO 2 emissions. Overall, the production of ammonia via the Haber-Bosch (H-B) process is responsible for up to 1.4% of the world’s carbon emissions. The development of a renewable pathway to NH 3 synthesis, which utilizes concentrated solar irradiation as a process heat instead of fossil fuels and operates under low or ambient pressure, will result in a decrease (or elimination) of greenhouse gas emissions as well as avoid the cost, complexity, and safety issues inherent in high-pressure processes. Most current efforts to “green” ammonia production involve either electrolysis or simply replacing the energy source for H-B with renewable electricity, but otherwise leaving the process intact. The effort proposed here would create a new paradigm for the synthesis of NH 3 utilizing solar-thermal heat, water, and air as feedstocks, providing a truly green method of production. The overall objective of the STAP (Solar Thermal Ammonia Production) project was to develop a solar thermochemical looping technology to produce and store nitrogen (N 2 ) from air for the subsequent production of ammonia (NH 3 ) via an advanced two-stage process. The goal is a cost-effective and energy efficient technology for the renewable N 2 production and synthesis of NH 3 from H 2 (produced from H 2 O) and air using solar-thermal energy from concentrating sunlight, under pressures an order of magnitude lower than H-B NH 3 production. Our process involves two looping cycles, which do not require catalysts and can be recycled. Over the course of the STAP project, we (1) developed and deeply characterized oxide materials for N 2 separation; (2) developed a method for the synthesis of metal nitrides, producing a series of quaternary compounds that have been heretofore unreported; (3) modeled, designed, and fabricated bench-scale tube and on-sun reactors for the N 2 production step and demonstrated the ability to separate N 2 over multiple cycles in the tube reactor; (4) designed and fabricated a bench-scale Ammonia Synthesis Reactor (ASR) and demonstrated the proof of concept of NH 3 synthesis via a novel looping process using metal nitrides over multiple cycles; and (5) completed a systems- and technoeconomic analysis showing the feasibility of ammonia production on a larger scale via the STAP process. The development of renewable, low-cost NH 3 will be of great interest to the chemicals industry, particularly agricultural sectors. The CSP industry should be both an important customer and potential end-user of this technology, as it affords the capability of synthesizing a promising thermochemical storage material on-site. Since the NH 3 synthesis step also requires H 2 , there will exist a symbiotic relationship between this technology and solar-thermochemical water-splitting applications. Green ammonia synthesis will result in the decarbonization of a hydrocarbon-intensive industry, helping to meet the Administration goal of industrial decarbonization by 2050. The resulting decrease in CO 2 and related pollutants will improve health and well-being of society, particularly for those living in the vicinity of commercial production plants.

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

One‐Step Thermal Gradient‐ and Antisolvent‐Free Crystallization of All‐Inorganic Perovskites for Highly Efficient and Thermally Stable Solar Cells

Abstract All‐inorganic perovskites have emerged as promising photovoltaic materials due to their superior thermal stability compared to their heat‐sensitive hybrid organic–inorganic counterparts. In particular, CsPbI 2 Br shows the highest potential for developing thermally‐stable perovskite solar cells (PSCs) among all‐inorganic compositions. However, controlling the crystallinity and morphology of all‐inorganic compositions is a significant challenge. Here, a simple, thermal gradient‐ and antisolvent‐free method is reported to control the crystallization of CsPbI 2 Br films. Optical in situ characterization is used to investigate the dynamic film formation during spin‐coating and annealing to understand and optimize the evolving film properties. This leads to high‐quality perovskite films with micrometer‐scale grain sizes with a noteworthy performance of 17% (≈16% stabilized), fill factor (FF) of 80.5%, and open‐circuit voltage ( V OC ) of 1.27 V. Moreover, excellent phase and thermal stability are demonstrated even after extreme thermal stressing at 300 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High-Strength, High-Ductility, High Entropy Alloys with High-Efficiency Native Oxide Solar Absorbers for Concentrating Solar Power Systems

This EPSCoR Project has been investigating the synergy between the excellent high-temperature mechanical behavior of FeMnNiAlCr high entropy alloys (HEA) and the high solar absorptance of their native oxides for high efficiency concentrated solar thermal power (CSP) systems working at >700°C. While HEAs have attracted substantial interest in recent years, most investigations have focused on their applications as structural materials rather than functional materials. This EPSCoR project discovered that FeMnNiAlCr HEAs can potentially be applied synergistically as both a structural and functional material for high-efficiency concentrating solar thermal power (CSP) systems working at >700°C. The HEA itself would be used in high-temperature tubing to carry molten salts or supercritical CO 2 , while its surface oxide would act as a high-efficiency solar thermal absorber. With Fe and Mn being the major components in these HEAs (adding up to ~70 at.% of the alloy), these materials are much more cost-effective than the Ni-based superalloys currently being investigated for high-temperature CSP systems. Through this research, these Fe-Mn based HEAs have demonstrated yield strengths 2-3x greater than that of stainless steel at 700°C and a creep lifetime >800 h at 700ºC under a typical CSP tubing mechanical load of 35 MPa. Their Mn-rich surface oxides maintain a high optical-to-thermal conversion efficiency of ~87% under 1000x solar concentration ratio for 20 simulated day-night thermal cycles between 750ºC and room temperature. In preliminary corrosion studies, these HEAs have sustained immersion in unpurified bromide molten salts for 14 days at 750°C with <2% weight loss, in contrast to 70% weight loss from a 316 stainless steel reference. The simultaneous achievement of promising mechanical, optical, and thermochemical properties in this FeMnNiAlCr system opens the door to new applications of HEAs in solar energy harvesting. Partnerships with Ames Laboratory and Oak Ridge National Laboratory (ORNL) also advanced our understanding of the fundamental structure-property relationships through atomic scale material characterization and first-principles computational modeling. The key research results in this project can potentially be extended to other HEAs and their native oxides. In terms of applications, the proposed FeMnNiAlCr HEA/native oxide system could potentially exceed the mechanical and the optical performance of existing tubing and solar coating materials under EERE’s CSP program at lower cost, which also aligns well with the EPSCoR Science and Technology strategies of New Hampshire in boosting the deployment of renewable energy.

14 SOLAR ENERGY↗
DOE OSTI2024

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↗
DOE OSTI2022

Chapter 10: Process Heating for Industry

The overall objective of this chapter is to help the reader better understand the technical feasibility, barriers and opportunities for renewable thermal energy systems (RTES). Solar thermal (ST) derived heat, which can be concentrating or non-concentrating, can be considered a sub-set of RTES solutions that can provide heat for industry. This chapter will focus on Industrial Process Heat (IPH) and District Heating Systems and will also highlight the difference between stand-alone and hybrid solutions. Different thermal energy sources (traditional and new) and technologies, that can provide the end-user heat delivered through many mediums, systems and for different purposes. Among various RTES, ST technologies will be the focus of this chapter.

district heating↗
DOE OSTI2021

High Flux Microchannel Receiver Development (Final Report)

The opportunity addressed in this project was using microscale heat exchanger technology for improving solar thermal central receiver efficiency. This will result in smaller, less expensive components and reduce the levelized cost of electricity from concentrated solar thermal power. This micro-pin solar receiver (MSR) directly heats high pressure (25 MPa) supercritical carbon dioxide (sCO 2 ) from 550°C to 720°C with an incident flux of at least 120 W/cm 2 at a receiver efficiency of >90% (assuming availability of 95% absorptivity coating), and receiver cost target of less than $\$$150/kWt. Realization of the MSR required an understanding of thermal hydraulic performance of sCO 2 in micro-pin passages, mechanical behavior of high nickel alloys at high temperatures including joints, advanced fabrication methods of high nickel alloys (etching, machining, brazing, welding, diffusion bonding), and the cost implications of these when the concept is scaled to production volumes. The technology can be used with gases (sCO 2 , helium, etc.) or with liquids such as molten salt or liquid metal. Given the high pressure associated with sCO 2 , its use demonstrates a “worst case” scenario, and the successful development of the MSR for this application will result in the development of a technology also applicable to a range of other heat transfer fluids that will enable next generation CSP plants, including support of the Gen3CSP program.

14 SOLAR ENERGY↗
DOE OSTI2024

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↗
DOE OSTI2021

Transparent Refractory Aerogels for Efficient Spectral Control in High–Temperature Solar Power Generation

Although spectrally selective materials play a key role in existing and emerging solar thermal technologies, temperature-related degradation currently limits their use to below 700 °C in vacuum and even lower temperatures in air. Here a solar-transparent refractory aerogel that offers stable performance up to 800 °C in air is demonstrated, which is significantly greater than its silica counterpart. This improved stability is attributed to the formation of a refractory aluminum silicate phase, which is synthesized using a conformal single cycle of atomic layer deposition within the high-aspect-ratio pores of silica aerogels. Furthermore, based on direct heat loss measurements, the transparent refractory aerogel achieves a receiver efficiency of 75% at 100 suns and an absorber temperature of 700 °C, which is a 5% improvement over the state of the art. Transparent refractory aerogels may find widespread applicability in solar thermal technologies by enabling the use of lower-cost optical focusing systems and eliminating the need for highly evacuated receivers. In particular, a shift to higher operating temperatures while maintaining a high receiver efficiency can enable the use of advanced supercritical CO 2 power cycles and ultimately translate to an ≈10% (absolute) improvement in solar-to-electrical conversion efficiency relative to existing linear concentrating systems.

14 SOLAR ENERGY↗
DOE OSTI2022

Concentrated solar photovoltaic and photothermal system

The present invention provides a hybrid, concentrating photovoltaic-solar thermal (CPV/T) system and components thereof, and methods for converting solar energy to electricity at high efficiencies while capturing and storing solar thermal energy for later deployment.

Codd, Daniel↗
DOE OSTI2024

Heliostat Observation System Commercialization Qualification HOS-C-Q (Final Technical Report)

Heliostat fields are one of the main components of a concentrated solar thermal plant. As GEN3 technology has been developed at pilot plant level targeting higher temperatures >700C, having a precise Heliostat field control system will enable the success of the GEN3 technology. Heliogen Inc. has developed the next generation of control systems for heliostat fields. Their early development was on single facet heliostats at their R&D facility in Lancaster, California. This new system allows for a closed loop integration to a current open loop setup of a regular Heliostat control system. Sandia National Laboratories and Heliogen Inc. have partnered together to test Heliogen’ s innovative new SOHOT system at the National Solar Thermal Test Facility.

14 SOLAR ENERGY↗
DOE OSTI2024

Evaluation of Additively Manufactured Monolithic SiC and SiC Ceramic Matrix Composites for Concentrating Solar Receiver Applications

Supported by an award from the Solar Technology Office, US Department of Energy, GE Aerospace Research in collaboration with Heliogen Holdings Inc, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR). We report the results of our study of the effective heat transfer characteristic of several candidate structure motifs, or feature geometries, made of SiC via additive manufacturing in a simulative laboratory test. The SiC structure motifs studied include different permutations of three-dimensional periodic lattices and defined shapes. The solar-thermal simulating laboratory test setup is constructed using a 4kW CO2 laser system with beam shaping optics to apply radiative heating power on one face of 2”-diameter cylindrical feature specimens representing the structure motifs of interest for receiver element design. 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 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.

14 SOLAR ENERGY↗
DOE OSTI2020

Low-cost desalination of seawater and hypersaline brine using nanophotonics enhanced solar energy membrane distillation

A stand-alone small-scale nanophotonics enhanced solar membrane distillation (NESMD) testbed was designed, developed, and tested for desalinating seawater and high salinity feedwaters. This NESMD system can take almost any source water and turn it into clean water with sunlight as the only energy source. The NESMD technology applies nanophotonic coating materials on a commercial hydrophobic polypropylene support of a polytetrafluoroethylene (PTFE) membrane surface. The photothermal coating serves as a solar thermal collector, absorbs solar energy, and generates highly localized heat on the membrane, while the rest of the membrane performs membrane distillation functions. The presented NESMD system is equipped with an internal heat recovery system with no need for external electricity and no additional water for cooling. The NESMD testbed is installed and tested at Rice University campus (29.7174° N, 95.4018° W). In this study, real seawater from Galveston Bay, Texas, U.S. and high salinity simulated feedwaters (total dissolved solids (TDS) of 113 200–200 000 PPM) have been tested for long-term testing under the weather conditions of Houston, Texas. Here, the field testing results showed stable desalination performance in consecutive 5–8 hour operation cycles, with a TDS removal of ≥99.5% in all experiments. An average daily membrane flux of ≥0.75 L m –2 h –1 was achieved at a solar intensity close to 1 kW m –2 without an external heat exchanger. Further investigations and improvements are required to enhance the performance of the reactor since it is still a new promising technology.

14 SOLAR ENERGY↗
DOE OSTI2024

Static metrology of the meter-scale deformable heliostat

This paper describes a heliostat metrology system which is developed based on deflectometry, utilizing a static perforated panel instead of conventional dynamic monitor displays to provide incident rays. The developed method is named static screen deflectometry (SSD). This robust and scalable method is especially valuable for outdoor tests of large reflectors used in concentrating solar-thermal power (CSP) systems. The developed method has been successfully demonstrated on a 2.4 𝑚 × 3.3 𝑚 float glass deformable reflector bent to focus sunlight at 113 𝑚 distance throughout a day. From images obtained from a camera at 50𝑚 distance, the reflector surface was measured to an accuracy of less than 1 𝑚𝑟𝑎𝑑 rms slope error in the full test scope.

14 SOLAR ENERGY↗