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DOE OSTI2025

High tensile alloy of copper to mitigate current collector deformation in silicon electrodes for lithium-ion batteries

The volumetric changes of silicon electrodes, along with the strong adhesive properties of certain binders, can lead to plastic deformation of the current collector and create damage in the electrode coating. Here, in this study, we report a detailed study of silicon coatings on a high-tensile alloy (HTA) foil of copper with strength over twice that of conventional copper foils. The HTA current collectors with high mechanical strength can mitigate plastic deformation upon continuous cycling. At moderate areal capacities (2.5–3 mAh cm −2 ), conventional copper foils show significant wrinkling after only a few electrochemical cycles, whereas the HTA foils remain intact. We demonstrate viability of the HTA foils in large format xx6395 pouch cells, in which the HTA current collectors remain intact even at an areal capacity of 4.5 mAh cm −2 ; in contrast, wrinkles form in conventional copper current collectors increasing the likelihood of lithium plating. Computational studies show that stresses generated during cycling of silicon electrodes are very high in the current collector and at the current collector-coating interface, explaining the wrinkling of conventional Cu foils. Our studies highlight importance of current collector to solve the electrochemical and chemo-mechanical performance challenges associated with high-loading silicon electrodes.

Chemo-mechanical degradation↗

DOE OSTI2022

Manufacturing Cost Analysis of Advanced Parabolic Trough Collector

The research team performed a detailed bottom-up manufacturing cost estimate for an advanced parabolic trough design - the Solar Dynamics Sunbeam-MT (Sunbeam Mid-Term). This includes all components for manufacturing and assembly in a manufacturing facility (e.g. space frame and arms), and the purchased parts (e.g. mirrors and receiver tubes). Estimates of the construction and assembly activities have been made to then determine an estimated installed cost. Prior analysis has already undertaken detailed bottom-up manufacturing, assembly, and construction analysis for the Ultimate Trough from schlaich bergermann partner (sbp), and this work updates the solar field cost estimates based on a similar aperture area as the SunBeam-MT. For this analysis, the Ultimate Trough is considered the commercial parabolic trough and the Sunbeam-MT as the advanced parabolic trough. For similarity, both the Sunbeam-MT and the Ultimate Trough have been modelled with a solar field with approximately 800,000 square meters (m2) in aperture area - the equivalent of a large CSP plant. The analysis has found a potential installed cost estimate of the Sunbeam-MT could be $120/m2 but must be built at scale to confirm this estimate. Compared to prior analysis, the commercial Ultimate Trough using U.S. conditions, has reduced in installed cost from $178/m2 to $152/m2. Both designs could be even cheaper with Chinese steel.

cost analysis↗

DOE OSTI2023

Toward Autonomous Field Inspection of CSP Collectors With a Polarimetric Imaging Drone

We developed a polarimetric imaging drone to perform field inspections of heliostats and carried out field tests at Sandia’s National Solar Thermal Test Facility (NSTTF). The preliminary results show that Degree of Linear Polarization (DOLP) and Angle of Polarization (AOP) images greatly enhanced the edge detection results compared with the conventional visible images, supporting fast and accurate detection of heliostat mirror edges and cracks. The system holds the promise to enable future automated detection of heliostats optical errors and mirror defects.

14 SOLAR ENERGY↗

DOE OSTI2024

Studying Wind Loading on CSP Collectors to Improve Performance and Reliability

Electricity generation through Concentrating Solar-thermal Power (CSP) adds the advantage of thermal energy storage and heat production. CSP collector costs constitute nearly one-third of total plant costs. Managing wind loading, especially dynamic wind loading caused by the turbulent wind flow, is a significant design challenge. Traditional collector designs rely on wind tunnel experiments and numerical simulations, which do not fully capture dynamic effects. Here, we provide an overview of NREL's activities on wind loading on CSP collectors, aiming to improve their reliability and cost-efficiency. We present insights from field measurements at operational parabolic trough and power-tower CSP plants. Over two years, we measured turbulent wind fields and resulting structural loads in a parabolic trough plant, revealing wind, turbulence, and collector field interactions. Similar measurements are ongoing at the Crescent Dunes heliostat field. These campaigns show how atmospheric turbulence, wind direction, and collector orientation affect dynamic wind loading. Upwind collector structures can generate turbulent structures, causing fluctuating loads at downstream collectors, impacting fatigue lifetime and optical efficiency. Preliminary results indicate that interior collectors experience higher turning moments than those at the edges, suggesting higher drive wear. At Crescent Dunes, we use instrumented heliostats at the field's edge and interior to study the translation of turbulent wind to dynamic structural loads. The campaign is still ongoing, and we will present first findings. Another focus of our work is tying the experimental wind loading findings to optical performance of the collectors, using simulation tools. For example, we derive torsional errors of the parabolic troughs - the angular offset from the sun position along a collector row. This error is impacted by wind-induced mirror deformations. Future work will focus on continuing the measurement efforts and combining them with computational fluid dynamic simulations. By providing detailed field measurements and validated models, our efforts aim to enhance understanding of wind loading on CSP collectors, improving their structural integrity and optical performance.

CSP↗

DOE OSTI2025

The Effect of a Carbon Fiber Layer Between the Cathode and the Current Collector on Battery Cell Performance

Contact resistance between the cathode active material (CAM) and the Al current collector can be reduced by applying carbon coatings to the Al current collector surface. However, this process requires an additional step of carbon layer coating on the current collector, which increases both manufacturing costs and processing time. In the present work, an interlayer of continuous unsized carbon fibers aligned in one direction (CF interlayer), is introduced between the Al current collector and the NMC811 cathode during cathode deposition on the Al current collector. This single-step approach eliminates the need for the additional carbon layer coating on the current collector. Additionally, this approach removes the use of toxic solvents and insulative polymers used for making the carbon coating. The CF interlayer improves the rate capability at higher C-rates. The CF interlayer lowers the contact resistance between the cathode particles and the current collector while improving the activation energy of charge transfer. The peel test showed that the CF interlayer does not affect the adhesion strength of the cathode layer with the current collector.

25 ENERGY STORAGE↗

DOE OSTI2024

Linear Solvers for Collector Systems of Generalized Large-scale Inverter-Based Resources

Collector systems for inverter-based resources (IBRs) are typically represented by equivalent circuits for electromagnetic transient (EMT) simulations. Recent studies have revealed that modeling a detailed collector system is essential to accurately represent the behavior of IBRs, especially when dealing with partial tripping during external disturbances. However, there are several challenges in simulating a detailed EMT model of a collector system due to the time required to simulate such systems. Thus, this paper investigates the modeling of a detailed collector system, taking into account its configuration and components as defined in IEEE standard 2800. The configurations include the collector systems of generalized large-scale IBR plants. The components include the main IBR transformer, collector bus, and feeders with lines and/or cables. The EMT model of the collector system is represented by differential algebraic equations (DAEs) that are discretized to form linear equations that are solved using linear solvers. In this paper, linear solvers are proposed based on the Schur complement method, which are utilized for simulation of the EMT model of collector systems of generalized large-scale IBRs to accelerate simulation speed while maintaining the accuracy of the results. The proposed solvers are verified by comparing the performance to that of linear solvers provided in MATLAB.

Choi, Jongchan↗

DOE OSTI2023

A lightweight and metal-free current collector for battery anode applications

The requirement for high energy density batteries is driving the development of high-capacity electrode materials while reducing the amount of inactive battery components such as separators, binders, and current collectors. Though current collectors are an inactive component, they are still required for successful working of a battery cell. Conventional current collectors include aluminum foil for cathode and copper foil for anode. Copper foil is quite heavy (8.7 mg/cm 2 ) for 10μm thickness. Therefore, there is a need for a lightweight current collector for anode applications. In this work, a metal-free current collector comprised of aligned carbon fiber (CFs) layer filled with carbon nanotubes (CNTs) mixed in polymer (P) is developed to be used as a current collector for anodes. Further, anodes coated on the CF-CNT-P showed lower charge transfer resistance and improved rate capability compared with the anodes fabricated on conventional copper foil-based current collectors. The CF-CNT-P are lighter (≈1.5 mg/cm 2 ) than the commonly used copper foil (8.7 mg/cm 2 ), which will increase the gravimetric energy density.

25 ENERGY STORAGE↗

DOE OSTI2023

Influence of Correlations on the Thermal Performance Modeling of Parabolic Trough Collectors

The influence of correlations on the thermal performance modeling of parabolic trough collectors was analyzed in this work. A versatile model for a parabolic trough collector was developed that allows one- and two-dimensional analysis and enables the use of correlations to calculate thermophysical properties and convection heat transfer coefficients. The model also allows the use of constant values for properties and/or coefficients obtained from the evaluation correlations at a specific temperature. The effect of each correlation was evaluated independently, and the results were compared with a reference case that considered a two-dimensional approach and used all the correlations. For the analyzed cases, the correlation for the absorber emittance has the strongest impact on the collector efficiency, leading to a lower error when used. Based on the results, a one-dimensional model approach considering a correlation for the absorber emittance leads to efficiency errors below 3% for collector lengths of up to 243.6 m. Compared with the reference case, a one-dimensional approach using all correlations for a collector with a length of 500 m, and operating with an inlet temperature of 773 K, can result in errors around 9%. However, using constant values for properties and heat transfer coefficients could lead to errors of up to 50%. Multiple thermal models for parabolic trough collectors proposed in the literature rely on a one-dimensional approach, estimated values for the heat transfer coefficients, and constant thermophysical properties. The errors associated with those approaches are analyzed and quantified in this work as a function of the collector length and operation temperature.

absorber emittance↗

DOE OSTI2021

Beneficiation of Bastnaesite Ore with New Flotation Collector Ligands

Interest in Rare Earth Elements (REEs) has increased due to their distinct properties and new applications. China currently has a monopoly on rare earth production due to the lack of an economically viable process used outside of China. Bastnaesite, a rare earth fluorocarbonate, is one of the most common minerals containing REEs, which is mostly comprised of cerium and other light REEs. The objective of this research is to find a novel collector for the beneficiation of bastnaesite through froth flotation experiments to increase the grade and recovery of rare earth oxides while rejecting the major gangue minerals. Microflotation and rougher bench flotation studies were evaluated to find optimal collector(s) from 19 possible candidates. Collectors 2, 5, and 8 were the top performing collectors chosen from microflotation experiments. A design of experiment matrix was set up to evaluate the variables, variable interactions, and provide a reference matrix for future optimization studies. Collector 2 was assessed to be the optimal collector. A rougher flotation experiment produced a rare earth oxide grade and recovery of 41% and 78%, respectively with a 91.5% rejection of calcite. Collector 8 and 14 also showed promising results to replace fatty acid. As such, this patent pending technology can serve to provide a pathway for efficient domestic REE production.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Flotation of Bastnaesite Ore Using Novel Collectors

Interest in rare earth elements (REEs) has increased due to their distinct properties and new applications. China currently has a monopoly on rare earth production due to the lack of an economically viable process used outside of China. Bastnaesite, a rare earth fluorocarbonate, is one of the most common minerals containing REEs, which is mostly comprised of cerium and other light REEs. The objective of this research is to find a novel collector for the beneficiation of bastnaesite through froth flotation experiments to increase the grade and recovery of rare earth oxides while rejecting the major gangue minerals. Microflotation and rougher bench flotation studies were evaluated to find optimal collector(s) from 19 possible candidates. Collector 2, 5, and 8 were the top performing collectors chosen from microflotation experiments. A design of experiment matrix was set up to evaluate the variables, variable interactions and provide a reverence matrix for future optimization studies. Collector 2 was assessed to be the optimal collector. A rougher flotation experiment produced a rare earth oxide grade and recovery of 41% and 78% respectively and a 91.5% rejection of calcite. Collector 8 and 14 also showed promising results in replace fatty acid.

Everly, Dylan↗

DOE OSTI2022

Method of coating an electrical current collector and electrodes resulting therefrom

The present invention is directed to a method of coating an electrical current collector comprising treating a portion of a surface of the electrical current collector with an adhesion promoting composition to deposit a treatment layer over the portion of the surface of the electrical current collector, wherein the resulting surface of the electrical current collector comprises (a) a treated portion comprising the treatment layer and (b) a non-treated portion that lacks the treatment layer; electrodepositing an electrodeposited coating layer from an electrodepositable coating composition onto the surface of the electrical current collector to form a coated electrical current collector; and rinsing the coated electrical current collector, wherein the electrodeposited coating layer substantially adheres to the treated portion of the surface and does not adhere to the non-treated portion of the surface. Also disclosed are electrodes and electrical storage devices.

Oakes, Landon J.↗

DOE OSTI2023

Aligned carbon fibers-carbon nanotube-polymer-based composite as lithium-ion battery current collector

High energy density demand is pushing the development of high-voltage cathode materials, which necessitates improved electrochemical stability of other battery components such as binders, electrolytes, and current collectors. Current collectors are considered to be an inactive component but still play an essential role. In this study, a metal-free composite film containing directionally aligned carbon fiber (CF), carbon nanotube (CNT), and polymer (P) was developed to replace aluminum foil as a cathode current collector, which relies on forming an Al 2 O 3 layer to ensure electrochemical stability at high voltage. Here, each component in the new cathode current collector played a functional role. The CNTs provided uniform current densities, and CFs improved the electronic conductivity and mechanical strength of the composite material. The polymer enhanced the adhesion of the cathode coating with the current collector and provided an impervious support to the cathode materials. The CF-CNT-P composite demonstrated excellent electrochemical and thermal stability. Cathodes coated on the CF-CNT-P composite exhibited lower charge transfer resistance, improved rate capability, and improved cyclic stability compared with the cathodes deposited on conventional aluminum foil. Additionally, the composite current collector was lighter (1.81 mg/cm 2 and 15 µm thick) than the commonly used aluminum foil (4.35 mg/cm2 and 15 µm thick), which can increase the cell energy density. Additionally, the CF-CNT-P did not need to be separated from the cathode coating during recycling and can be burnt out with binder, simplifying the recycling process.

25 ENERGY STORAGE↗

DOE OSTI2023

Wind Loading on Parabolic Trough Collectors: Wind and Structural Loads Measurements at an Operational Powerplant

Concentrated Solar Power (CSP) is a promising method for using solar power for electricity generation with thermal energy storage for industrial applications. Solar collectors constitute almost 1/3 of the total cost of the power plant. One of the primary drivers of unrealiability of these collectors is wind-driven loading of mirrors, support structures, and drives. To date, the design of the solar collector structures has relied on data from wind tunnels that do not adequately capture the dynamic effects observed at scale. NREL initiated a field measurement campaign at the operational Nevada Solar One (NSO) parabolic trough powerplant. At this plant, parabolic trough solar collectors track the sun from east to west in the course of a day and face varying wind loads depending on the wind properties and the angle of the troughs. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs, providing insights into structural dynamic response, and generating a comprehensive wind-loading dataset for validating simulations of wind loading on collector structures. The measurements at NSO consist of sonic anemometers on masts at different heights to characterize the incoming flow and conditions at four trough rows at the edge of the trough field. In addition, a Doppler Lidar scans the horizontal plane above the troughs. The wind measurements at NSO have been continuously collecting data since October 2021 and are combined with structural load measurements that started in November 2022. The load measurements were installed on the same four outermost trough rows and include support structure bending moments, drive torque moments, dynamic accelerations of the spaceframe, mirror displacement, and tilt angles. Measurements are planned to continue until May 2023, providing a first-of-a-kind, high-resolution multi-month dataset of combined wind and load measurements. In this presentation, we show first results of the measurement campaign. Based on the measurements, we identified three main factors altering the flow over the parabolic troughs: Wind speed, wind direction, and the angle of the parabolic troughs. Most interactions between incoming wind and the trough field are observed when the wind blows perpendicular to the trough rows. In this case, the first rows experience the highest wind speed and block the downwind rows, creating conditions with decreased wind speed and enhanced turbulence within the trough field. Also, turbulent length scales are smaller after the first row. This leads to the highest static loads (bending and torque moments) at the first row but potentially increased dynamic loads within the field. We illustrate our findings with case studies focused on different wind conditions and will present fatigue analysis to highlight the impact of wind-driven loads on collector structures.

CSP collectors↗

DOE OSTI2021

Computational and Experimental Validation of Fractal-Fin, Dimpled Solar Heat Collector

A 3 foot x 3 foot x 3 foot aluminum solar collector was manufactured using computer numerical control. The interior of the device included six triangular dimpled fins for enhanced heat transfer. The interior vertical wall on the south side was also dimpled. The solar collector working fluid was based on water, and the collector consisted solely of passive heat transfer mechanisms (no moving parts), making it ideal for off-the-grid and rural applications. Two types of heat transfer experiments were conducted. One experiment had external flat heaters attached on the top and the front side, while the other four sides were insulated. Except for the bottom surface, the second experiment had all its exterior surfaces sprayed with black solar paint to collect as much solar heat as possible. Temperature data as a function of time was collected using 14 thermocouples spread strategically throughout the solar collector. In addition, computational fluid dynamics (CFD) simulations were conducted using the dynamic Smagorinsky large eddy simulation turbulence model. The first simulation considered that both the top and front surfaces were exposed to a fixed temperature of 313.7 K (105 °F), while the remaining four surfaces were insulated. For the second simulation, all conditions were the same, except that the temperature for both heated surfaces was raised to 350 K (170.3 °F). The two temperatures are expected to bound the solar collector operational temperature during the late- Spring, Summer, and early-Fall months. The solar collector design, experimental data, CFD output, and a discussion of five manufacturing approaches and costs are documented in this report.

14 SOLAR ENERGY↗

DOE OSTI2022

Fractal-Fin, Dimpled Solar Heat Collector with Solar Glaze

Exterior solar glaze was added to a 3 foot x 3 foot x 3 foot aluminum solar collector that had six triangular dimpled fins for enhanced heat transfer. The interior vertical wall on the south side was also dimpled. The solar glaze was added to compare its solar collection performance with unglazed solar collector experiments conducted at Sandia in 2021. The east, west, front, and top sides of the solar collector were encased with solar glaze glass. Because the solar incident heat on the north and bottom sides was minimal, they were insulated to retain the heat that was collected by the other four sides. The advantages of the solar glaze include the entrapment of more solar heat, as well as insulation from the wind. The disadvantages are that it increases the cost of the solar collector and has fragile structural properties when compared to the aluminum walls. Nevertheless, prior to conducting experiments with the glazed solar collector, it was not clear if the benefits outweighed the disadvantages. These issues are addressed herein, with the conclusion that the additional amount of heat collected by the glaze justifies the additional cost. The solar collector glaze design, experimental data, and costs and benefits are documented in this report.

14 SOLAR ENERGY↗

DOE OSTI2024

Dynamic Wind Loading on CSP Collectors Caused by Turbulent Wind Fluctuations: Insights from a 2-Year Field Campaign

Concentrating Solar Power (CSP) is a promising solar technology for electricity generation with thermal energy storage and with the additional benefit of industrial heat production. Wind loading on CSP collector structures, such as parabolic troughs or heliostats, is one of the primary drivers of their structural design costs. In particular, dynamic wind loading is a major source of uncertainty in the collector design process, which heavily relies on wind tunnel testing. In the field, the turbulent nature of the incoming wind creates fluctuating loads (support structure loads and resulting mirror deflections) on the collectors, with impacts on fatigue lifetime and optical performance. As is well known, wind tunnel tests cannot entirely reproduce the complex turbulent wind conditions typically observed at full-scale plants. To shed light on this topic, NREL initiated a field campaign at the operational Nevada Solar One (NSO) powerplant that uses parabolic troughs as solar collectors. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs. We use the published 2-year dataset of high-resolution combined wind and structural loads measurements [1] to characterize the dynamic structural wind response. For quantifying dynamic wind loading, we apply the concept of admittance functions, which are spectral transfer functions that couple the turbulent wind to resulting structural loads (aerodynamic admittance), and to the structural response (mechanical admittance). In practice, aerodynamic admittance describes which turbulent eddy sizes are effective in creating structural loads. The mechanical admittance describes in which frequency ranges these loads are reinforced or dampened by the structure. While these functions are an established concept in civil engineering, their recent application to a single full-scale heliostat [2] proved their broader applicability to CSP collectors. Here, we present a characterization of admittance functions for full-scale parabolic trough collectors and show how wind characteristics (mean wind speed and direction, turbulent kinetic energy, turbulent length scales), the sun-tracking trough angle, and row position alter the admittance functions. Further, we study to which extent the admittance functions are universal for a specific trough geometry and how our findings compare to reported heliostat results. References [1] https://data.openei.org/submissions/5938. [2] Blume, K., Roger, M., and Pitz-Paal, R. 2023b. "Simplified analytical model to describe wind loads and wind-induced tracking deviations of heliostats." Solar Energy, 256, 96-109. https://doi.org/10.1016/j.solener.2023.03.055.

admittance functions↗

DOE OSTI2022

The cost savings potential of controlling solar thermal collectors with storage for time-of-use electricity rates

Homes and commercial buildings account for roughly 40% of U.S. energy consumption. A significant portion of this energy consumption, and therefore utility cost, comes from domestic hot-water use. Solar collectors such as flat plate collectors, evacuated tubes, and combined photovoltaic/thermal panels, are renewable options that collect thermal energy and could help reduce utility costs. Hot water is generated by pumping a working fluid through the solar collector, where the fluid captures thermal energy via absorbed solar radiation incident on the collector surface. The collection of heat coincides with the availability of solar radiation, but the best time to use this thermal energy depends on the utility rate at a given time, which often changes throughout the day. In this work, we implement and simulate a control strategy using Transient System Simulation Tool (TRNSYS) that reduces utility costs by controlling when the system stores and uses thermal energy based on solar availability and time-of-use electricity rates. Our modeled results show that the control strategy can reduce utility costs associated with using hot water between 3% and 30%. Here, we also show how the on-peak utility rates, the size and type of the solar collectors, and the location's climate impact the results.

14 SOLAR ENERGY↗

DOE OSTI2021

Prevention of lithium-ion battery thermal runaway using polymer-substrate current collectors

Isolating electronically conducting material from internal short circuits is a promising way to prevent the onset of thermal runaway within lithium-ion cells. Here, a metal-coated polymer current collector, which is designed to disconnect internal short circuits by withdrawing from the heating region, is tested in 18650 cells. In addition to having lower mass and manufacturing costs, cells with metal-coated polymer current collectors demonstrate a reduced risk of thermal runaway during nail penetration. High-speed synchrotron X-ray radiography of 18650 cells during nail-penetration testing, in tandem with pre- and post-mortem X-ray computed tomography, provides insights into the function of the current collectors. The results are compared with those of 18650 cells with standard commercial aluminum and copper current collectors. Cells with aluminum-coated polymer current collectors demonstrated 100% success in thermal runaway prevention during nail penetration, retaining a cell voltage >4.00 V, while standard cells consistently experienced thermal runaway.

25 ENERGY STORAGE↗