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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Design of a novel carbon/carbon composite microvascular solar receiver

Solar thermal power tower systems are the primary technology being proposed for solar electricity from thermal energy. Operational limits on these towers are often driven by mechanical properties under significant thermal loads, particularly at the receiver where incoming flux is converted to thermal energy. While the solar receiver’s efficiency is largely driven by its optical properties, thermomechanical stresses on the receiver limits the operational envelope. One pathway to higher efficiency is greater allowable solar fluxes on the receiver but novel materials are required. The present study uses computational fluid dynamics to describe a parametric design space for a microvascular carbon/carbon composite solar receiver as a new material option for high flux solar receivers. Simulations are conducted for different microvascular geometries considering the role of material properties and heat transfer fluids, for the impact on thermal efficiency, and allowable strain. Results show that microscale receiver modules made of the proposed carbon/carbon composite could achieve thermal efficiencies over 90% and full-scale receivers can achieve up to 85% thermal efficiency for the design explored considering realistic strain limits, flux levels, and material properties. These values are highly dependent on the heat transfer fluid pairing, the through plane thermal conductivity of the carbon/carbon composite, the path architecture of the microscale receiver, and the incident solar flux profiles.

14 SOLAR ENERGY↗
NASA NTRS1984

Ceramic Solar Receiver

Solar receiver uses ceramic honeycomb matrix to absorb heat from Sun and transfer it to working fluid at temperatures of 1,095 degrees and 1,650 degrees C. Drives gas turbine engine or provides heat for industrial processes.

Robertson, C., Jr.↗
DOE OSTI2026

Prototype Modeling for a Light-Trapping Planar-Cavity Enclosed Particle Solar Receiver

Concentrating solar thermal (CST) systems present a promising avenue for affordable and reliable energy production. Solar receivers are key components that determine the efficiency and longevity of these systems. Particle-based solar receivers have emerged as a compelling alternative to traditional technologies, offering several advantages that address limitations in current CST systems. This is especially true as next-generation CST technologies target applications including electricity generation, thermochemical processes, and industrial process heat, many of which necessitate higher operating temperatures than current commercial molten salt systems. Molten-salt thermal energy storage (TES) systems, commonly used in CSP, face challenges related to freezing and corrosion. Particle-based TES systems, in contrast, do not experience these issues, as particles are stable at high temperatures, exceeding 1000 degrees Celsius. This capability allows for a wider range of applications, including those requiring higher temperatures for industrial processes and efficient electricity generation. A novel innovation in particle-based solar receiver technology is the light-trapping planar cavity receiver (LTPCR) configuration developed by NREL. The LTPCR design consists of small cavity-like structures using opaque planar surfaces, enabling efficient capture and absorption of solar energy. A high incident flux concentration at the cavity aperture is absorbed on the receiver walls, and subsequently transferred to particles on the inside of cavities. The particles flow through the system, forming a fluidized bed inside of the receiver panels, effectively capturing the absorbed solar heat. Air is used as a fluidizing medium in this process to enhance particle heat transfer and mixing. The effectiveness of this design lies in its ability to manage solar flux conditions and ensure high solar-to-thermal receiver efficiency. A 100-kW prototype is currently being tested at the King Saud University in Saudi Arabia to assess the receiver performance. A range of modeling analyses for the optical, thermal, and mechanical effects were conducted to assess the performance of the receiver under on-sun conditions. The solar flux resulting from the KSU heliostat field was modeled using NREL SolTrace software and produced up to 600 kW/m2 at the receiver aperture. The solar flux absorbed on the receiver walls was then used within a computational fluid dynamics (CFD) model to predict wall temperature distributions along with radiation and convection loss. A two-phase CFD model was developed for the fluidized bed of silica sand inside the receiver panels to predict local wall-to-particle heat transfer coefficients, particle temperature distributions, and outlet temperature of the particles. We have also conducted analyses to understand the thermomechanical behavior of these innovative enclosed light-trapping solar receivers optimized for particle heating. We used finite element analysis (FEA) to predict the receiver's performance using temperature distributions obtained from CFD and based on the resulting stress profiles, evaluated creep-fatigue damage with a goal of achieving a 30-year service life. Analysis showed a significant impact of the particle-to-wall heat transfer coefficients (HTCs) on receiver performance, with higher HTCs resulting in reduced stress and increased lifespan. For instance, when using Inconel 740H, increasing the HTC from 800 W/m2 K to 1400 W/m2 K increased the creep life from 4,000 hours to over 100,000 hours. This highlights the importance of understanding and optimizing heat transfer in the design of high-efficiency receivers.

14 SOLAR ENERGY↗
DOE OSTI2024

Development of Ti 3 SiC 2 MAX phase tubular structures for solar receiver applications

Solar receiver tubes are key components of concentrating solar-thermal power (CSP) systems that harvest solar energy. For better efficiency, the Gen3 CSP receivers, which collect heat into a heat transfer fluid, require a temperature exceeding 700 °C during operation and need to perform under extreme conditions of high temperature and high thermal stress. Operators are seeking CSP designs using new high-temperature structural materials with high thermal conductivity and high creep resistance to achieve a design life of 30 years and thus help recover the plant capital cost sooner. MAX phase materials, which consist of an early transition metal element, an A-group element, and carbon or nitrogen, are expected to exhibit high creep resistance as well as high fracture toughness. Here, in this paper, we describe fabricating both (1) dense Ti 3 SiC 2 MAX phase disks and (2) short-length tubes using field-assisted sintering technology (FAST). First, the disk samples that we fabricated are fully dense and contain ≈90 % Ti 3 SiC 2 MAX phase materials and ≈10 % TiC phase materials. We determined a flexure strength of 519 ± 32 MPa by conducting a four-point bending test at room temperature with rectangular bar samples of ≈100 % density. The thermal conductivity of the Ti 3 SiC 2 MAX phase samples, measured by light flashing analysis, decreases linearly from a value of 41 W . m -1 . K -1 at room temperature to a value of 36 W . m -1 . K -1 at 650 °C. A solar reflectance measurement of the Ti 3 SiC 2 MAX phase revealed that, temperature increases from 400 to 1400 °C, thermal emittance increases from 0.39 to 0.49, while selectivity decreases from 1.8 to 1.4, respectively. Whereas the surface oxidized MAX phase samples after 100 h exposure to air at 1000 °C exhibit that of SiC. Next, we discuss fabrication of the crack-free Ti 3 SiC 2 MAX phase tubular structures accomplished by using FAST processing in graphite bedding. A Ti 3 SiC 2 MAX phase content of > 95 % with traceable ≈3% remaining TiC phase and ≈15 % porosity were demonstrated after high-temperature annealing. An average fracture strength of ≈250 MPa was determined with Ti 3 SiC 2 MAX phase tubes of ≈85 % density by diametral compression testing at room temperature. Our work demonstrated that using FAST processing to produce Ti 3 SiC 2 MAX phase tubular structures for CSP receiver applications is a viable approach.

14 SOLAR ENERGY↗
DOE OSTI2022

Falling particle solar receivers

Falling particle solar receivers, systems, and methods are disclosed that include one non-linear falling particle curtain or two or more falling particle curtains within a solar receiver that receives incident solar radiation. The particles heated in the solar receiver may be used to heat a secondary fluid. In an embodiment, the particles may be recirculated to improve energy capture and thermal efficiency. In other embodiments, an air curtain may be used across the aperture of the receiver, and flow-control devices may be used to evenly spread particles across the width of the receiver inlet. Finally, feed particles may be preheated using heat from the solar receiver.

Ho, Clifford K.↗
DOE OSTI2022

Concentrated solar power generation using solar receivers

Inventive concentrated solar power systems using solar receivers, and related devices and methods, are generally described. Low pressure solar receivers are provided that function to convert solar radiation energy to thermal energy of a working fluid, e.g., a working fluid of a power generation or thermal storage system. In some embodiments, low pressure solar receivers are provided herein that are useful in conjunction with gas turbine based power generation systems.

Anderson, Bruce N.↗
NASA NTRS1984

High-Temperature Helical-Tube Solar Receiver

Solar-thermal receiver used with circular parabolic concentrator to supply about 58 kW thermal power to Brayton engine or industrial process. Solar radiation focused into open end of cylindrical ceramic thermal inertial sleeve 8 in. in diameter that reradiates energy to helical heatexchanger tube surrounding sleeve.

Robertson, C. S., Jr.↗
NASA NTRS1990

Simplified Calculation Of Solar Fluxes In Solar Receivers

Simplified Calculation of Solar Flux Distribution on Side Wall of Cylindrical Cavity Solar Receivers computer program employs simple solar-flux-calculation algorithm for cylindrical-cavity-type solar receiver. Results compare favorably with those of more complicated programs. Applications include study of solar energy and transfer of heat, and space power/solar-dynamics engineering. Written in FORTRAN 77.

Bhandari, Pradeep↗
NASA NTRS1989

Simplified calculation of solar flux distribution on the side wall of cylindrical cavity solar receivers

A simple solar flux calculation algorithm for a cylindrical cavity type solar receiver has been developed and implemented on an IBM PC-AT. Using cone optics, the contour error method is utilized to handle the slope error of a paraboloidal concentrator. The flux distribution on the side wall is calculated by integration of the energy incident from cones emanating from all the differential elements on the concentrator. The calculations are done for any set of dimensions and properties of the receiver and the concentrator, and account for any spillover on the aperture plate. The results of this algorithm compared excellently with those predicted by more complicated programs. Because of the utilization of axial symmetry and overall simplification, it is extremely fast. It can be esily extended to other axisymmetric receiver geometries.

Bhandari, P.↗
DOE OSTI2022

Solar receivers and methods for capturing solar energy

Thermal receivers, systems, and methods are disclosed that efficiently capture concentrated solar energy into a plurality of heat absorption bodies for conversion into thermal energy. In an embodiment, the thermal receivers, systems, and methods enable simultaneous electricity conversion and thermal energy capture. The receiver design enables a high penetration of concentrated sunlight deep into the thermal receiver to increase light trapping and reduce thermal losses. The thermal receiver is integrated with a photovoltaic (PV) receiver platform that converts some of the incident light to electricity while passing the remaining light to the thermal receiver. In another embodiment, other thermal receivers, systems, and methods are disclosed that efficiently capture concentrated solar energy into a sheet of falling particles. In an embodiment, the thermal receivers, systems, and methods enable simultaneous electricity conversion and thermal energy capture.

Ho, Clifford K.↗
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 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 NTRS1995

Analysis of solar receiver flux distributions for US/Russian solar dynamic system demonstration on the MIR Space Station

The United States and Russia have agreed to jointly develop a solar dynamic (SD) system for flight demonstration on the Russian MIR space station starting in late 1997. Two important components of this SD system are the solar concentrator and heat receiver provided by Russia and the U.S., respectively. This paper describes optical analysis of the concentrator and solar flux predictions on target receiver surfaces. The optical analysis is performed using the code CIRCE2. These analyses account for finite sun size with limb darkening, concentrator surface slope and position errors, concentrator petal thermal deformation, gaps between petals, and the shading effect of the receiver support struts. The receiver spatial flux distributions are then combined with concentrator shadowing predictions. Geometric shadowing patterns are traced from the concentrator to the target receiver surfaces. These patterns vary with time depending on the chosen MIR flight attitude and orbital mechanics of the MIR spacecraft. The resulting predictions provide spatial and temporal receiver flux distributions for any specified mission profile. The impact these flux distributions have on receiver design and control of the Brayton engine are discussed.

Kerslake, Thomas W.↗
DOE OSTI2023

Helical Fins for Concentrated Solar Receivers: Design Optimization and Entropy Analysis

Concentrated solar power (CSP) with thermal energy storage (TES) has the potential to achieve grid parity. This can be realized by operating CSP systems at temperatures above 700 °C with high-efficiency sCO 2 power cycles. However, operating CSP systems at such temperatures poses several challenges, among which the design of solar receivers to accommodate increased thermal loads is critical. To this end, this work explores and optimizes various swirl-inducing internal fin designs for solar receiver tubes. These fin designs not only improve the thermal performance of receiver tubes but also levelize temperature unevenness caused by non-uniform thermal loading. In this work, the geometric parameters of the fin designs are optimized to maximize the Nusselt number with a constraint on the friction factor. This optimization, however, is computationally intensive, requiring hundreds of simulation calls to computational fluid dynamics (CFD) models. Here, to circumvent this problem, surrogate models are used to approximate the simulation outputs needed during the optimization. In addition, this study also examines the fin designs from an entropy generation perspective. To this end, the entropy contributions from thermal and viscous effects are quantitatively compared while varying the operational Reynolds number.

14 SOLAR ENERGY↗
DOE OSTI2023

Influence of Temperature on Properties and Dynamics of Gas-Solid Flow in Fluidized-Particle Tubular Solar Receiver

A fluidized particle single-tube solar receiver has been tested for investigating the gas-particle characteristics that enable the best operating conditions in a commercial-scale plant. The principle of the solar receiver is to fluidize the particles in a vessel – the dispenser – in which the receiver tube is plunged. The particles are flowing upward in the tube, irradiated over 1-meter height, by applying an overpressure in the dispenser. Experiments with a concentrated solar flux varying between 188 and 358 kW/m² are carried out, and the particle mass flux varied from 0 to 72 kg/(m²s). The mean particles and external tube wall temperatures in the irradiated zone are heated from the ambient to respectively 700°C and 940°C. It is shown that the temperature rise leads to a decrease of the particle volume fraction. Furthermore, a self-regulation of the system is evidenced with a short transient regime. This characteristic is essential from the operational viewpoint. The thermal efficiency of the receiver increases with the particle flow rate, reaching between 60 and 75% above 30 kg/(m²s). Several fluidization regimes are identified thanks to pressure signal analyses, like slugging, turbulent and fast fluidization, showing that regimes transitions are strongly affected by the temperature.

Gueguen, Ronny (ORCID:0000000252368638)↗
NASA NTRS1981

Air Brayton Solar Receiver, phase 2

An air Brayton solar receiver (ABSR) is discussed. The ABSR consists of a cylindrical, insulated, offset plate fin heat exchanger which is mounted at the focal plane of a fully tracking parabolic solar collector. The receiver transfer heat from the concentrated solar radiation (which impinges on the inside walls of the heat exchanger) to the working fluid i.e., air. The hot air would then e used to drive a small Brayton cycle heat engine. The engine in turn drives a generator which produces electrical energy. Symmetrical and asymmetrical solar power input into the ABSR are analyzed. The symmetrical cases involve the baseline incident flux and the axially shifted incident fluxes. The asymmetrical cases correspond to the solar fluxes that are obtained by reduced solar input from one half of the concentrator or by receiver offset of plus or minus 1 inch from the concentrator optical axis.

Deanda, L. E.↗
DOE OSTI2023

Particle Flow Distribution in a Fluidized-Particles Multitube Solar Receiver

A fluidized-particles two-tube solar receiver was tested at ambient temperature at PROMES Laboratory to investigate the influence of an inhomogeneous solar flux density on the particle mass flow rate between the tubes. The principle of this 3rd generation solar receiver is to fluidize the particles in a container, called dispenser, in which the tubes’ bottom are immersed. The fluidized particles are flowing upward the tubes by applying an overpressure in the dispenser. Air velocities are changed inside the tubes, thanks to air mass flow controllers, to represent temperature heterogeneity between the tubes. Air velocities from 0.05 up to 0.52 m/s were tested, both in homogeneous and heterogeneous conditions. In the heterogeneous ones, the differences in air velocity between the tubes aim to mimic a difference in temperature from 20 to 100 % with homogeneous air flow rates injected. The following conclusions were drawn. First, the particle mass flux in the tubes are the same with homogeneous air velocities, each one following a calibration map previously obtained. Second, different air velocities lead to different particle mass flux. Third, the rise of the total particle mass flux diminishes the pressure in the dispenser. Four, this diminution of pressure leads to a decrease of the particle mass flow rate of the tube with the lower air velocity. This influence can lead in some cases to the stop of the fluidized bed circulation in the affected tube.

Sahuquet, Guillaume (ORCID:0000000302752890)↗
NASA NTRS1981

Steam Rankine Solar Receiver, phase 2

A steam rankine solar receiver (SRSR) based on a tubular concept was designed and developed. The SRSR is an insulated, cylindrical coiled tube boiler which is mounted at the focal plane of a fully tracking parabolic solar reflector. The concentrated solar energy received at the focal plane is then transformed to thermal energy through steam generation. The steam is used in a small Rankine cycle heat engine to drive a generator for the production of electrical energy. The SRSR was designed to have a dual mode capability, performing as a once through boiler with and without reheat. This was achieved by means of two coils which constitute the boiler. The boiler core size of the SRSR is 17.0 inches in diameter and 21.5 inches long. The tube size is 7/16 inch I.D. by 0.070 inch wall for the primary, and 3/4 inch I.D. by 0.125 inch wall for the reheat section. The materials used were corrosion resistant steel (CRES) type 321 and type 347 stainless steel. The core is insulated with 6 inches of cerablanket insulation wrapped around the outer wall. The aperture end and the reflector back plate at the closed end section are made of silicon carbide. The SRSR accepts 85 kwth and has a design life of 10,000 hrs when producing steam at 1400 F and 2550 psig.

Deanda, L. E.↗