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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Gen3 Gas Phase System Development and Demonstration (Final Technical Report)

Work undertaken in this project seeks to transform the current baseline technology – which is a collection of related but separately developed components and concepts – into a unified and operating test facility and an accompanying preliminary commercial design. This project is motivated by the primary goal of developing a system to absorb concentrated solar energy and deliver it into thermal energy storage at temperatures above 700°C, thereby enabling integration with a high-efficiency supercritical carbon dioxide (sCO 2 ) power cycle to achieve or exceed a levelized cost of electricity (LCOE) target of 6 ¢ per kilowatt-hour electric (kW e -hr). The proposed baseline solution utilizes a high-temperature gas phase (GP) system interfacing with a two-tank particle thermal energy storage (TES) and intermediate heat exchangers to supply sCO 2 at 20-25 megapascals (MPa) and 700°C at the turbine inlet.

14 SOLAR ENERGY↗
DOE OSTI2022

Methods and systems for thermal energy storage and their use in buildings applications

The present disclosure relates to particle-based thermal energy storage (TES) systems employed for the heating and cooling applications for residential and/or commercial buildings. Particle-based TES systems may store thermal energy in the particles during off-peak times (i.e., when electricity demand and/or costs are relatively low) and remove the stored thermal energy for heating or cooling applications for buildings during peak times (i.e., when electricity demand and/or costs are relatively high).

Ma, Zhiwen↗
DOE OSTI2026

Modeling and Experimental Validation of a Direct-Contact Counter-Flow Fluidized Bed Heat Exchanger for Thermal Energy Storage (TES) Applications

Particle-based thermal energy storage (TES) systems are an emerging energy storage technology. The technological advances have reduced costs, making TES more competitive and reliable in the marketplace but an efficient and reliable operation is heavily dependent on coherent heat transfer between air to particles or vice versa. The particle-based TES technologies provide an intermediate system that can store energy for short (0-10 h), long (10-200 h) and seasonal (> 200 h) timescales. The TES systems store energy by converting electricity to thermal energy; electricity can be directly sourced intermittent generation technologies and/or the grid, helping manage peak loads and other mismatches in supply and demand. The overall efficiency of the TES system depends on the performance of system components (particle storage silos and particle transfer mechanism etc.). The particle heat exchanger is one of the key system components that affects the system efficiency. The pressurized fluidized bed heat exchanger (PFB HX) performance is challenging to predict due to the chaotic behavior of particle and fluid interaction. This research presents a computational study of a novel direct-contact, counter-flow and air-to-particles PFB HX, that contributes in advancing the particle-based long-duration TES technologies. For the current analysis an unsteady Eulerian-Eulerian CFD model was developed and validated against experiments performed at the National Laboratory of the Rockies for two particle sizes (600 ..mu..m and 825 ..mu..m ). Following validation, parametric simulations were conducted to evaluate the effects of interphase drag models (Syamlal-O'Brien and Gidaspow), particle size, bed height and the influence of a frictional-viscosity term on hydrodynamics and heat transfer between the air & particles. The key findings from the analysis are: (1) for the studied operating window Syamlal-O'Brien provides superior agreement with measured gas temperatures (errors generally < 10%) while Gidaspow shows large deviations for the coarse particle case; (2) model predictions are most sensitive in the lower 0.2 m above the air distributor where bubble initiation and local mixing dominate interphase heat transfer; (3) representation of the distributor (number of inlet ports) materially affects predicted local mixing and temperature stratification; and (4) the Eulerian-Eulerian framework reproduces bulk thermal trends but shows regime dependent limitations for coarse particles, motivating mesoscale informed closures for scale-up analysis for future studies. These results provide validated guidance for drag selection and distributor design in particle-based thermal energy storage applications. Collectively, the validated model and parametric results quantify key drivers of PHB-HX performance and provide practical guidance for design and optimization. The results provide confidence in the model predictability and provide a step forward to improve on heat exchange performance. The demonstrated performance and modeling approach support the deployment and further development of this novel PHB-HX concept for robust, particle-based long-duration thermal energy storage systems.

25 ENERGY STORAGE↗
DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage

Industrial process heating (IPH) accounts for approximately 70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately 1500 TWht (approximately 60%) of IPH demand is in the temperature range of 100-300. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. TES development has historically been dominated by technologies suitable for deployment with concentrating solar power (CSP). State-of-the-art thermal storage deployed commercially with power tower CSP plants uses a 60%/40% NaNO3/KNO3 molten salt and operates between temperatures of approximately 280 degrees Celsius and 570 degrees Celsius using a two-tank configuration. However, these nitrate salts are unsuitable for operation outside of this temperature range due to a high freezing point of approximately 220 degrees Celsius, and limits on high-temperature salt stability and corrosion resistance of containment alloys. Other materials being investigated for TES include those based on: (1) sensible energy storage (various molten salt compositions, inert solid particles, rocks or pebble beds, sulfur, water, concrete, graphite, etc.), (2) latent energy storage in materials that undergo solid-liquid phase change at relevant temperatures (organic materials for low-temperature applications, inorganic salts and/or metals for high-temperature applications), or (3) thermochemical energy storage (hydrides, hydroxides, carbonates, metal oxides, etc.). The application temperature and challenges pertaining to storage material and/or containment cost, energy density, long-term thermal and cyclic stability, and charge/discharge heat transfer effectiveness drive material selection for a given IPH or electricity generation application. Sulfur is a cheap commodity at $80/ton compared to $1100 - 1300/ton for conventional salts. When using a metric of storage cost per kWh, sulfur costs around 2-3 $/kWh. Previous sulfur TES development focused on high temperature (>600 degrees) concentrated solar power applications with sulfur encapsulated in pipes and flow of gaseous HTF (air) in the shell side. However, for lower-temperature IPH applications in the range of approximately 100-300 degrees Celsius Element 16 adopted a compact and scalable TES design with molten sulfur in the shell and HTF pipes submerged in the molten sulfur bath. The low-cost molten sulfur TES for dispatchable IPH has deployment potential for broad applications. The spatial and temporal evolution of the HTF and sulfur temperature is critical to the TES system performance, and thus detailed modeling can improve understanding of the performance and facilitate design improvements. Using high performance computing and computational fluid dynamics (CFD) a low-cost molten sulfur thermal energy storage (TES) system for industrial process heating (IPH) applications was developed. The unique challenges in CFD modeling of sulfur TES are the sharp property changes of sulfur relevant to the working temperatures. Above 159, liquid sulfur undergoes polymerization, and the viscosity of sulfur rapidly increases by several orders of magnitude between 159 degrees Celsius and 188 degrees Celsius, followed by a decrease in viscosity beyond 188 degrees Celsius due to thermal bound dissociation. In addition, various concentrations of H2S impurities can also modify sulfur viscosity. This numerical challenge is especially relevant to transient simulation of the sulfur TES charging and discharging processes as the extreme property variations limit the applicability of traditional heat transfer correlations. Transient CFD simulations including the temperature-dependent sulfur properties and geometric complexity of the TES design were used to predict the effect of natural convection during charging and discharging on the heat transfer process, sulfur temperature uniformity, charge/discharge rates, and performance of the storage devices. The CFD model was validated with experimental results for a full charge and discharge cycle. The work will show 3D and 2D simulation comparisons aimed to facilitate rapid design iterations and a machine learning based design optimization approach.

CFD↗
DOE OSTI2024

Performance analysis of integrated Nuclear-Solar Energy system sharing same molten salt thermal energy storage

Advanced nuclear reactors may be deployed with integrated thermal energy storage to improve flexibility and maximize revenue. This presents opportunities for thermal integration with concentrating solar power (CSP) to generate component synergies and/or improve performance. Here in this study, a computational model is developed for an integrated nuclear and CSP system that both share the same molten salt thermal energy storage (TES). Optimized dispatch schedules are developed subject to various market conditions, and the ratio of the nuclear to CSP thermal output is also varied. Performance of the combined system is compared to separate nuclear and solar plants, to determine if there is an overall benefit that can be derived from sharing the TES. Given sufficient volatility in electricity prices (e.g., under CAISO market conditions), synergies of up to 8% in net revenue are observed as a result of sharing the same TES, primarily due to improved revenue from enabling operation of the turbine closer to its design point, as well as being able to better take advantage of higher electricity prices. The synergy benefits are largest when the nuclear and solar plants have similar thermal output. However, when prices are less volatile the opposite behavior can be observed and it can be preferable to operate the nuclear plant as a baseload generator.

14 SOLAR ENERGY↗
NASA NTRS1987

Microgravity fluid management requirements of advanced solar dynamic power systems

The advanced solar dynamic system (ASDS) program is aimed at developing the technology for highly efficient, lightweight space power systems. The approach is to evaluate Stirling, Brayton and liquid metal Rankine power conversion systems (PCS) over the temperature range of 1025 to 1400K, identify the critical technologies and develop these technologies. Microgravity fluid management technology is required in several areas of this program, namely, thermal energy storage (TES), heat pipe applications and liquid metal, two phase flow Rankine systems. Utilization of the heat of fusion of phase change materials offers potential for smaller, lighter TES systems. The candidate TES materials exhibit large volume change with the phase change. The heat pipe is an energy dense heat transfer device. A high temperature application may transfer heat from the solar receiver to the PCS working fluid and/or TES. A low temperature application may transfer waste heat from the PCS to the radiator. The liquid metal Rankine PCS requires management of the boiling/condensing process typical of two phase flow systems.

Migra, Robert P.↗
DOE OSTI2022

Development of Numerical Model of Metal Foam with PCM for the Estimation of Effective Thermal Conductivity

Global warming due to climate change is a threat to humankind. Nuclear energy is one of the promising solutions to reduce fossil fuel usage. Nuclear energy can handle the base load, compensating for the volatility of renewable energy. If nuclear energy could achieve load following capability, the combination with renewable energy would be more suitable. Thermal energy storage (TES) is one of the options for enabling load following of nuclear reactors. The TES makes it possible to store surplus nuclear thermal energy and release it later as needed. In Idaho National Laboratory (INL), a new concept of latent heat TES integrated with high-temperature heat pipe has been proposed and is under development, which is called Heat pipe-Integrated Thermal Battery (HITB). HITB exchanges thermal energy between the reactor system and TES via heat pipe. The heat transferred to TES medium, made of phase change material (PCM), stores energy as sensible heat and/or latent heat. As PCM typically has poor thermal conductivity, however, various heat transfer enhancement techniques are required to achieve a rapid charging cycle. There are many techniques to enhance the heat transfer ability of TES medium such as disk, fin, and metal foam. Among them, metal foam is an appropriate option to enhance the heat transfer because it maximizes the heat transfer area through metal wicks. Metal foam is a lightweight metal structure that has a high porosity of over 0.9. The typical materials for metal foam are Aluminum, Copper, Nickel, and Silicon Carbide (SiC). Metal foam not only enhances heat transfer via conduction but also increases contact surface area. In the HITB design , the metal foam is being considered as one of the options to enhance the heat transfer of TES medium (PCM) [1]. To predict the enhanced thermal performance of TES, one should properly estimate the effective thermal conductivity of metal foam combined with PCM material or calculate heat transfer in distributed model. There are many experimental works that provides effective thermal conductivity of metal foam with various PCM [2,3]. Also, many theoretical models were developed based on the unit cell model of metal foam [4,5]. With a distributed model, on the other hand, detail heat transfer characteristics between metal foam and PCM material can be analyzed considering the geometry or buoyancy effect. However, due to the complex geometry of metal foam pores, the computational cost for three-dimensional modeling highly increases. Therefore, if metal foam structure can be modeled in simple and repetitive design, the computational cost would decrease Among the various metal foam models [2], lattice model is one of the simple and extendable design. The porosity and pores per inch (PPI) can be characterized by the size and spatial distance of lattice structure. If the three-dimensional metal foam model consists of lattice structure could properly estimate the heat transfer, which is characterized by effective thermal conductivity, it would be a good option to assess the thermal performance of metal foam with PCM. In this study, a three-dimensional numerical model was developed to simulate conductive heat transfer between metal foam and PCM. The three-dimensional lattice structure of square pillars was selected as a basic structure of the metal foam. The calculation result was characterized by the effective thermal conductivity of the whole domain. A sensitivity study was conducted for mesh size, domain size, and PPI to check whether the calculation result gives a converged result or not. Lastly, the effective thermal conductivity from the lattice model was compared with existing experimental data to validate the model result

25 ENERGY STORAGE↗
DOE OSTI2024

Stress Relaxation Cracking of Alloys at Temperatures Higher Than 540°C

Type 347H stainless steel (347H SS), used in commercial concentrating solar power (CSP) thermal energy storage to store solar-salt at a temperature of 565°C, has been reported in the literature to be susceptible to stress-relaxation cracking (SRC). The welded heat-affected zone (HAZ) and fusion zone (FZ) of 347H SS, particularly in thick sections, are known to be susceptible to failure during post-weld heat treatment (reheat cracking). SRC could also occur after months or years under an elevated-temperature service environment. Two conditions must be present for failure to occur in the HAZ and/or FZ: 1) a modified or sensitized microstructure and 2) sufficiently high tensile residual stresses present at the elevated service temperature. The overarching goal of this project is to recommend SRC mitigation protocols to avoid susceptibility to fail through SRC at temperatures relevant for CSP. Post weld heat treatment conditions and alternative alloys are investigated as potential mitigation solutions to SRC. We used Gleeble thermomechanical simulation tests and finite element (FE) models to understand the susceptibility of 347H SS to SRC as a function of temperature, stress, and microstructure. We started with a literature review of weldability issues with 347H SS and techniques to mitigate SRC in 347H SS weldments. Next, we used Gleeble experiments to determine reheat cracking susceptibility in the simulated HAZ of 347SS weldments and an alternative alloy, 316L SS (NUCL 167 SPH) with boron added. We also performed Gleeble experiments to compare the reheat cracking susceptibility of 347H cross welded with two different fillers: E347, which is used in some commercial CSP TES tanks, and E16.8.2. We validated the experimental results with FE models of the residual stresses. We found that although the 316L (NUCL 167 SPH) is less susceptible to reheat cracking, it is slightly weaker than 347H and ASME BP&V codes limit its use to a service condition of 565°C. We also found that welds using E16.8.2 as the weld filler are less susceptible to failure than those using E347, likely due to the higher creep ductility of E16.8.2, and that it may be used as an alternative filler for repair welding of 347H welds or as the primary choice of filler for newly developed weld joints. We also found that post weld heat treatment could be a viable solution for mitigating stress in E347-347H SS thick, constrained welds, like those found in CSP tanks, and propose several options for mitigating SRC in existing and future TES tanks.

14 SOLAR ENERGY↗
DOE OSTI2024

Salt Tank Testbed: a Test Site Designed to Replicate Floor Buckles Observed in Commercial TES Tanks

A test site has been designed and is under construction to replicate the buckling failure ob-served in several in-service storage tanks for nitrate salts operating up to 565°C. In commercial tanks multiple factors have been identified that influence the floors susceptibility to buck-ling, including: the as-manufactured shape of the floor, high compressive stresses due to thermal gradients and/or friction, fluid inventory and absolute temperature. Based on exten-sive modeling analysis it was determined that similar buckles can be reproduced in a scaled test tank (approximately 9x smaller than a representative commercial tank design). To buckle the scaled tank a radial thermal gradient is generated in the tank with a low fluid level, the fluid level is then increased while maintaining the thermal gradient; based on the modeling results just one of these cycles can plastically deform the tank floor. The test site which is under construction is designed to replicate this damaging cycle at lower temperatures. The goal of testing will be to reproduce this damaging cycle and buckle the scaled test tank floor, allowing proper model validation and a methodology for comparing different tank designs at a smaller (and less costly) scale.

25 ENERGY STORAGE↗
NASA NTRS1998

The Athena Mars Rover Science Payload

The Mars Surveyor missions that will be launched in April of 2001 will include a highly capable rover that is a successor to the Mars Pathfinder mission's Sojourner rover. The design goals for this rover are a total traverse distance of at least 10 km and a total lifetime of at least one Earth year. The rover's job will be to explore a site in Mars' ancient terrain, searching for materials likely to preserve a record of ancient martian water, climate, and possibly biology. The rover will collect rock and soil samples, and will store them for return to Earth by a subsequent Mars Surveyor mission in 2005. The Athena Mars rover science payload is the suite of scientific instruments and sample collection tools that will be used to perform this job. The specific science objectives that NASA has identified for the '01 rover payload are to: (1) Provide color stereo imaging of martian surface environments, and remotely-sensed point discrimination of mineralogical composition. (2) Determine the elemental and mineralogical composition of martian surface materials. (3) Determine the fine-scale textural properties of these materials. (4) Collect and store samples. The Athena payload has been designed to meet these objectives. The focus of the design is on field operations: making sure the rover can locate, characterize, and collect scientifically important samples in a dusty, dirty, real-world environment. The topography, morphology, and mineralogy of the scene around the rover will be revealed by Pancam/Mini-TES, an integrated imager and IR spectrometer. Pancam views the surface around the rover in stereo and color. It uses two high-resolution cameras that are identical in most respects to the rover's navigation cameras. The detectors are low-power, low-mass active pixel sensors with on-chip 12-bit analog-to-digital conversion. Filters provide 8-12 color spectral bandpasses over the spectral region from 0.4 to 1.1 micron Narrow-angle optics provide an angular resolution of 0.28 mrad/pixel, nearly a factor of four higher than that of the Mars Pathfinder and Mars Surveyor '98 cameras. Image compression will be performed using a wavelet compression algorithm. The Mini-Thermal Emission Spectrometer (Mini-TES) is a point spectrometer operating in -the thermal IR. It produces high spectral resolution (5 /cm) image cubes with a wavelength range of 5-40 gm, a nominal signal/noise ratio of 500:1, and a maximum angular resolution of 7 mrad (7 cm at a distance of 10 in). The wavelength region over which it operates samples the diagnostic fundamental absorption features of rockforming minerals, and also provides some capability to see through dust coatings that could tend to obscure spectral features. The mineralogical information that Mini-TES provides will be used to select from a distance the rocks and soils that will be investigated in more detail and ultimately sampled. Mini-TES is derived from the MO/MGS TES instrument, but is significantly smaller and simpler. The instrument uses an 8-cm Cassegrain telescope, a Michelson interferometer, and uncooled pyroelectric detectors. Along with its mineralogical capabilities, Mini-TES can provide information on the thermophysical properties of rocks and soils. Viewing upward, it can also provide temperature profiles through the martian atmospheric boundary layer. Elemental and Mineralogical Composition: Once promising samples have been identified from a distance using Pancam/Mini-TES, they will be studied in detail using up to three compositional sensors that can be placed directly against them by an Instrument Arm. The two compositional sensors, presently on the payload are an Alpha-Proton-X-Ray Spectrometer (APXS), and a Mossbauer Spectrometer. The APXS is derived closely from the instrument that flew on Mars Pathfinder. Radioactive alpha sources and three detection modes (alpha, proton, and x-ray) provide elemental abundances of rocks and soils to complement and constrain mineralogical data. The Athena APXS will have a revised mechanical design that will cut down significantly on backscattering of alpha particles from martian atmospheric carbon. It will also include a target of known elemental composition that will be used for calibration purposes. The Athena Mossbauer Spectrometer is a diagnostic instrument for the mineralogy and oxidation state of Fe-bearing phases, which are particularly important on Mars. The instrument measures the resonant absorption of gamma rays produced by a Co-57 source to determine splitting of nuclear energy levels in Fe atoms that is related to the electronic environment surrounding them. It has been under development for space flight for many years at the Technical University of Darmstadt. The Mossbauer Spectrometer (and the other arm instruments) will be able to view a small permanent magnet array that will attract magnetic particles in the martian soil. The payload may also include a Raman Spectrometer. If included, the Raman Spectrometer will provide precise identification of major and minor mineral phases. It requires no sample preparation, and is also sensitive to organics. Fine-Scale Texture: The Instrument Arm a also carries a Microscopic Imager that will obtain high-resolution monochromatic images of the same materials for which compositional data will be obtained. Its spatial resolution is 20 micron/pixel over a 1 cm depth of field, and 40 micron/pixel over a 1-cm depth of field. Like Pancam, it uses the same active pixel sensor detectors and electronics as the rover's navigation cameras. The Instrument Arm is a three degree-of-freedom arm that uses designs and components from the Mars Pathfinder and Mars Surveyor '98 projects. Its primary function is instrument positioning. Along with the instruments noted above, it also carries a brush that can be used to remove dust and other loose coatings from rocks. Sample Collection and Storage: Martian rock and soil samples will be collected using a low-power rotary coring drill called the Mini-Corer. An important characteristic of this device is that it can obtain intact samples of rock from up to 5 cm within strong boulders and bedrock, Nominal core dimensions are 8xl7 mm. The Mini-Corer drills a core to the commanded depth in a rock, shears it off, retains it, and extracts it. It can also acquire samples of loose soil, using soil sample cups that are pressed downward into loose material. The Mini-Corer can drill at angles from vertical to 45' off vertical. It has six interchangeable bits for long life. Mechanical damage to the sample during drilling is minimal, and heating is negligible. After acquisition, the sample may be viewed by the arm instruments, and/or placed in one of 104 compartments in the Sample Container. A subset of the acquired samples may be replaced with other samples obtained later if desired. The Sample Container has no moving parts, and is mounted external to the rover for easy removal by the Mars Surveyor 2005 flight system. Operation of the rover will make extensive use of automated onboard navigation and hazard avoidance capabilities. Otherwise, use of onboard autonomy is minimal. Data downlink capability is about 40 Mbit/sol, and the use of the Mars Surveyor '01 orbiter for data relay imposes a limit of at most two command cycles per sol. Because of the significant amount of time available between command cycles, all payload elements will be operated sequentially, rather than in parallel.; this approach also significantly simplifies operations and minimizes peak power usage. The landing site for the '01 rover has not been selected yet. Site selection will make as full use as possible of Mars Global Surveyor data, and will involve substantial input from the broad Mars science community. Summary: The following table describes the mass, power, providers, and key scientific objectives of all the major elements of the Athena payload. Additional Athena payload information may be found at: http://astrosun.tn.cornell.edu/athena/index.html. Additional information contained in the original.

Squyes, S. W.↗