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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 OSTI2024

Energy Storage Improves Power Plant Flexibility and Economic Performance

Most existing coal-fired power plants were designed for sustained operation at full load to maximize efficiency, reliability, and revenue, as well as to operate air pollution control devices at design conditions. Depending on plant type and design, these plants can adjust output within a fixed range in response to plant operating or market conditions. The need for flexibility driven by increased penetration of variable and non-dispatchable power generation, such as wind and solar, is shifting the traditional mission profile of thermoelectric power plants in three ways: more frequent shutdowns when market or grid conditions warrant, more aggressive load ramp rates (rate of output change), and a lower minimum sustainable load, which provides a wider operating range and helps avoid costly plant shutdowns. Recent studies have shown that the flexibility of a coal-fired power plant can be improved by energy storage. The objective of this work was to analyze a set of energy storage options and determine their impact on the flexibility and economics of a representative coal-fired power plant. The effect of three energy storage systems integrated with a coal power plant on plant flexibility and economics was investigated. The results obtained in this project show that energy storage systems integrated with a thermal power plant improve plant flexibility and participation in the energy and ancillary services markets, which improves plant financial performance.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Design and experimental testing of a 150 kWh thermal battery using thermosiphons embedded in a concrete matrix for power plant flexible operation

One of the options for achieving the global temperature limitation of 1.5 °C target, for the mitigation of global warming, is based on the better penetration of renewables into the electrical grid. This has imposed a burden to fossil fuel fired power plants since they are required to operate away from their baseload mode to compensate for the inherent intermittence of the renewable power. Integrating energy storage with fossil plants is an option to achieve their needed flexibility. A cost competitive energy storage option for the solution is based on storing sensible heat in concrete. Here, this paper reports research results and development of a thermal battery cell (TBC) capable of operating at temperatures up to 425 °C. A novel concept consisting of a concrete matrix for sensible heat storage, engineered to provide enhanced thermal and mechanical properties, and twenty-two thermosiphon elements, engineered for dual action were designed and fabricated into a single thermal energy storage (TES) module. Research for the development of the components for the TBC was performed in the laboratory. Efficient heat transfer, to/from the storage media, was demonstrated under several charging and discharging conditions with a thermal storage capacity of 150 kWh th and a rapid discharge, making the TBC suitable for fast ramping when integrated with a fossil fuel fired power plant. Efficient radial heat transfer to the concrete was observed due to the well designed spacing and location of thermosiphons in the radial direction. A minimal temperature difference of 2 °C, between the thermosiphons bottom and top was obtained, demonstrating the isothermicity of those elements. An overall end-to-end TBC energy-to-energy round trip efficiency of 70% was achieved.

25 ENERGY STORAGE↗
DOE OSTI2020

Using Concentrating Solar Power to Create a Geological Thermal Energy Reservoir for Seasonal Storage and Flexible Power Plant Operation

Abstract We propose a hybrid renewable energy system—a geothermal energy storage system (GeoTES) with solar—to provide low-cost dispatchable power at various timescales from daily, to weekly, to seasonally. GeoTES with solar uses a concentrating solar power collector field to produce hot water that is injected into a sedimentary basin to create a synthetic geothermal resource. The stored geothermal heat can then be dispatched when required by the electrical grid. GeoTES is particularly valuable for a grid with a high penetration of non-flexible renewable technologies such as photovoltaic and wind power. In this work, a sophisticated hybrid model is developed to assess the technical and economic potential of GeoTES by combining IPSEpro, which is a power-cycle simulation tool, and SAM, an economic analysis tool by National Renewable Energy Laboratory (NREL). The analysis shows with proper initial charging period that the heat loss in storage is almost negligible and is a suitable technology for long-term energy storage. Various power-cycle options are evaluated, and the most suitable power cycle is selected for further study. Annual calculations of the GeoTES system indicate that a levelized cost of storage (LCOS) of 12.4 ¢/kWh e can be achieved for seasonal storage of 4000 h; this value is much lower than the existing long-term storage. The LCOS of GeoTES is insensitive to the storage duration above 8 h, unlike battery and molten-salt thermal storage systems. This result demonstrates that GeoTES can be a competitive seasonal storage technology in the future electricity market. The levelized cost of electricity of the GeoTES system is also carefully analyzed and can vary between 10.0 and 16.4 ¢/kWh e , depending on solar-collector prices.

25 ENERGY STORAGE↗
DOE OSTI2023

Dispatch analysis of flexible power operation with multi-unit small modular reactors

The relevance of nuclear power plant flexible power operation (FPO) is rising due to increased penetration of variable renewables. Small Modular Reactors (SMRs) such as NuScale are envisaged to have multiple units on one site. This provides opportunities for coordinating FPO between units, but also introduces challenges as common services (e.g., refueling equipment) must be shared between units and fuel loadings may be standardized. It is therefore important to quantify whether FPO with SMRs is economically beneficial. Here, this paper quantifies the economics of FPO on different timescales to analyze refueling outages of such multi-unit SMRs. A 24-h price-taker profit maximization of SMR operation is first solved considering revenues from wholesale power and ancillary service (AS) markets. The results are then used to find the most profitable operation strategy over several years for multiple units at the site accounting for the physics and materials limits on NPP operation, including refueling outages. Results show a small but appreciable participation of nuclear into AS, contributing 4% of revenues. Due to the longer fuel cycle, over a decade of operation the units’ refueling outages drifted by 3 months, ultimately leading to refueling during summer.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Co-Firing Switchgrass and Waste Coal in A Power Plant: A Techno-Economic and Life Cycle Evaluation for The Ohio River Valley (SWITCH) (Final Technical Report for Ohio State/FE0032204)

Abandoned coal mine lands (AMLs) represent one of the most persistent environmental challenges in the United States. Prior to the enactment of the Surface Mining Control and Reclamation Act (SMCRA) in 1977, coal mining operations were not legally required to reclaim disturbed lands, leaving behind approximately 500,000 AML sites nationwide. These sites pose severe environmental and health risks, including acid mine drainage, soil and water contamination, and spontaneous combustion of waste coal piles. Millions of Americans live within one mile of these AMLs, underscoring the urgency of remediation. Traditional reclamation practices, such as planting cool-season grasses, often fail to fully restore ecological function or leverage the economic potential of these lands. This project addressed these challenges by developing integrated strategies for resource recovery, land reclamation, and sustainable energy production. This project evaluated an integrated strategy to convert this liability into an opportunity by recovering waste coal and co-firing it with switchgrass (Panicum virgatum L.) cultivated on reclaimed or marginal AML areas in existing coal-fired power plants. Switchgrass not only provides a renewable feedstock but also aids in land reclamation and carbon sequestration. 1) Remote Sensing and Machine Learning for Waste Coal Identification Using Sentinel-2 satellite imagery and supervised classification, we applied four machine learning models to detect historical waste coal piles. Random Forest achieved the highest accuracy (precision: 86%, recall: 77%). Time-series analysis revealed gradual vegetation recovery since 1986, indicating natural reclamation processes in historical sites, while active mining areas showed ongoing disturbance. This workflow enables scalable monitoring and prioritization of reclamation efforts. 2) UAS-Based Stockpile Volume Estimation To quantify recoverable waste coal, we evaluated Unmanned Aerial Systems (UAS) equipped with Light Detection and Ranging (LiDAR) and multispectral sensors. Structure-from-Motion (SfM) photogrammetry combined with interpolated Digital Terrain Models (DTMs) achieved strong agreement with LiDAR reference volumes (Root Mean Square Error (RMSE) ≈147 m 3 , Mean Absolute Percentage Error (MAPE) ≈2%). Sensitivity analysis confirmed that spatial resolution significantly influences accuracy, emphasizing the need for high-resolution data for precise volume estimation. This approach offers a scalable, cost-effective, and accurate alternative to conventional ground-based surveys. 3) Switchgrass Cultivation for Bioenergy and Water Quality Improvement We assessed the hydrological and water quality impacts of converting AMLs to switchgrass production areas using the Soil and Water Assessment Tool (SWAT). Results showed that converting 10% of the watershed area into the switchgrass production zone reduced streamflow by 3.1%, total suspended solids by 18.1%, total nitrogen by 7.6%, and total phosphorus by 6.2%, while achieving biomass yields of 8.6–9.2 metric tons per hectare. These findings highlight switchgrass as a dual-benefit strategy for land reclamation and bioenergy feedstock production. 4) Integrated Co-Firing and CCS for Carbon-Negative Power Generation We modeled co-firing scenarios using the Power Plant Flexible Model (PPFM) to evaluate plant efficiency, greenhouse gas (GHG) emissions, and levelized cost of electricity (LCOE). Without carbon capture and storage (CCS), increasing switchgrass co-firing ratios reduced LCOE from $\$$150/MWh at 0% biomass to $\$$110/MWh at full substitution. Under CCS, costs remained higher (~$\$$250/MWh at 0% biomass) but decreased to $\$$200/MWh at 100% biomass, while enabling net-zero or carbon-negative electricity due to switchgrass sequestration benefits. Although CCS introduced efficiency penalties, pairing it with biomass co-firing offset these impacts and maximized climate benefits. Overall, optimizing co-firing ratios between 60-100%, supported by reliable logistics and storage strategies, emerged as a practical pathway to balance affordability, sustainability, and net-zero or negative GHG emissions while promoting productive reuse of AMLs.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Mid Infra-Red Laser Sensor for Continuous Sulfur Trioxide Monitoring to Improve Coal-Fired Power Plant Performance during Flexible Operations

During the course of this project, we performed exhaustive research and development of SO3/H2SO4 sensing technology for coal-fired power plant applications (Figure 1). The development culminated in a successful field campaign of a prototype continuous real-time H2SO4 monitor at a coal-fired power plant (TRL 6) accomplishing the primary goal of the project. The developed sensors utilize tunable laser absorption spectroscopy (TLAS) operating in the mid-infrared (Mid-IR) wavelength region, which is the so-called “molecular fingerprint” region. Systems operating in the Mid-IR have orders of magnitude more sensitivity than systems operating at shorter wavelengths, such as near-infrared (NIR). However, NIR systems are more widespread due to more mature supporting technology (e.g., fiber optics, optical components, etc.). In this project, we not only produced a specific Mid-IR sensor, we also advanced Mid-IR sensor technology in general through the development and demonstration of such supporting technology. In this project, we also developed proprietary broad tuning lasers enabling the ability to effectively measure SO3, H2SO4, H2O, and SO2. Different molecular species have unique spectral signatures that can be probed with lasers operating at different wavelengths. Standard TLAS uses relatively narrow wavelength tuning distributed feedback (DFB) lasers, which can typically only target a single species with narrow features, and are not appropriate for species with broad features, such as SO3 or H2SO4. In contrast, by developing unique, broad-tuning laser technology, we were able to measure these species, as well as SO2 and H2O simultaneously. Furthermore, to enable real-time analysis at a power plant, we modified a commercially available heated gas cell to operate in the Mid-IR wavelength range and fiber coupled the lasers to enable remote delivery of the beams. To generate reference data (library spectra), our collaborators at the University of California Irvine (UCI) developed a catalytic SO3 generation facility. It is worth mentioning that representative H2SO4 and SO3 Mid-IR spectra are not a part of any publicly available database and the data generated under this project is a valuable resource in and of itself. In addition, based on the UCI study we determined that detection of SO3 is complicated by the very strong SO2 absorption. For that reason, we concentrated on H2SO4 detection. Since SO3 and H2SO4 exist in a flue gas in a state of equilibrium, which depends on temperature and humidity, by measuring water concentration and controlling the temperature of the gas cell, we developed an approach to determine SO3 concentration from the H2SO4 measurement. During the development phase of the project, we performed three testing campaigns at our collaborator’s FERCo flue gas facility with conditions representative of the coal-fired power plant (~ 40ppm SO3, 1700ppm to 2800 ppm SO2, 10% water) with the exception of particulate matter. After three test campaigns at FERCo we performed field testing at Harrison Power Station. The final system was mounted on a duct and measured H2SO4, SO2 and water. The tests were highly successful with a demonstrated real-time H2SO4 precision of 1 ppm with a 1 second update. Our collaborators at EPRI conducted an industry survey and determined that there is a very high interest for the SO3/H2SO4 monitoring in the power generation industry as well as in heavy industries in general. Furthermore, work performed by OptoKnowledge beyond the scope of this project under a synergistic DOE SBIR determined another approach to SO3 detection. We applied for Phase II on this SBIR for development a of versatile SO3/H2SO4 sensor but were not selected. We are currently looking for another opportunity to leverage all the technological advancements produced by this project including but not limited to the flue gas facility at UCI, the hardware and software developed, and relationships with FERCo, EPRI CEMTEK, and Harrison Station.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to flexibly dispatch energy. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating solar thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also cascading lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and simulated using SimTech IPSEpro process modeling software. The design configuration depends on the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year; therefore, off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗
DOE OSTI2024

Environmental Validation of Materials and Design Concepts to Enable Operational Flexibility of Existing Coal Power Plants

Increasingly, coal-fired power plants are required to balance power grids by compensating for the variable electricity supply from renewable energy sources. Fossil-fueled power plants, originally designed to be base loaded, will increasingly need to operate on a load following or cyclic basis. This demanding requirement for operational flexibility will need to be evaluated for resilience to frequent start-ups, meeting major and rapid load changes, and providing frequency control duties. Our research objective was to evaluate and improve flexibility of existing power plants by improving and redesigning components and defining new operational strategies, with acceptable impacts on component life, efficiency and emissions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Dynamic optimization and economic evaluation of flexible heat integration in a hybrid concentrated solar power plant

Hybridization of concentrated solar power (CSP) plants provides flexibility in operation that can drastically improve the solar-to-electric (STE) efficiency and levelized cost of electricity (LCOE) relative to standalone CSP plants. Flexible heat integration (FHI) is a novel concept where the collection and integration of CSP within a power plant is modified relative to the amount of solar energy available. FHI improves the thermal efficiency of a hybrid solar tower steam Rankine cycle power plant but leads to increased pumping needs due to continuously elevated molten salt flow rates through the collection system, which can negatively impact STE efficiency. The present work is carried out to maximize the STE efficiency of a hybrid CSP plant utilizing FHI by employing a dynamic optimization framework where a genetic algorithm optimizes the operation of the plant over a given solar irradiance profile. The study concerns a plant hypothetically located in Salt Lake City, Utah. Here, the optimization results confirm the accuracy of a predictive heuristic where the preferred operation of the plant can be estimated relative to local peaks in the incident power generated by the heliostat collection field. The optimized FHI operation demonstrates a yearly STE efficiency of 13.8%, whereas the equivalent base-level hybrid and solar-only plants exhibit solar efficiencies of 13.4% and 11.2%, respectively. Economic analysis shows that FHI reduces yearly natural gas costs, leading to a $\$0.5$/MWh reduction in LCOE relative to the base-level hybrid configuration. Overall, the results show that hybrid FHI schemes exhibit economic benefits along with observed thermodynamic improvements.

14 SOLAR ENERGY↗