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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Equivalent Breakeven Installed Cost: A Tradeoff-Informed Measure for Technoeconomic Analysis of Candidate Heliostat Improvements

Technoeconomic analysis (TEA) is commonly used to determine economic viability of power-generating technologies, including concentrating solar power (CSP) and thermal (CST) production plants. Levelized cost of electricity (LCOE) and analogous measures provide an estimate of long-term costs for operating power plants over their designed lifetimes by accounting for revenues and costs in a time-discounted manner. While these measures are effective when assessing a technology’s total lifecycle costs and productivity under various designs, TEA of candidate incremental technology improvements from the lens of LCOE can be limited when required investment and LCOE impacts are small. In this work, we propose a novel metric for TEA of a plant component technology that recasts relative changes in levelized system costs into component-specific capital cost budgets. This measure, which we refer to as the equivalent breakeven installed cost, is the maximum budget for the technology component that leads to improved levelized costs. We illustrate the usefulness of this metric using the example of candidate heliostat improvements for a CSP tower plant. Here, the results suggest that a reduction in mirror washing costs yield a total plant O&M cost of $37/kWe-yr, which is a breakeven proposition if the average reflectance is reduced from 0.90 to 0.85 as a result of the cost savings.

Zolan, Alexander (ORCID:0000000326017604)↗
DOE OSTI2022

Innovative Method for Welding in Generation 3 CSP to Enable Reliable Manufacturing of Solar Receivers to withstand Daily Cycling at Temperatures Above 700°C (Final Technical Report)

Inconel® Alloy 740H® (alloy 740H) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. Over the past ~20 years the alloy has been optimized for weldability and high-temperature stability, approved for use in different applications. Development of a supply chain combined with the advantageous properties of the alloy (high-temperature creep strength, oxidation and corrosion resistance, etc.) have resulted in the alloy being applied to new high-temperature power cycle demonstration projects, and of particular interest are applications to concentrating solar power (CSP) to enable higher-efficiency Generation 3 CSP systems and the corresponding supercritical CO 2 (sCO 2 ) power cycle components (heat exchangers, piping, etc.). The high allowable stresses of alloy 740H also make it a desirable material for current Generation 2 CSP solar power receivers to improve cyclic capability and/or reduce receiver height. Recent experiences in demonstration projects utilizing alloy 740H identified cracking issues during welding and fabrication. In this project, a detailed study was done to confirm and clarify the Stress Relaxation Cracking (SRxC) mechanism, also known as stress relief cracking or strain-age cracking (SAC), during post-weld heat-treatment (PWHT). This involved detailed microscopy and advanced characterization to understand the root cause(s) of three failures obtained from industry. Based in-part on these findings, a targeted laboratory based SRxC test method was utilized to evaluate variables such as heat-to-heat variations, strain level, PWHT temperature, and starting material condition on three heats of alloy 740H. Industrial shop welding of cold-worked plates was also conducted. The research showed the following: SRxC was confirmed as the cracking mechanism for all field failures; Stress state (from residual stresses, constraint, deformation, and local stress concentrations) was playing a significant role in field failures and laboratory testing confirmed increasing susceptibility for all heats with increasing strain levels. High levels of microstructural strain were identified at crack initiation locations, in some cases leading to local recrystallization; Precipitate free zones (PFZs) at grain boundaries were found at relaxation cracks and crack initiation locations uniquely associated with SRxC in alloy 740H. Laboratory testing reproduced this microstructural feature which had only previously been reported in long-term creep testing of weldments. Advanced nano-scale characterization confirmed the presence of a moving boundary leading to coarsening of precipitates and PFZs where damage accumulated; The research suggested heat-to-heat variations due to local chemistry and processing may influence SRxC susceptibility, but more work is needed to fully clarify these effects. To disseminate the key learnings from this research to the scientific and engineering communities and alloy 740H end users, multiple technical publications and presentations were made, an industrial alloy 740H users meeting was held, and a new industry guideline specification document which can be directly implemented by end-users of alloy 740H was produced.

14 SOLAR ENERGY↗
DOE OSTI2021

Infrared transmissive concentrated photovoltaics for coupling solar electric energy conversion to solar thermal energy utilization

The use of photovoltaic (PV) cells to convert solar energy to electricity is becoming increasingly prevalent; however, there are still significant limitations associated with the widespread adoption of PV cells for electricity needs. There is a clear need for a high efficiency solar power system that supplies electricity at a competitive cost and that provides for an on-demand supply of electricity as well as energy storage. By combining aspects of concentrated solar power and concentrated photovoltaics, the present invention provides a device that enables the conversion of sunlight to electricity at very high efficiencies and that enables the transmission of thermal energy to heat storage devices for later use. The disclosed device enables transmissive CPV through the use of a multijunction PV cell mounted on a transparent base. The use of a multijunction cell allows for highly efficient absorption of light above the bandgap of the lowest bandgap subcell. The transparent base permits transmission of a high percentage of the remaining light below the bandgap of the lowest bandgap subcell. The present invention also discloses a method of generating electricity through the use of a transmissive CPV device. Sunlight is concentrated onto one or more surfaces of the device. High energy light is absorbed by a multijunction PV cell and converted directly to electricity, while low energy light is transmitted through the device into a thermal storage device, which may then be coupled to a heat engine to generate dispatchable electricity.

Escarra, Matthew David↗
DOE OSTI2024

Status Quo and Gap Analysis of Heliostat Field Deployment Processes for Concentrating Solar Tower Plants

In this study, deployment of the solar field of a concentrating solar power plant is one of many factors that are integral to the success of a project. Knowledge transfer from outside the industry is limited due to the unique nature of heliostats, which redirect sunlight to a receiver with high precision while maintaining a high level of reflectivity. Moreover, learning from project to project can be limited due to the site-specific nature of projects, as the market includes several developers, each with their own unique design. In this paper, we discuss the state of the art in heliostat field deployment. We cover all the key aspects of deployment from project assessment to a fully functioning system, which include site selection, layout development, supply chain, assembly, site preparation and construction, calibration, and operations and maintenance. We then perform a gap analysis on field deployment and recommend priorities for future research.

14 SOLAR ENERGY↗
DOE OSTI2023

Thermal hydraulic characteristics of liquid sodium and supercritical CO 2 in a diffusion bonded heat exchanger

Compact heat exchangers are being examined for use in advanced, high-temperature nuclear or concentrated solar power plants to improve thermal efficiencies and reduce capital costs. At the time of this work, no experimental investigation of liquid sodium in the popular diffusion-bonded heat exchanger design had been performed. Herein this paper describes the thermal-hydraulic and overall operations performance observed during testing of a 316/L stainless steel “zig-zag” microchannel heat exchanger operating between a (0.5 kg/s) sodium loop and a (0.3 kg/s) recuperated supercritical CO 2 system with outlet conditions up to 550 °C at 16 MPa. Observed pressure drop is presented in the form of an effective friction factor correlation which aligns closely with recent experimental data. The thermal performance of this heat exchanger, measured by its overall conductance under various flow conditions, was decomposed to examine the independent convection behaviors of both the CO 2 and sodium streams. These results are presented in the form of Nusselt correlations fitted to the experimental data. The sodium heat transfer correlation aligns closely with the widely accepted Lubarsky-Kaufman correlation, while the CO 2 heat transfer correlation lies between previous correlations developed by computational and experimental methods. This was the first long-duration use of sodium in a microchannels (~1.8 mm hydraulic diameter) heat exchanger. The use of an oxide control system enabled trouble-free operation of the heat exchanger for over 150 h of high-temperature operation. This first-of-a-kind demonstration using liquid sodium and supercritical carbon dioxide shows great promise for further application of this technology in advanced nuclear or solar power plants.

42 ENGINEERING↗
DOE OSTI2024

A Nonintrusive Optical Approach to Characterize Heliostats in Utility-Scale Power Tower Plants: Camera Position Sensitivity Analysis

Optics plays a major role in the effectiveness of concentrating solar power (CSP) technologies. The nonintrusive optical (NIO) approach developed by the National Renewable Energy Laboratory uses uncrewed aircraft system (UAS)-based imaging to survey heliostats in a commercial-scale power tower CSP plant and characterize their optical errors. The image processing algorithm uses photogrammetry to calculate the camera position for each image frame, and the accuracy of the estimated optical errors is highly sensitive to the calculated camera position accuracy. In this study, we simulate a series of case studies in python to examine the impact of different parameters of the sensitivity of the camera calculation, including the number of facet corners used as control points for the photogrammetric calculation, precision error in the detected pixel locations of the facet corners in the image, and precision error of the canting and mounting positions of the facets of the heliostat. The case studies consider heliostat geometry based on three commercial designs to serve as representative examples of different possible sizes of heliostats that the NIO method could be applied to. The results show that increasing the number of control points can improve accuracy for heliostats with many facets, pixel precision has a significantly larger impact on camera calculation accuracy than facet canting and mounting errors, and the camera distance and focal length must be chosen to ensure adequate pixel accuracy on the heliostat surface depending on the size of heliostat. In conclusion, based on the results, recommendations for the allowable values of each parameter are provided to achieve the required NIO optical error estimation accuracy depending on the size of heliostat.

14 SOLAR ENERGY↗
DOE OSTI2023

Modeling of Stress Distribution in Molten Salt Thermal Energy Storage Tanks for In-Service Central Receiver Power Plants

Failures in molten nitrate salts thermal energy storage tanks (TES) have been occurring in several concentrating solar power (CSP) plants around the world after a few months or years of operation. These failures are mainly related to a combination of high stress, corrosion, large deformation, and thermal cycling. Most of these failures are a consequence of the infancy of this technology; technical standards for design, fabrication, implementation, and operation of molten salt tanks operating at temperatures up to 565 degrees Celsius do not exist and most of current in-service tanks have been designed using the recommendations from the American Petroleum Institute (API) 650 and the American Society of Mechanical Engineers ASME section II standards, which are applicable for TES tanks operating at lower temperatures. We have developed a 3-dimensional model of a representative molten salt hot tank design that uses typical CSP plant operation conditions and allows determining the temperature and stress distribution in the tank. The model also considers the initial floor residual stresses and distortion after its welding fabrication. We have identified critical thermal gradients in the tank floor and shell and locations in the tank where the stresses are high and could become susceptible points for failure.

concentrating solar power↗
DOE OSTI2021

Bimodal particle distributions with increased thermal conductivity for solid particles as heat transfer media and storage materials

Solid particles are being considered in several high temperature thermal energy storage systems and as heat transfer media in a variety of advanced power generation systems, particularly in concentrated solar power plants. The downside of such an approach is the low overall heat transfer coefficients caused by the inherently low thermal conductivity values of the low-cost solid media when coupled to heat exchanger for the power cycle working fluid. Choosing the right particle size distribution, emittance, and material of the solid media can all make a substantial difference in packed bed thermal conductivity. Current research though exclusively focuses on continuous unimodal distributions of particles. Here, in this work, we propose the use of a binary particle system with a bimodal size distribution to significantly increase packed bed thermal conductivity by reducing packed bed porosity. This is the first study related to ceramic solid particle heat transfer that has considered the thermal conductivity of non-unimodal size distributions at room and elevated temperatures. The following study found that for the binary particle system using Carbo particles CP 16/30 – CP 70/140 where the large particle volume fraction was 50% there was an 17–47% increase in packed bed thermal conductivity when compared with a nearly unimodal particle size distribution of CP 16/30 between 50 and 300 °C. Two different porosity and effective thermal conductivity models were studied, with one providing better prediction of porosity but both effective thermal conductivity models providing less predictive capacity. Importantly this approach can have a substantial impact of thermal performance, with little to no impact on the particle cost.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Analysis of Molten Salt Thermal Energy Storage Tank Sizing and Preheating

Molten Salt Thermal energy storage (TES) is essential for concentrating solar power (CSP) plants, enhancing their capacity factor and dispatchability to ultimately reduce electricity costs. This technology is becoming more important for other technologies including nuclear power, thermal-electrical storage, and concentrating solar thermal (CST). While molten salt TES tanks have been successfully deployed in lower-temperature parabolic-trough plants, the current state-of-the-art central receiver systems operating at temperatures up to 565 degrees Celsius have experienced costly and frequent failures. These failures are associated with the immaturity of the technology and problems in tank design, fabrication, commissioning and, sometimes, aggressive operation. A primary contributing factor is the absence of a dedicated technical standard for high-temperature molten nitrate TES tanks; designers must currently rely on existing codes like API 650 and ASME Section II, which are insufficient because they fail to account for the unique demands of high temperatures, thermal cycling, and transient conditions.

25 ENERGY STORAGE↗
DOE OSTI2024

Resources, Training, and Education Under the Heliostat Consortium: Industry Gap Analysis and Building a Resource Database

Concentrating solar power is not a widely deployed or known technology area, and the heliostat workforce community in the United States is currently small, with knowledge and expertise not widely available. The resource, training, and education (RTE) topic within the Heliostat Consortium (HelioCon) was established to address this. RTE encompasses resources, practices, and programs to ensure that (1) newcomers to the heliostat development community have an adequate knowledge base and training to conduct R&D efforts, (2) outsiders to the field are provided with resources and opportunities to join the workforce, and (3) the workforce community is a productive, healthy, and fulfilling environment for all workers. In the first year of the project, a roadmap study was conducted, in which the major gaps in RTE were identified by consulting experts in the industry, with the top gap being the lack of public accessibility to concentrating solar-thermal power (CSP) knowledge. Here, to address this, the HelioCon team has been developing a centralized web-based resource database, containing a reference library, educational videos, lists of components suppliers and software/metrology tools, a power tower plant database, and information on existing standards/guidelines.

14 SOLAR ENERGY↗
DOE OSTI2024

Siting Analysis of a Solar-Nuclear-Desalination Integrated Energy System

Nuclear power is typically deployed as a baseload generator. Increased penetration of variable renewables motivates combining nuclear and renewable technologies into Integrated Energy Systems (IES) to improve dispatchability, component synergies and, through cogeneration, address multiple markets. However, combining multiple energy resources heavily depends on the proper selection of each system’s location and design limitations. In this paper, co-siting options for IES that couple nuclear and concentrating solar power (CSP) with thermal desalination are investigated. A comprehensive siting analysis is performed that utilizes global information survey data to determine possible co-siting options for nuclear and solar thermal generation in the United States. Viable co-siting options are distributed across the Southwestern U.S., with the greatest concentration of siting options in the southern Great Plains, although siting with higher solar direct normal irradiance is possible in other states such as Arizona and New Mexico. Brackish water desalination is also attractive across the southwest U.S. due to high water stress, but for brackish water desalination reverse osmosis (an electricity driven process) is most cost- and energy-efficient, which does not require co-siting with the thermal generator. The most attractive state for nuclear and thermal desalination (which is more attractive when using seawater) is Texas, although other areas may become attractive as water stress increases over the coming decades. Co-siting of all CSP and thermal desalination is challenging as attractive CSP sites are not coastal.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Impact of Dry Cooler Air-Side Performance on a sCO2 Power Cycle for a CSP Application

Uncertainty around the design and control of the supercritical CO2 power cycle must be reduced before this technology can be implemented for large-scale grid support. To better understand the day-to-day performance of an sCO2 cycle, off-design performance calculations must be included for all power block components, and performance assumptions must be removed. This study has expanded the modeled scope to include the air-side performance for the dry cooler and has incorporated discretized heat transfer calculations for both streams through the pre-cooler to better predict off-design performance. This study considered a recompression Brayton cycle in a concentrating solar power application. The cycle model utilized fixed sCO2 turbomachinery maps for the main compressor, recompressor, and expander operating to supply approximately 10 MW gross at the design point. Fixed vendor-supplied fan curves were used to calculate the air-side performance of the dry cooler. The primary heater was modeled considering both the sCO2 and heat transfer fluid streams. Off-design performance was predicted for an ambient temperature range of 0-55℃, a HTF temperature range of 705-735℃, and a HTF mass flow range of 50-105% of the design point value. To understand the importance of modeling the air-side performance, the cycle off-design performance was also calculated using a constant CO2 outlet temperature assumption and a constant approach temperature assumption for the dry cooler. Results show that using these assumptions can significantly alter the power output and cycle efficiency predictions.

14 SOLAR ENERGY↗
DOE OSTI2022

Integrated Heat Pump Thermal Storage and Power Cycle for CSP (Final Technical Report)

Pumped thermal energy storage (PTES) is a storage system that stores electricity in thermal reservoirs. In this project, methods of integrating PTES with concentrating solar power (CSP) systems were investigated and their feasibility evaluated. Hybrid "solar-PTES" devices can provide both flexible renewable power generation as well as a variety of electricity storage services. Techno-economic models of PTES and solar-PTES were developed and used to assess their performance, cost, and commercial viability. Systems were optimized using multi-objective optimization techniques. The value that these storage devices provide to the grid was estimated using production cost modelling. Key advances made in this project include the development of detailed techno-economic models that improve state-of-the-art assessments of these technologies. Off-design models were developed and used in grid-analysis models. This work describes for the first time how PTES and solar-PTES behave over a range of operating points and assesses the value that these systems can provide to the electrical grid. Feedback was obtained from experts in the field, which clarified key technological and economic barriers that must be addressed to improve the feasibility of these devices.

14 SOLAR ENERGY↗
DOE OSTI2021

Methods for Representing Flexible, Energy-Constrained Technologies in Utility Planning Tools

Capacity expansion models are widely used by power system researchers, planners, and policy analysts to evaluate alternative power system investment scenarios. With the increasing deployment of wind and solar in the US, there has been much focus on improving the representations of variable generation (VG) technologies within capacity expansion models. Models that capture the variable net-load profiles and larger reserve requirements associated with high penetration VG systems represent an improvement to classic capacity expansion models, but fall short of capturing the complexities associated with storage technologies, such as battery energy storage (BES) and concentrating solar power with thermal energy storage (CSP with TES). While difficult to model in a capacity expansion setting, these technologies are potentially competitive sources of flexibility with the intriguing characteristics of being able to absorb VG that would otherwise be curtailed and directly contribute to renewable energy goals, respectively. In this paper we present methods for accurately representing these technologies in a large-scale capacity expansion model with high electrical and geospatial resolution. VG modeling techniques, including novel methods for capturing curtailment due to unit commitment and other hourly dispatch phenomena, are also reviewed. Modeling for a region in the southwestern United States demonstrates the economic relevance of being able to explicitly trade off the costs and capabilities of energy-constrained technologies, especially BES, against other resources in the near-term, in time to make plans for the coming decade

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Life Cycle Emissions Factors for Electricity Generation Technologies

This dataset consists of a table containing the distribution of literature estimates of greenhouse gas emissions for the following electricity generation and storage technologies: biopower, coal, concentrating solar power, geothermal, hydrogen storage, hydropower, lithium-ion battery storage, natural gas, nuclear, ocean, oil, photovoltaic, pumped-storage hydropower, and wind. Quartile estimates of life cycle emissions factors in units of grams of carbon dioxide equivalent per kilowatt hour of generation (g CO2e/kWh) are provided for the following life cycle stages: one-time upstream, ongoing combustion, ongoing non-combustion, one-time downstream, and total. Literature estimates were compiled by the LCA Harmonization study and subsequent updates, as detailed in the factsheet which accompanies this dataset, https://www.nlr.gov/docs/fy21osti/80580.pdf .

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

A non-intrusive optical approach to characterize heliostats in utility-scale power tower plants: Flight path generation/optimization of unmanned aerial systems

A newly developed in situ non-intrusive optical (NIO) approach has been developed to survey various types of heliostat optical errors for a concentrating solar power (CSP) tower plant. To measure mirror surface slope error, facet canting error, and heliostat tracking error at a sub-milliradian accuracy, NIO requires several reflection images scanned over each individual heliostat. For a utility-scale plant that typically includes more than 10,000 heliostats, an unmanned aerial system (UAS) is crucial for efficient implementation of the NIO method. Here, we develop a flight path generation/optimization algorithm to plan more efficient UAS paths to collect NIO data over a utility-scale heliostat field. The algorithm considers NIO data requirements, all potential constraints, optimization within each subfield, and operational flexibility. Case studies are presented to illustrate the feasibility and robustness of the developed flight path algorithm. The path planning algorithm may also find applications elsewhere, such as drone-driven imaging under extreme conditions.

14 SOLAR ENERGY↗