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At least 37 records · Page 2

Characterization of solid particle candidates for application in thermal energy storage and concentrating solar power systems

Thermal energy storage (TES) enables concentrating solar power to remain competitive in the renewable energy mix by firming up intermittent solar resource and providing grid services such as load shifting. Free from siting constraints, stand-alone TES systems show promise as a low-cost alternative to traditional pumped-storage hydropower or compressed air energy storage. At the core of all TES technologies is a storage medium, the selection of which governs many aspects of system design and operation. Although the majority of commercial installations utilize molten salts, solid particles can demonstrate stability over wider temperature ranges. This amounts to increased energy storage densities and corresponding reductions in system cost which is essential in achieving low-cost energy storage. In this work, eight solid particle candidates are systematically identified and screened for application in a specific particle-TES system. The five most promising candidates (CARBO CP and HSP, calcined flint clay (CFC), brown fused alumina (BFA), and silica sand) are further characterized by size and morphology for fluidization suitability, flowability for particle transport, and thermal stability. Calcined flint clay and brown fused alumina are eventually down-selected due to thermal instability at the target operational temperature of 1200 °C. Although the physical characteristics of CARBO outperform silica sand in all categories examined, the marginal performance gains are considered insufficient to justify the additional media cost so silica sand is selected as the leading candidate. Within the silica sand (α-quartz) space, the high end of Geldart Group B particles is identified to satisfy the target fluidization regime for the application of interest without compromising particle flowability. Here, in focused testing, Silica 460 is shown to exhibit sufficient stability through long-duration (500-hour) thermal and cyclic testing (1200 °C), 10-hour testing at 1400 °C, and in contact with candidate refractory containment materials. Finally, an average heat capacity of 1.1 J/g∙ °C is measured over 300-1200 °C with a quartz inversion enthalpy (ΔH α-β ) of 10.7J/g.

14 SOLAR ENERGY↗

Design of a Compact Dry Cooler With an Aluminum Heat Exchanger Core for a Supercritical CO2 Power Cycle Is Evaluated for a Concentrating Solar Power Application

Abstract As the supercritical CO2 power cycle develops and the component technologies mature, there is still a need to reduce the associated capital and operating costs to maintain a competitive levelized cost of electricity (LCOE) in order to enter the market. When considering concentrating solar power (CSP) coupled with an sCO2 power block and sensible thermal storage, the technology presents a clean source for utility-scale power generation to support baseload or peak-load electrical demand. However, the LCOE of the technology is still considered higher than the competing technologies and should be reduced to better compete in the market; 2030 targets for dispatchable solar plants are 5¢/kWh for baseload CSP and 10¢/kWh for peaker plants, as set by the United States Department of Energy. In response to this need, this study is targeting improvements in the power cycle precooler to reduce power block contribution to LCOE. This study considers a dry cooler, as CSP plants are sensitive to water consumption because many installations are slated for remote or arid locations where solar irradiance is very high, but water is scarce. Furthermore, the power block footprint for an sCO2 system is quite compact, especially as compared to a steam cycle. Therefore, there is interest in installing a more compact dry cooler that is proportional to the reduced footprint sCO2 power block, while conventional dry coolers are an order of magnitude larger. The competing goals of size, performance, and cost were considered in this study to develop a compact dry cooler that can easily be packaged with the power block, significantly reducing the installation and transport cost compared to the current state of the art, while maintaining or improving upon the heat transfer performance and impact on plant LCOE. This paper details the high-level findings of a large dry cooler sensitivity study for design point selection, design of the compact dry cooler, expected year-round performance for the dry cooler and the power cycle, and the predicted LCOE for a 30-year plant life. It was found that an aluminum heat exchanger core can be suitably designed to meet the pressure and temperature requirements for a precooler in an sCO2 recompression Brayton cycle. The dry cooler assembly was found to have improved heat transfer performance, allowing for increased cycle efficiencies and a reduced plant LCOE. When coupled with a centrifugal blower and compact transition duct, the dry cooler assembly was able to reduce the installation footprint by over 50%.

14 SOLAR ENERGY↗

Analysis of thermal and mechanical properties with inventory level of the molten salt storage tank in central receiver concentrating solar power plants

Molten salt thermal energy storage (TES) tanks ensure steady power output of concentrating solar power (CSP) plants; however, recent tank failures have highlighted the need for further analysis. Current studies primarily focus on analyzing the molten salt flow, heat transfer, and thermal efficiency. Additionally, research on the latest tank structures is limited and lacks newest experimental validation. This study measures temperature and molten salt inventory levels in the high-temperature tank at a 50 MW central receiver CSP plant, connected to the power grid in 2019. A multi-physics model was developed to evaluate thermal and mechanical properties of TES tanks by combining computational fluid dynamics and finite element modeling using real plant data. Heat loss, temperature, displacement, and stress distribution of the tank at different inventory levels were investigated. Results show that ambient air velocity near the tank roof reaches 2.14 m/s, much higher than 0.2 m/s near the wall. The temperatures of inventory fluid and tank are close, varying slightly at different levels due to thermal conduction and radiation. Because the heat loss strongly depends on temperature, the total tank loss remains nearly constant across inventory levels. Larger temperature gradients and thermal stresses are primarily localized along the tank floor edge and the air-salt interface. Notably, the maximum thermal stress at the tank edge is three times higher than that at the interface. The magnitude of total stress changes by less than 5 MPa with and without thermal load, indicating that high temperatures exert only a minor impact on tank stress. In contrast, thermal load significantly affects tank deformation, particularly at the roof edge, where values exceed 150 mm. Despite the large variation in molten salt levels, tank wall temperatures and displacements present a minor change, suggesting a weak correlation with inventory levels. In conclusion, the findings obtained in this study provide important insights on the TES tank that could be used to optimize tank design and operation strategies.

14 SOLAR ENERGY↗

Vascular Carbon/Carbon composites for concentrated solar power

Due to their exceptional mechanical and thermal properties under high temperature conditions, for the first time, a novel vascular (embedded channels) Carbon/Carbon (C/C) composite was developed for use as a modular concentrated solar power (CSP) gas receiver. The fabrication process involves the combination of the vaporization of sacrificial component (VaSC) technique with conventional methods to produce C/C composites with well preserved channels. Different heat treatments were evaluated together with X-ray diffraction (XRD) analysis to determine optimal fabrication conditions that maintains the material and channel’s integrity. Mechanical testing confirms that structural integrity is maintained, with statistical analyses indicating no compromise in flexural strength or modulus. Furthermore, this research introduces an innovative pathway for efficient CSP gas receivers, which can bridge the gap towards improved energy generation efficiency in next-gen CSP plants through higher operating temperatures with the use of C/C composites.

14 SOLAR ENERGY↗

Multi-Objective Optimization of a Bi-Metal High-Temperature Recuperator for Application in Concentrating Solar Power

Supercritical CO 2 closed Brayton cycles are a major candidate for future power cycle designs in concentrating solar power applications, with high-temperature recuperators playing an essential role in realizing their high thermal efficiency. Here, printed circuit heat exchangers (PCHEs) are often chosen for this role due to their thermal-hydraulic and mechanical performance at high temperatures and pressures, all while remaining compact. However, PCHEs can be costly because of the high-performance materials demanded in these applications, and the heat exchanger internal geometry is restricted by their manufacturing process. Additively manufactured heat exchangers can address both of these shortcomings. This work proposes a modular bi-metal high-temperature recuperator with integrated headers to be produced with additive manufacturing. Beginning with existing PCHE channel geometries, a 1D heat exchanger model is developed. Then, multi-objective optimization is used to maximize the heat transfer effectiveness of a lab-scale device while limiting its size. Two distinct channel geometries emerge from the optimization. Optimal designs achieve up to 88% effectiveness with negligible pressure drop. Deterioration of effectiveness due to axial conduction of heat in the heat exchanger walls is found to be a notable problem for lab-scale PCHEs, and the optimal designs obtained here minimize its detrimental effects. A sensitivity analysis reveals that the effectiveness of the recuperator is much less sensitive to variation in mass flowrate in off-design operation when axial conduction is significant, while increasing the length of the device easily increases effectiveness.

14 SOLAR ENERGY↗

Effects of Particle Size and Concentration of Magnesium Oxide on the Lubricating Performance of a Chloride Molten Salt for Concentrating Solar Power

One engineering challenge for the next-generation concentrating solar power (CSP) is to identify appropriate heat transfer and thermal energy storage media. A chloride salt mixture (20 wt % NaCl + 40 wt % MgCl 2 + 40 wt % KCl) in a molten phase is proposed as a potential fluid for carrying the heat as well as lubricating the CSP pump bearings. Due to the hygroscopic nature of MgCl 2 , the presence of magnesium oxide (MgO) particles is inevitable. In order to understand the impact of MgO particles, this study investigated the tribological behavior of the molten chloride salt mixture containing MgO of various particle sizes and concentrations. Tests were conducted at 750 °C in a dry Ar environment using a zirconia ball sliding against a Haynes 244 alloy disc lubricated by the molten salt. There was a clear trend of the increased friction coefficient and wear loss for a larger particle size and/or a higher concentration of MgO. Distinct wear mechanisms were identified for the ceramic ball and alloy disc. Results provide fundamental insights for this new research avenue of molten salt lubrication for CSP.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Using concentrating-solar-power plants as economic carbon-free capacity resources

Deep decarbonization of electricity systems raises concerns about the need for generating capacity that can maintain reliable energy supply. Given this concern, we explore the ability of concentrating-solar-power plants with thermal energy storage to provide a carbon-free source of such capacity. We develop an approach to assessing the capacity contribution of concentrating-solar-power plants that considers future systems. Such considerations are important, because of potential differences in net-load patterns compared to today (e.g., due to higher renewable-energy penetrations). Using historical data spanning an 18-year period, we demonstrate that concentrating-solar-power plants with thermal energy storage can provide this necessary capacity with little impact on their financial viability. We examine the impact of myopic decisions and imperfect foresight of future system conditions on the operation of concentrating-solar-power plants and the resultant impact on their capacity contributions. We find that imperfect foresight can have limited impacts on such a use of concentrating-solar-power plants, so long as proper forecasting techniques are developed and used. Overall, our work shows that concentrating-solar-power plants with thermal energy storage may have a role to play in delivering reliable electricity supply in a decarbonized energy system.

14 SOLAR ENERGY↗

Assessing the Optical Performance Impact of Tracking Error in an Operational Concentrated Solar Power Plant Using Monte Carlo Ray-Tracing Simulation

Concentrating Solar Power (CSP) provides firm and dispatchable electricity due to its thermal storage and hybridization capabilities, which supports the decarbonization of our energy supply. Of the various CSP technologies, parabolic trough collectors are the most mature, with over 500 MW operating worldwide. The optical performance of parabolic trough systems is sensitive to tracking error, which is defined as the angular offset of a collector away from the sun position in the transversal plane. Tracking error commonly occurs due to non-continuous adjustment of the trough angle to point toward the sun, but other factors such as gravity, heating, and wind loading can also contribute to tracking error. Researchers have explored the impact of tracking error on optical performance both numerically and experimentally, but existing studies do not include measurements from operational utility-scale power plants. Tilt angle measurements of parabolic troughs at operational utility-scale power plants illustrate spatial variations in optical performance and include various sources of tracking error such as gravity, heating, and wind loading. To fully characterize wind driven loads on parabolic troughs, we are conducting a long-term field measurement campaign at the Nevada Solar One CSP plant located in Boulder City, NV, which has a nominal capacity of 72 MW and 0.5 hours of full-load storage. We record load measurements on four outer trough rows, collecting support structure bending moments, drive torque moments, dynamic accelerations of the spaceframe, mirror displacement, and tilt angles. Using the tilt measurements acquired at 20 Hz frequency, we calculate the deviation between the nominal sun position and the tracker angle. Using a Monte-Carlo ray-tracing simulation software, we assess the impact of the tracker angle deviation on optical performance throughout the diurnal cycle at various spatial locations within the CSP plant. In our view, this first-of-a-kind study will provide important guidance for future trough designs that reduce the impact of various sources of tracking error on performance.

concentrating solar power↗

Steady-state off-design modeling of the supercritical carbon dioxide recompression cycle for concentrating solar power applications with two-tank sensible-heat storage

Concentrating solar power researchers are evaluating the potential of the supercritical carbon dioxide recompression cycle to improve the thermal efficiency and decrease the capital costs of next-generation systems. This analysis investigates the steady-state off-design performance of a recompression cycle integrated with two-tank sensible-heat thermal energy storage as the ambient temperature and heat-transfer fluid (HTF) inlet conditions to the cycle change. This paper presents off-design component models and then cycle convergence and control models to maximize net cycle power output while constraining the high-side pressure and air-cooler fan power to their respective design values and fixing the cycle HTF outlet temperature to its design value. Results show that inventory control and air-cooler fan power are important control parameters that can be optimized to maximize off-design power output as the ambient temperature and HTF mass flow rate diverge from design. The high-side pressure and fan power constraints cause the cycle net power to degrade when the ambient temperature is warmer than the design value, and this study calculates a maximum mass flow rate for hot days above which the cycle cannot achieve the design HTF outlet temperature. Finally, the analysis shows that optimizing compressor shaft speeds can improve cold-day performance by around 1.5 percentage points and part-load performance by up to 2.5 percentage points versus a baseline case with no active compressor control.

14 SOLAR ENERGY↗

Analysis and Optimization of the Recompression Cycle with High Temperature Recuperator Bypass for Concentrating Solar Power Applications

This work analyzes the sCO2 recompression with high temperature recuperator (HTR) bypass power cycle for use in concentrating solar power (CSP) systems. CSP operation differs from other thermal power plants in that CSP must balance between maximizing the heat transfer fluid (HTF) temperature difference and maximizing the cycle thermal efficiency, which typically are inversely related. Large HTF temperature differences reduce the size and cost of thermal energy storage (TES), improve the solar receiver efficiency, and require lower mass flow rates that reduce pumping power required to elevate the HTF to the receiver. The recompression cycle with HTR bypass potentially offers improved thermal efficiency with larger HTF temperature differences as compared to the recompression cycle, and it has fewer turbomachinery components than the partial cooling cycle. The recompression with HTR bypass cycle adds a second lower temperature primary heat exchanger which transfers heat from the HTF to the fraction of sCO2 flow that bypasses the HTR. We developed a model to compare the recompression with HTR bypass cycle to the recompression and partial cooling cycles. A sweep of design parameters including bypass fraction, recompression fraction, recuperator conductance, and pressure ratio is used to form a pareto-optimal front with the cycle thermal efficiency and HTF temperature difference as objectives. An optimization routine has also been developed to find optimal design point parameters for a target HTF temperature difference. The performance of the recompression with HTR bypass cycle is compared with recompression and partial cooling cycles.

concentrating solar power↗

UHTC-TPMS Heat Exchangers for Concentrating Solar Power Applications with Thermal Energy Storage in Molten Chlorides

Concentrating solar power (CSP) plants convert energy from sunlight into electricity. Generally, a heliostat field is used to reflect sunlight and concentrate it onto a receiver, which heats the receiver and/or the media flowing through it. A flow loop transports the media through the system to a heat exchanger before returning the media back to the receiver to be reheated. The heat extracted by the heat exchanger is then converted into electricity using a conventional heat engine.

14 SOLAR ENERGY↗

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.↗

Investigation of Best-Practices and Computationally Inexpensive Radiative Exchange Models for Discrete Element Method Modeling of Aluminosilicate Particles in Concentrating Solar Power Environments

Chemically inert, aluminosilicate based particles have been investigated as both a thermal transport and sensible energy storage medium for concentrating solar power facilities. These particles will experience a wide range of operating temperatures (300-1000 K) and handling conditions (dense to dilute falling particle curtains, dense granular flows, or dense structures), requiring specially-designed and optimized infrastructures. The relative influence of collisional and frictional interactions between particles varies based on temperature-dependent particulate properties and greatly impacts the bulk, granular flow behavior. These underlying physics are captured using discrete element method modeling tools. However, this modeling method is computationally expensive as each particle position and interaction is tracked during the simulation. These modeling methods are further complicated by introducing temperature-dependent particle properties, high-temperature radiative exchange, and directional irradiation sources experienced by granular flows in concentrating solar power environments. In this study, coupled experimental and numerical slump testing of aluminosilicate particles was performed and computationally efficient radiative exchange models were evaluated to establish best-practices for discrete element method models for concentrating solar power environments. The three particle types investigated included Carbobead HSP 30 /60, Carbobead CP 30/60, and Granusil 4030. Existing modeling limitations and computationally-efficient multi-modal heat transfer models were evaluated using Aspherix®, a commercial discrete element method software. High-temperature (< 1073 K) slump testing of aluminosilicate particles was performed to investigate the deviation between experimentally-observed and numerically-predicted angles of repose introduced by computation-time reduction practices including the relaxation of the particle elastic modulus and coarse-graining. Coarse-graining is used to use a single modeled particle that is representative of a collection of smaller particles, decreasing the computational cost at the expense of geometric accuracy. Additionally, relaxation of the elastic modulus is used to reduce computational time at the expense of an increased, modeled particle overlap. Prior studies have determined that aluminosilicate particles retain a high elastic modulus at high temperatures (< 1073 K), requiring small simulation timesteps to ensure resolved contact forces resemble appropriate solid mechanics. A parametric study was performed to evaluate the influence of computation time improvements on the deviation between experimental and modeled angle of repose across high temperatures < 1073 K. Additionally, numerical case studies were performed on candidate particle systems at varying porosities and temperatures. These studies were performed to investigate the influence of computationally-efficient radiative-exchange modeling methods coupled to Aspherix® on modeled accuracy and computation time. The recently-developed distance-based approximation was evaluated in estimating radiative exchange between particles and participating surfaces located in close proximity. The distance based approximation was developed to use tabulated estimates of the radiative distribution factor between individual particles and surfaces in close proximity (< 40 particle radii). These methods were expanded to the aluminosilicate particles of interest, including the influence of particle size distributions. To capture radiative exchange between particles and surfaces not in close proximity (> 40 particle radii) and to capture the absorption of directional irradiation from concentrating solar resources, a volumetrically-averaged radiative distribution factor was calculated between the modeled granular flow and surfaces using Monte Carlo ray-tracing for participating media. Volume-averaged absorption and scattering coefficients were predicted using a volumetric discretization of the modeled domain with monodisperse approximations based on geometric optics and experimentally-determined scattering phase functions for aluminosilicate particles.

14 SOLAR ENERGY↗

Evaluation of thermal energy storage for central receiver concentrating solar power plants under charging cycles through structural assessment

Electricity production by concentrated solar power (CSP) systems has stood out among energy transition alternatives due to their large generation capacity (between 30 MW and 400 MW) and high capacity factor (80%) when incorporating thermal storage systems (TES). Although TES tanks in operation worldwide are made of austenitic steels with remarkable mechanical and anticorrosive properties, operational failures have been reported due to low-cycle fatigue, creep, and the abrupt release of residual stresses generated during tank manufacturing. A critical operation for salt tanks is the initial daily charging operation, given the low fluid level and the thermal gradients between the inventory and the salt entering the tank. This study presents a structural simulation of a 39.6 m-diameter molten salt tank for central receiver CSP plants, accounting for temperature and pressure variations during charging and different sparger ring inlet configurations. The initial pre-stressed condition of the floor, resulting from the manufacture of welded plates, is used as a boundary condition. The fatigue and creep life analyses were performed in accordance with the ASME BPVC and API standards. It was found that the tank's floor is in a less favourable mechanical condition than the wall, due to its initial manufacturing condition and the maximum temperature differences during charging. A critical zone was identified in an area affected by residual stress on the floor and under the sparger ring. The baseline sparger ring configuration, with 52 2-inch-diameter orifices and a flow direction of 90 degrees , results in an average floor stress of approximately 25 MPa and creep damage after 1.2 years of tank operation.

14 SOLAR ENERGY↗

Black-Box Optimization for Design of Concentrating Solar Power and Photovoltaic Hybrid Systems with Optimal Dispatch Decisions

The hybridization of concentrating solar power (CSP) and photovoltaics (PV) can enable dispatchable renewable electricity generation at a lower price than current stand-alone CSP systems. However, designing a CSP-PV hybrid system can be challenging because of the many degrees of freedom in design that affect the internal and external system interactions and trade-offs. We develop a methodology to determine optimal designs for CSP-PV hybrids by implementing NLopt's derivative-free, or “black-box,” algorithms around pre-existing CSP-PV hybrid simulation software that utilizes the National Renewable Energy Laboratory’s System Advisor Model (SAM); we then employ a dispatch optimization model to determine operational decisions that maximize a plant’s profits. We present optimal designs for CSP-PV hybrid systems dispatching against four time-of-delivery (ToD) pricing structures. NLopt’s algorithms can improve the base case design’s power purchase agreement (PPA) price by 15% to 21%, depending on the ToD pricing structure. In addition, we present the resulting optimal CSP-PV hybrid design’s annual performance metrics, which tend to have capacity factors between 50% and 62%, but are able to generate electricity during the year’s highest-valued periods about 90% of the time. Lastly, we investigate the trade-offs between capacity factor and PPA price using Pareto fronts and demonstrate that, for some ToD pricing structures, the system capacity factor can increase by 20% but at the expense of a 2% increase in PPA price.

black-box↗

Addressing Failures in Molten Salt Thermal Energy Storage Tank for Central Receiver Concentrating Solar Power Plants

The thermal energy storage (TES) system is a critical component in concentrated solar power (CSP) plants that increases the plant's capacity factor and economic competitiveness by reducing the levelized cost of energy (LCOE) while simultaneously increasing the value of the delivered energy. Failures including molten-salt leaks and diverse localized cracking after several months to a few years of operation have been reported in hot tanks for CSP plants operating around the world. A model of a molten salt thermal energy storage tank was developed and validated to analyze the impact of different tank design features on the temperature and stress distributions as a function of typical plant operation conditions. Design features included the floor plate thicknesses, friction coefficients between the tank floor and the foundation, and the sparger ring location. Maximum stresses in the tank floor frequently surpassed the yield point of the material during operation, leading to a detriment of the tank's lifetime. Recommendations on design features to improve the reliability of new molten salt tanks for CSP plants are provided.

concentrating solar power↗

The material challenges of the next generation of concentrated solar power

This is an introductory seminar about the cleantech-to-market pathway with a focus on material innovation in Concentrated Solar Power. This seminar will first lay out the business model of cleantech companies to identify the players in technical innovation. With a summary of the desires of the major player, this seminar will dive into the possibility, potential, and challenges of next-generation Concentrated Solar Power to answer these desires, followed by a detailed discussion on the material challenges. The scope of our project “Scalable, Infiltration-Free Ceramic Matrix Composite for the molten salt receiver” will be presented as one potential way to solve these challenges. In the end, this seminar will present some job opportunities to inspire the audience to participate in cleantech innovation.

42 ENGINEERING↗

Thermophysical Properties Experimentally Tested for NaCl-KCl-MgCl 2 Eutectic Molten Salt as a Next-Generation High-Temperature Heat Transfer Fluids in Concentrated Solar Power Systems

A new eutectic chloride molten salt, MgCl 2 -KCl-NaCl (wt% 45.98–38.91–15.11), has been recognized as one of the most promising high-temperature heat transfer fluids (HTF) for both heat transfer and thermal storage for the third-generation concentrated solar power (CSP) systems. For the first time, some essential thermophysical properties of this eutectic chloride molten salt needed for basic heat transfer and energy storage analysis in the application of concentrating solar power systems have been experimentally tested and provided as functions of temperature in the range from 450 °C to 700 °C. The studied properties include heat capacity, melting point, heat of fusion, viscosity, vapor pressure, density, and thermal conductivity. The property equations provide essential database for engineers to use to calculate convective heat transfer in concentrated solar receivers, heat exchangers, and thermal storage for concentrated solar power plants.

14 SOLAR ENERGY↗