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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 OSTI2020

GEOPHIRES Simulations for Deep Direct Use (DDU) Projects

This folder contains the GEOPHIRES codes and input files for running the base case scenarios for the six deep direct-use (DDU) projects. The six DDU projects took place during 2017-2020 and were funded by the U.S. Department of Energy Geothermal Technologies Office. They investigated the potential of geothermal deep direct-use at six locations across the country. The projects were conducted by Cornell University, West Virginia University (WVU), University of Illinois (U of IL), Sandia National Laboratory (SNL), Portland State University (PSU), and National Renewable Energy Laboratory (NREL). Four projects (Cornell, WVU, U of IL, SNL) investigated geothermal for direct heating of a local campus or community, the project by PSU considered seasonal subsurface storage of solar heating, and the NREL project investigated geothermal heating for turbine inlet cooling using absorption chillers. To allow comparison of techno-economic results across the six DDU projects, GEOPHIRES simulations were set up and conducted for each project. The GEOPHIRES code was modified for each project to simulate the local application and incorporate project-specific assumptions and results such as reservoir production temperature or financing conditions. The base case input file is included which simulates the base case conditions assumed by each project team. The levelized cost of heat (LCOH) is calculated and matches the base case LCOH reported by the project teams.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Heliostat sizing methodology for concentrating solar thermal industrial process heat projects

This study presents a method to obtain a heliostat size that minimizes the levelized cost of heat (LCOH) of a heliostat-based concentrating solar thermal system for applications of solar heating for industrial processes at operating temperatures from 565 to 1550°C. The method extends prior work by embedding a routine for system design that obtains near-optimal subsystem sizes, increasing the fidelity of drive cost functions, and adding an optical performance model to supplement the previously developed cost models, which we update to reflect current pricing trends. An illustrative business case is developed for Daggett, California, targeting specified annual thermal energy outputs of 50 to 400 GWh th . Optical performance is modeled using verified estimates from the literature. A surrogate heliostat cost model, derived from commercial heliostat designs and scaled for production volume, installation, and operations and maintenance costs, is used to develop cost functions. Results show that heliostat size strongly affects the LCOH, producing a characteristic U-shaped trend with a robust near-optimal window of 7-20 m 2 ; the heliostat size producing the lowest project cost in our study grows slightly as the project size increases, and is reduced as the operating temperature increases. The findings in this study are consistent with the general trend of smaller heliostats being deployed at existing projects for high-temperature industrial process heat and reflect the significant reduction in power electronics and other per-heliostat costs. The methodology we propose is general and can be tailored to revised cost curves as the technology continues to evolve.

14 SOLAR ENERGY↗
DOE OSTI2024

Thermal and Well Flow Performance of Closed-Loop Geothermal in the Wattenberg Area: Preprint

Closed-loop geothermal systems provide an alternative to resource-constrained hydrothermal systems and stimulation-intensive enhanced geothermal systems. In this work, we apply the slender-body theory (SBT) model, to simulate the well flow and heat transfer performance of U-loop well designs drilled in the Wattenberg area of the Denver-Julesburg Basin. Three U-loop well patterns are investigated including a single, double, and multi-lateral design. The subsurface within area is characterized by deep, hot (> 200degreesC) igneous/metamorphic basement rock underlying multiple sedimentary formations. The lateral section(s) of the U-loop lies within a target depth of 6 km where temperatures are estimated to approach 300degreesC. As a base case, conduction-only heat transfer is investigated through simulations with the SBT model within U-loops with open-hole laterals that exchange heat directly with the hot dry rock using water as a working fluid. The utilization of supercritical CO2 as a heat transfer fluid is also considered. For each scenario, the system performance in terms of annual heat production and temperature profile over a 20-year project lifetime are assessed. Also, the levelized costs of heat and electricity (LCOH and LCOE) are determined using a top-down technoeconomic analysis model. The results show that the performance and cost optimized U-loop design is one having an injection-production well spacing of 1,000 meters with ten 50-meter-spaced laterals that traverse a subsurface system with a temperature gradient of 60degreesC/km. By injecting 20 degreesC-water at a rate of 60 kg/s through this loop, an average heat production of 19 MWth can be achieved, resulting in an LCOE and LCOH of $136/MWh and $1.53/GJ, respectively, over a 20-year project life.

closed-loop geothermal↗
DOE OSTI2025

Thermal and Well Flow Performance of Closed-Loop Geothermal in the Wattenberg Area

Closed-loop geothermal systems provide an alternative to resource-constrained hydrothermal systems and stimulation-intensive enhanced geothermal systems. In this work, we apply the slender-body theory (SBT) model, to simulate the well flow and heat transfer performance of U-loop well designs in the Wattenberg area of the Denver-Julesburg Basin. Three U-loop well patterns are investigated, including a single-, double-, and multi-lateral design. The subsurface within the area of interest is characterized by deep, hot (> 200 degrees C) igneous/metamorphic basement rock underlying multiple sedimentary formations. The lateral section(s) of the U-loop lie(s) within a target depth of 6 km, where temperatures are estimated to approach 300 degrees C. As a base case, conduction-only heat transfer is investigated through simulations with the SBT model within U-loops with open-hole laterals that exchange heat directly with the hot, dry rock using water as a working fluid. The utilization of supercritical CO2 as a heat transfer fluid is also considered. For each scenario, the system performance in terms of annual heat production and temperature profile over a 20-year project lifetime are assessed. Also, the levelized costs of heat and electricity (LCOH and LCOE) are determined using a top-down techno-economic analysis model. The results show that the performance- and cost-optimized U-loop design is one having an injection-production well spacing of 1,000 meters with ten 50-meter-spaced laterals that traverse a subsurface system with a temperature gradient of 60 degrees C/km. By injecting 20 degrees C-water at a rate of 60 kg/s through this loop, an average heat production of 19 MWth (i.e., 2.2 MWe net plant output) can be achieved, resulting in an LCOE and LCOH of $136/MWhe and $1.53/GJ, respectively, over a 20-year project life.

closed-loop geothermal↗
DOE OSTI2021

An Integrated Feasibility Study of Reservoir Thermal Energy Storage (RTES) in Portland, OR, USA

In regions with long cold overcast winters and sunny summers, Deep Direct-Use (DDU) can be coupled with Reservoir Thermal Energy Storage (RTES) technology to take advantage of pre-existing subsurface permeability to save summer heat for later use during cold seasons. Many aquifers worldwide are underlain by permeable regions (reservoirs) containing brackish or saline groundwater that has limited beneficial use due to poor water quality. We investigate the utility of these relatively deep, slow flowing reservoirs for RTES by conducting an integrated feasibility study in the Portland Basin, Oregon, USA, developing methods and obtaining results that can be widely applied to RTES systems elsewhere. As a case study, we have conducted an economic and social cost-benefit analysis for the Oregon Health and Science University (OHSU), a teaching hospital that is recognized as critical infrastructure in the Portland Metropolitan Area. Our investigation covers key factors that influence feasibility including 1) the geologic framework, 2) heat and fluid flow modeling, 3) capital and maintenance costs, 4) the regulatory framework, and 5) operational risks. By pairing a model of building seasonal heat demand with an integrated model of RTES resource supply, we determine that the most important factors that influence RTES efficacy in the study area are operational schedule, well spacing, the amount of summer heat stored (in our model, a function of solar array size), and longevity of the system. Generally, heat recovery efficiency increases as the reservoir and surrounding rocks warm, making RTES more economical with time. Selecting a base-case scenario, we estimate a levelized cost of heat (LCOH) to compare with other sources of heating available to OHSU and find that it is comparable to unsubsidized solar and nuclear, but more expensive than natural gas. Additional benefits of RTES include energy resiliency in the event that conventional energy supplies are disrupted (e.g., natural disaster) and a reduction in fossil fuel consumption resulting in a smaller carbon footprint. Key risks include reservoir heterogeneity and a possible reduction in permeability through time due to scaling (mineral precipitation). Lastly, a map of thermal energy storage capacity for the Portland Basin yields a total of 43,400 GWh, suggesting tremendous potential for RTES in the Portland Metropolitan Area.

14 SOLAR ENERGY↗
DOE OSTI2023

Durable and Low-Cost Fractal Structured Multifunctional Coatings for Next-Generation CSP

Fractal coatings on various low-cost and high-temperature metallic substrates such as SS316, SS347, In800H, In740H, In625, Haynes 230, etc. were fabricated employing our patented novel electrodeposition process at various deposition potentials and deposition times, as well as chemical etching. The best combination of the materials and processing conditions were co-optimized for the reliable and repeatable fabrication of the multifunctional coatings. Surface morphologies were examined using SEM and AFM, and fractal characterization was done using a 3D optical surface profiler. Fractal dimension was used to identify successful fabrication and material parameters. The mechanical durability of the coatings was evaluated using several standardized tests, such as sand abrasion (ASTM D968) and adhesion (ASTM D3359), to fully characterize and demonstrate the mechanical durability of the fabricated surfaces. HTF immersion tests on the fractal multifunctional coatings were conducted based on a modification of the ASTM D870, which is established for static water immersion testing. To calculate the corrosion rates and descaled weight loss of the samples subjected to thermal exposure for different time durations (100 h, 300 h, 500 h, and optionally 750 h) to estimate the corrosion rate. While protecting the substrates from corrosion is an important goal, an allied goals is also to examine the post-corrosion temperature stability and properties of the molten salts themselves due to the dissolution of the constituents of the alloys and the corrosion products from the coatings that cause “fouling” of the molten salts. Fouling characteristics of the different molten salt HTFs exposed to coated and uncoated substrates were investigated. Finally, considering a prototype molten salt/sCO2 heat exchanger, cost/performance model is developed to demonstrate that the coatings on low-cost alloys such as stainless steel provide lower levelized cost of heat exchanger compared to high nickel content Ha230.

14 SOLAR ENERGY↗
DOE OSTI2024

Case Studies and Parametric Analysis of Heliostat Performance With a Tradeoff-Informed Technoeconomic Analysis Metric

The Heliostat Consortium (HelioCon) was launched in 2021 to advance heliostat technology. Here this work presents a collection of baseline case studies for the technoeconomic analysis (TEA) of candidate heliostat improvements for concentrating solar power (CSP) and concentrated solar thermal (CST) systems that employ central receivers. The case studies we develop include a large-scale CSP plant, a smaller, modular CSP plant, and a small CST plant used for industrial process heat. In this work, we also 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. Finally, we perform a parametric analysis to show the impact of candidate technologies on the levelized cost of heat and, by extension, equivalent breakeven installed cost.

14 SOLAR ENERGY↗
DOE OSTI2021

Renewable Thermal Energy Systems Designed for Industrial Process Solutions in Multiple Industries

The need for renewable heat in industry is vital for the next decade and beyond. Industrial decarbonization is a key area that must be accelerated, to foster the removal of fossil fuels from the provision of heat, especially at low temperatures. This paper looks at the development and results of case studies for understanding the economics and potential for renewable thermal energy systems (RTES), particularly in hybrid configurations to provide industrial process heat (IPH). For the case studies, these include non-concentrating e.g., heat pumps, and concentrating collectors e.g., parabolic trough collectors and direct steam generation (DSG)-linear Fresnel collectors (LFCs). The results show that a levelized cost of heat (LCOH) of $6-$8 per million British Thermal Units (MMBTU) is possible, depending on the direct normal irradiance (DNI) and the system sizing e.g., to increase the solar fractions. In Arizona for example, with a DNI of 7.36 kWh/m2/day, the base case for the DSG-LFC system with 6hrs of thermal energy storage could potentially meet a 1 MWth load 80% of the year.

concentrated solar thermal↗
DOE OSTI2021

Geothermal Heat Recovery Complex: Large-Scale, Deep Direct-Use System in a Low-Temperature Sedimentary Basin (Final Report)

A feasibility study of using deep direct-use (DDU) geothermal energy to heat agricultural research facilities (ARFs) was conducted at the University of Illinois at Urbana-Champaign (U of IL) and its similar application to military facilities in the Illinois Basin (ILB). The geothermal energy system (GES) investigated utilizes low-temperature (30–90°C; 90–190°F) geothermal fluid (i.e., brine) from an extraction well that is part of a deep, two-well (doublet) system that extends to the bottom of the ILB. The geothermal reservoir modeled, the Mt. Simon Sandstone (MSS), is about 1,280 m (4,200 feet) deep and 457 m thick (1,500 feet) beneath the U of IL. The DDU GES surface infrastructure includes heat exchangers connected in-parallel to pipelines carrying the geothermal fluid and fresh cold and hot water. Analysis of the GES indicated that the MSS can provide a baseload of 2 MMBtu/hr to heat the ARFs by extracting 954 m³/d (6,000 barrels/day [bbl/d]) of geothermal fluid that has a temperature of 44–46 °C (111–115 °F). In addition to analyzing the levelized cost of heat (LCOH) and life cycle costs, the environmental effects of the DDU GES were evaluated, including reduced greenhouse gas (GHG) emissions and water consumption. Multiple system designs were evaluated and then ranked based on their maximum heating performance, energy efficiency, and cost recovery. This feasibility study identified the key components of the fully-integrated DDU technology that can be implemented, both technically and economically. The results and information from this study provides end-users and policy makers with guidance for additional research on the specific components of DDU technology such that its widespread use can provide an uninterruptible energy source, increase resilience from extreme weather conditions, reduce U.S. dependency on fossil fuels, and reduce greenhouse gas (GHG) emissions. The site-specific part of this study gives U of IL administrators a realistic and pragmatic assessment of the financial resources necessary to add a DDU GES in the MSS to the campus’ energy portfolio.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Techno-Economic Performance of Eavor Loop 2.0

This project evaluated techno-economic performance for a sample Eavor-Loop 2.0 design for electricity production and direct-use heating. The Eavor-Loop 2.0 design investigated is a 7.5-km deep closed-loop geothermal system consisting of 12 laterals for a total of more than 90 km of downhole well and lateral length. Both a high geothermal gradient scenario of 60 degrees C/km and a low geothermal gradient scenario of 30 degrees C/km were considered. With pure water injected at 60 degrees C and 80 kg/s, reservoir simulations with the Slender-Body Theory simulator indicate average production temperatures over a 30-year lifetime of ~125 degrees C and ~210 degrees C for the low and high geothermal gradient scenario, respectively. These correspond to heat production of ~22 M Wth and ~51 M Wth, respectively. Using IPSEpro simulations, we find average power production of ~2.2 M We and ~8.6 M We, respectively, for a subcritical organic Rankine cycle power plant with air-cooled condensers. Cost estimates indicate the overall capital and levelized costs are dominated by the lateral drilling cost. Obtaining a levelized cost of electricity below $70/M Wh requires a geothermal gradient of 60 degrees C/km, a discount rate below 9%, and lateral drilling cost below $400/m. A well cost model indicates that ~$400/m for the Eavor-Loop 2.0 design investigated can be obtained for a drilling rate of penetration about 40 ft/hr (with bit life of 50 hours), and omitting casing and cement. Traditional (geothermal) well drilling has achieved these drilling rate conditions, including the Utah FORGE project where the rate of penetration has exceeded 50 ft/hr in granite. However, it is unclear if these conditions are still valid for drilling the Eavor-Loop 2.0 laterals (i.e., ~82 km of laterals at 4 to 7.5-km vertical depth with rock temperatures up to 460 degrees C), as such downhole completion has never been developed before. Competitive levelized cost of heat values ($1.2-$8.2/GJ) are calculated, even for the low geothermal gradient scenario (30 degrees C/km) and lateral drilling cost of $600/m.

advanced geothermal system↗
DOE OSTI2024

Techno-Economic Simulation Results Using dGeo for EGS-Based District Heating in the Northeastern United States

This dataset presents the results of techno-economic simulations performed using the Distributed Geothermal Market Demand Model (dGeo) to evaluate the feasibility of Enhanced Geothermal Systems (EGS)-based district heating in the Northeastern United States. Developed by the National Renewable Energy Laboratory (NREL), dGeo is a geospatially resolved, bottom-up modeling framework designed to explore the deployment potential of geothermal distributed energy resources. The dataset, created as part of the Cornell EGS Ground-Truthing Project, provides census tract-level data that includes inputs and outputs such as thermal demand, road length, energy prices, geothermal system sizing, annual energy contributions from geothermal and natural gas peaking boilers, system capital costs (CAPEX), operation and maintenance costs (OPEX), and the levelized cost of heat (LCOH). Key simulation parameters include geothermal gradients, measured well depths, production temperatures, and district heating piping lengths based on S1400 neighborhood road lengths. The simulations assume a target bottom hole temperature of 80C and the development of new district heating networks in each census tract.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Techno-economic design of a linear Fresnel reflector for industrial process heat

A techno-economic model of a Concentrating Solar Thermal (CST) system using a Linear Fresnel Reflector (LFR) has been developed. LFRs can deliver process heat suitable for a range of industries, including food and beverage production. This model uses an adaptive algorithm to calculate the optimal secondary reflector shape given the geometry and optical properties of the rest of the system. A ray-tracing program is used to calculate optical efficiency over a wide range of longitudinal and transversal incidence angles and subsequently evaluate the annual efficiency at a given geographical location. A specific LFR design developed by Hyperlight Energy was modelled, and this industrial partner provided a detailed cost breakdown which was used as the basis of an economic model. Combining the technical and economic data facilitates the calculation of the Levelized Cost of Heat (LCOH). The influence of a number of parameters on the annual efficiency and LCOH is explored; notable parameters include the absorber height, the number, width, and spacing of the primary mirrors, the aim point, and the secondary reflector shape and width. By identifying an optimal combination of these parameters, we reduce the LCOH of the industry partner’s system design by 9.2%, from 14.4 $\$/MWh_{th}$ to 13.0 $\$/MWh_{th}$. In comparison, the LCOH of a natural gas boiler delivering the same annual quantity of heat is 29 $\$/MWh_{th}$, which indicates that LFRs can be a competitive heat source for industrial processes.

14 SOLAR ENERGY↗
DOE OSTI2022

Renewable Thermal Hybridization Framework for Industrial Process Heat Applications

Solar industrial process heat (SIPH) technologies, such as concentrating solar power collectors, could economically replace the steam or heat needs at many industrial sites by providing high-temperature heat transfer fluids (HTFs) such as pressurized water, synthetic-oil, or direct steam. Renewable thermal energy systems (RTES) could be hybridized with different renewable options e.g., flat plate collectors with parabolic trough collectors, or combined with existing heat supplies (e.g., fossil fuels), to give options for targeted SIPH applications, industrial decarbonization and the reduction of fuel consumption. Hybrid solutions and thermal energy storage will be important for the dispatch of heat at optimal times needed by the demand side of the buildings and industrial applications. At present, there is no integrated modeling tool for hybrid RTES, and this paper highlights the development of a renewable thermal hybridization framework for IPH use that is built from existing tools like System Advisor Model. The long-term vision for the framework (through significant further research) is to develop a coupled hybrid energy generation and cost analysis tool, where the tool could help the user in determining the most suitable and cost-effective technologies for their applications. Ongoing work will look to add costs for RTES options and further refinement on the selection of suitable technologies. This future tool could calculate the levelized cost of heat of various RTES hybrid options, by taking the user's solar resource, fuel costs, industrial heat demand profile, available land, and other factors into account to determine the applicability into their process.

concentrating solar power↗
DOE OSTI2020

Deep Direct-Use Geothermal Feasibility Study for Hawthorne NV

The Hawthorne Nevada, deep direct-use geothermal study is a two-year effort funded by the U.S. Department of Energy to determine the techno-economic feasibility of implementing a large-scale, direct-use facility for the Hawthorne Army Depot (HAD) and the public facilities of the city of Hawthorne and Mineral County. The approach links a production side analysis (PSA) and a demand side analysis (DSA) into a whole-system analysis (WSA) to provide an integrated assessment of the resource and the probability of delivering economically viable direct-use energy to Hawthorne. Hawthorne, Nevada is in the western part of the Basin and Range province and has been the focus of geothermal investigations for over 40 years. Over the last 15 years, several studies completed by the U.S. Navy Geothermal Program Office (GPO) in conjunction with industry professionals quantified the existence of several low temperature geothermal prospects, the most promising of which is called Prospect A. The promise of Prospect A is based on drilling and flow testing that produced ~100 °C water at flow rates of up to 31 l/s (500 gallons per minute). Measured productivity indexes range from 40-85 l/s/MPa, suggesting a warm and productive heat source. Despite the promise of the resource, uncertainties in its spatial extent and long-term sustainability mean that techno-economic analyses must include probabilities of the sustainability of the resource under different operating scenarios. Here, the PSA is conducted by integrating a wide range of disparate data to estimate lognormal P90, P50, and P10 resource capacities. These capacities are used as input to a thermal-hydrologic (T-H) model to estimate thermal drawdown for each capacity estimate for several different DSA scenarios. Using a systems-based approach, the WSA links the dynamic T-H simulations of the PSA/DSA combinations with the techno-economic model GEOPHIRES to account for both the temporal dynamics and uncertainties in the system to produce probabilistic distributions of several performance metrics including the levelized cost of heat (LCOH) and the return on investment (ROI). This report is the final delivery for the project and documents the study's activities and results.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Navigating Economies of Scale and Multiples for Nuclear-Powered Data Centers and Other Applications with High Service Availability Needs

Nuclear energy is increasingly being considered for such targeted energy applications as data centers in light of their high capacity factors and low carbon emissions. This paper focuses on assessing the tradeoffs between economies of scale versus mass production to identify promising reactor sizes to meet data center demands. A framework is then built using the best cost estimates from the literature to identify ideal reactor power sizes for the needs of the given data center. Results should not be taken to be deterministic but highlight the variability of ideal reactor power output against the required demand. While certain advocates claim that with the gigawatts of clean, firm energy needed, large plants are ideal, others advocate for SMRs that can be deployed in large quantities and reap the benefits from learning effects. The findings of this study showcase that identifying the optimal size for a reactor is likely more nuanced and dependent on the application and its requirements. Overall, the study does show potential economic promise for coupling nuclear reactors to data centers and industrial heat applications under certain key conditions and assumptions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Minimizing grid energy consumption in wastewater treatment plants: Towards green energy solutions, water sustainability, and cleaner environment

Wastewater treatment plants (WWTPs) consume significant amount of energy to sustain their operation. From this point, the current study aims to enhance the capacity of these facilities to meet their energy needs by integrating renewable energy sources. The study focused on the investigation of two primary solar energy systems in As Samra WWTP in Jordan. The first system combines parabolic trough collectors (PTCs) with thermal energy storage (TES). This system primarily serves to fulfill the thermal energy demands of the plant by reducing the demands from boiler units, which allows more biogas for electricity generation. The second system is a photovoltaic (PV) system with Lithium-Ion batteries, which directly produces electricity that will be used to cover part of the electrical energy demands of plant. To assess the optimal configuration, two distinct scenarios have been formulated and compared to the current case scenario (SC#1). The first scenario focuses on maximizing the net present value (NPV) and minimizing the levelized cost of electricity (LCOE). The second scenario is centred on minimizing the levelized cost of heat (LCOH). The findings indicate that both scenarios succeeded in reducing the reliance on the grid to a value that reach 1 %. Moreover, they both reduced biogas percentage in energy production from 88 % to approximately 65 % through the integration of the PV system. In terms of thermal demand, SC#2 reduced the reliance on biogas boiler units from 100 % to 25 %, while SC#3 achieved an even more impressive reduction to just 8 %. The best LCOE value was attained in SC#2, at 0.0895 USD/kWh, with an NPV of 10.54 million USD. Conversely, SC# 3 yielded an LCOH value of 0.0432 USD/kWh th compared to 0.0534 USD/kWh th USD for SC#2. In conclusion, despite their relatively high capital and operating costs, SC#2 and SC#3 managed to substantially decrease the annual electricity expenditure from approximately 2 million USD to 86,000 USD and 0 USD, respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗
DOE OSTI2023

The Internal Compound Parabolic Concentrator (ICPC): a Novel Low Cost Solar Thermal Collection System for Desalination Processes

The research team at UC Merced designed, prototyped, and tested (1) a novel low cost non-tracking solar thermal collector/concentrator called the Integrated Compound Parabolic Concentrator (ICPC) and (2) a low-cost phase-change thermal energy storage system. Together these technologies can significantly reduce the levelized cost of heat from solar thermal sources while also incorporating features of dispatchability and portability. The ICPC allows elevated temperature and efficiency in a low cost, non-tracking collector. The collector has demonstrated 60% ±4% solar to thermal modules efficiency at fluid outlet temperature of 120°C. The raw material cost of the collector system is reduced by utilizing low cost aluminum minichannels. The collector design is also amenable to economic mass production. A 200 tube, 10 kW prototype array was constructed and tested, yielding over 6 kWh/day on average at outlet fluid temperature exceeding 120°C.

14 SOLAR ENERGY↗