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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Designing a Particle Flow Control Apparatus

Flow control within a particle-based Concentrated Solar Power (CSP) system is essential in determining the heat transfer coefficient, and therefore, the power generation capability of these systems. There are three areas where particle flow control is significant: the receivers, storage tanks, and particle-sCO2 heat exchangers. The focus of this work is on designing a new mechanism to control the flow in the particle-sCO2 heat exchangers due to the simplicity and potential cost savings when compared to the other areas of interest. The goal is for this new design to have quicker response times in terms of particle flowrate than a slide gate or flow control valve, which are designs currently used. The design resembles that of a chuck mechanism within a drill where a rotation of the sleeve elicits movement of the jaws both vertically and horizontally to close the outlet area of the nozzle. Additionally, this design will utilize the current actuator that is already used within these heat exchangers to reduce the complexity of implementation. The jaws are designed to be closed at an angle of 76˚ which is just slightly steeper than the hopper leading to the mechanism. Furthermore, this design can be tuned to limit particle bridging and other particle flow phenomena that result in blockages. The prototypes were 3D printed out of polylactic acid (PLA) and scaled up to 100%, 200%, and 400% to be able to observe the velocity profiles of the mechanism more clearly. Experiments are performed with this prototype to compare the inlet and outlet mass flow rates at different configurations of the jaws. The particles used in these experiments are 0.3mm HSP 40/70 that are commonly used in particle-based CSP systems.

14 SOLAR ENERGY↗
DOE OSTI2022

Initial Heliostat Supply Chain Analysis

Globally, the growing demand for concentrating solar power (CSP) technologies, primarily for electricity generation plants has been met with supply chains primarily composed of plentiful commodity materials such as steel, aluminum, and glass. Often the majority of the commodity materials are sourced within the domestic market where generating plants are constructed. Although specialty components are required for CSP solar field components - including mirror panels used for heliostat applications - these specialty components constitute about 30-50% of total system installed costs. Only a few companies and countries, including the United States, have developed the capacity to supply such specialty components. This report is an initial assessment of the global and U.S. heliostat supply chain.

14 SOLAR ENERGY↗
DOE OSTI2021

Novel Binderjet Additive Heat Exchangers: A Pathway to 5¢/kWh CSP

General Electric (GE) Research is developing a Binderjet manufacturing processes and heat exchanger core design to enable low-cost high temperature Recuperators (HTR) for Concentrated Solar Power (CSP) supercritical carbon dioxide (sCO2) power cycles. The objective is to show a path for greater than or equal to 10% cost reduction for an HTR that enables meeting the DOE SunShot goal of 5c/kWh for CSP plants. As part of the DOE program, GE is developing a novel trifurcating heat exchanger (HX) for HTR using binderjet additive manufacturing process that could meet the cost targets. As part of the 2021 CSP summit presentation, GE demonstrates that the build control of HX cores using the binderjet process are within the program targets. Preliminary cost estimates of the overall heat exchanger using a modular HX design shows cost reductions greater than 10% target allowing significant margin for assembly and inspections costs. Additional cost reduction plans are also highlighted.

14 SOLAR ENERGY↗
DOE OSTI2022

Facility to Alleviate Salt Technology Risks (FASTR): Design Report

The Facility to Alleviate Salt Technology Risks (FASTR) is a versatile, high-temperature (>600°C) molten chloride salt test facility designed to enable a variety of testing to advance the Generation 3 (Gen 3) Concentrated Solar Power (CSP) molten salt technology. FASTR includes a salt preparation system and a forced flow test loop with a suite of instrumentation. The FASTR loop is capable of 725°C operation and flow rates of 3–7 kg/s, and it includes heated and cooled sections and swappable components to enable testing of future vendor-supplied hardware. The salt preparation system supplies large batches (e.g., 200 kg) of clean salt for use in the FASTR forced convection loop. This report summarizes the design and capabilities of FASTR in its as-built form as of December 2022.

14 SOLAR ENERGY↗
DOE OSTI2023

Facility to Alleviate Salt Technology Risks (FASTR): Commissioning Update

The Facility to Alleviate Salt Technology Risks (FASTR) is a versatile, high-temperature (>600°C) molten chloride salt test facility designed to enable a variety of testing to advance the Generation 3 (Gen 3) concentrated solar power (CSP) molten salt technology. FASTR includes a salt preparation system and a forced flow test loop with a suite of instrumentation. The FASTR loop is capable of operating at 725°C with flow rates of 3–7 kg/s, and it includes heated and cooled sections and swappable components to facilitate testing future vendor-supplied hardware. The salt preparation system supplies large batches of clean salt for use in the FASTR forced circulation loop. This report summarizes the shakedown and initial operation of the FASTR forced circulation loop through December 2022.

14 SOLAR ENERGY↗
DOE OSTI2023

Re-Designing the CSP Thermal Energy Storage System to Enable Higher-Temperature Performance at Reduced Cost (Final Technical Report)

Current commercial concentrating solar power (CSP) plants distinguish themselves from ordinary photovoltaic (PV) power plants by storing enough collected energy to enable generation for several hours after the sun goes down. CSP plants store this energy in the sensible heat of nitrate salts in large metallic storage tanks. Stainless-steel AISI 347H (SS347H) is needed for the hot tank operating at about 565 degrees C whereas carbon steel is sufficient for the cold-tank materials. Two-tank nitrate-salt thermal energy storage (TES) is presently in use in several trough-based CSP plants in Europe and in the U.S., operating up to about 390 degrees C. Three commercially operating tower-based CSP plants - Gemasolar in Spain, Crescent Dunes in Nevada, and Noor III in Morocco - use the same approach, storing nitrate salts at temperatures up to 580 degrees C. SS347H is many times more expensive than carbon steel and constitutes a significant cost element in today's CSP plants. Hence, CSP developers need to close the cost gap with PV-based solar plants by making cost reductions in every system of the plant. Redesigning the TES tanks is one opportunity for cost reduction.

14 SOLAR ENERGY↗
DOE OSTI2022

Development of In-Situ Corrosion Kinetics and Salt Property Measurements (Final Technical Report)

The goal of this research is to fill the knowledge gaps of salt properties and gain a fundamental understanding of corrosion mechanisms, thereby to guiding material selections of salts and containment materials. The proposed research is focused on building unique cross-cutting research capabilities that can perform research and analysis relevant to the following three research topics important for Generation 3 Concentrating Solar Power Systems: (1) Material characterization including investigations of fluid thermophysical properties and stability, (2) Durability testing of containment materials, and (3) Corrosion behavior characterization relative to levels of known contaminants (e.g., water and oxygen) in Heat Transfer Fluid (HTF).

14 SOLAR ENERGY↗
DOE OSTI2023

Digital Twin Development of FASTR

This work package is focused on creating a digital twin (DT) of the Facility to Alleviate Salt Technology Risks (FASTR) experiment. FASTR is a high-profile facility tasked with maturing molten salt applications such as liquid salt energy storage, concentrated solar power facilities, and molten salt cooling systems supporting other advanced reactor technologies, all of which may be incorporated as components within the Integrated Energy Systems (IES) program. As part of creating a digital twin (DT), verification and validation (V&V) has been performed for the physics-based model, and gaps have been identified. Additionally, a preliminary integration of the FASTR model has been completed with the existing physics-based model of the Thermal Energy Distribution System (TEDS)/Microreactor AGile Non-nuclear Experimental Testbed (MAGNET) facility at Idaho National Laboratory (INL). A Functional Mock-up Unit (FMU) of the physics-based system model and a reduced-order model (ROM) were both used to test for a preliminary hardware in the loop operation when the physical loop was offline. Future tasks could include improving the physics-based model to better match the available experimental data, improving the hardware in the loop integration, and improving the integration with the TEDS model.

14 SOLAR ENERGY↗
DOE OSTI2023

Clear-Sky Probability for the 2023 Annular Solar Eclipse and the 2024 Total Solar Eclipse Using the NREL National Solar Radiation Database

The National Renewable Energy Laboratory (NREL) and collaborators have created a clear-sky probability analysis to help guide viewers to the 2023 annular solar eclipse and the 2024 total solar eclipse. Using cloud and solar data from the NREL National Solar Radiation Database (NSRDB), the analysis provides cloudless-sky probabilities specific to the date, time, and location of each eclipse with a 4-km resolution. Though not intended to be an eclipse weather forecast, the detailed maps can help guide eclipse enthusiasts to likely optimal viewing locations. Additionally, high-resolution data are presented for the centerline of the path of each eclipse, representing the likelihood for cloudless skies and atmospheric clarity. The NSRDB provides industry, academia, and other stakeholders with high-resolution solar irradiance data to support feasibility analyses for photovoltaic and concentrating solar power generation projects.

14 SOLAR ENERGY↗
DOE OSTI2023

Design and Development of a Particle Flow Control Mechanism for Particle-Based CSP System Applications

Within particle-based Concentrated Solar Power Systems (CSP), particles are the heat transfer medium, and therefore, the heat transfer effectiveness of these systems is reliant on their ability to effectively control particle mass flow rate. The vast majority of approaches for particle flow control in high temperature CSP is based on a slide-gate approach where a gate is linearly actuated across a tear-drop shaped opening. The slide-gate mechanism has a sensitivity of 0.354 g/s-mm, which is defined as the mass flow rate over the position of the gate. In the present work, we have designed and tested a new particle flow control mechanism with the potential for faster response times and different sensitivities than a slide gate approach enabling more control of particle flow. The new device enables flow control through moving jaws diagonally to change the outlet area. The new devices sensitivity value follows a quadratic curved as compared to the slide-gate’s linear slope over the same jaw movement. A larger sensitivity value is directly related to a quicker response time when utilizing the same actuator.

14 SOLAR ENERGY↗
DOE OSTI2024

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

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

14 SOLAR ENERGY↗
DOE OSTI2024

Near-Net-Shape Hot Isostatic Press Manufacturing Modality for sCO2 CSP Capital Cost Reduction

Through this DOE funded 3.5-year research project, feasibility of fabricating supercritical carbon dioxide (sCO2) turbine components by powder metallurgy (PM) based near-net-shape (NNS) hot isostatic pressing (HIP) was demonstrated in a turbine nozzle ring, a turbine casing with Haynes 282 powder, and a bimetallic pipe with Haynes 282 and SS415 powder. As-HIP microstructure of various powders and HIP processing conditions was studied to downselect a condition for the prototype components. Tensile strength and low cycle fatigue (LCF) capability of PM HIP 282 was found to be superior to cast 282, despite a debit in creep stress capability that could be mitigated by component design modification. Near-Net-shape with minimal post machining was achieved by modeling the non-uniform shrinkage during HIP cycle and designing the HIP tooling to meet dimensional targets. The prototypes of turbine nozzle ring and bimetallic pipe were successful in achieving overall dimension, microstructure, and properties, despite dimensional tolerance affected by chemical milling rate. The prototype of a 1700lbs turbine casing was partially successful in achieving dimension, microstructure in as-HIP state, and providing consistent mechanical properties, however, cracking issue during post heat treatment required further investigation. The estimated manufacturing cost using NNS HIP was a ~50% reduction compared to forging with extensive machining, which translated into ~$100/kWe CAPEX cost reduction for concentrated solar power (CSP) power block.

14 SOLAR ENERGY↗
DOE OSTI2024

Development of a Particle Flow Control Mechanism

The next generation of Concentrated Solar Power (CSP) systems are utilizing solid particles as the heat transfer medium. The state-of-the-art particle flow control mechanism currently utilized is the slide-gate mechanism which functions by linearly actuating a gate across a tear-drop shaped opening. The sensitivity, which is a measure of the change in mass flow rate per unit movement of the slide-gate, is 0.354 g/s-mm[1]. The slide-gate’s main shortcomings include particle lodging and particle leakage between the plates, and difficulty actuating under the pressure from the particles. The goal of a new device is to minimize or eliminate these flaws. The new proposed device functions similar to a chuck mechanism in a drill where a rotation of an outer ring produces a change in outlet area through moving “jaws” diagonally. This mechanism aims to solve the issues of the slide-gate by having the jaws on the outside of the particle flow volume to reduce the probability of particle lodging, and the jaw tips are designed to overlap as they actuate to reduce particle leakage. Additionally, the vertical orientation of the device as well as the inclined movement of the jaws allows for easier actuation of the device under pressure. Experiments involving 3D printed prototypes have been carried out, producing a max mass flowrate of about 50 g/s and a sensitivity curve with the equation 𝑦 (𝑔/𝑠) = 0.0851𝑥^2(𝑔/𝑠−𝑚𝑚2) +3.6993𝑥(𝑔/𝑠−𝑚𝑚). These experiments validated the device’s capability to address the shortcomings of the slide-gate. Currently, an aluminum model of the device is being tested at room temperature, and a stainless-steel model is being developed to be tested at 700oC, which is the expected operating temperature of the CSP system. Furthermore, simulations are on-going to predict the mass flowrate of different device configurations at room and high temperatures.

14 SOLAR ENERGY↗
DOE OSTI2024

Electrochemical Control for Corrosion in Molten Chlorides During CSP Plant Operation

The Liquid Pathway of the Concentrating Solar Power Generation 3 (CSP Gen3) program proposed low-cost molten chloride salt for energy storage. However, online corrosion control was identified as a remining major risk of the Liquid Pathway approach. This project addressed that risk. Electrochemical solutions for corrosion mitigation during CSP plant operation were investigated and their feasibility and scalability were evaluated. The leading cause of corrosion in molten chloride salt systems was identified as corrosive impurities that form within the salt upon exposure to trace amounts of air and moisture. Leveraging electrochemistry, reduction/oxidation reactions can be employed to remove these corrosive impurities. In Phase 1 of this project, a bench-scale batch electrochemical reactor was designed, fabricated, and used to assess the kinetics and thermodynamics of electrochemical salt purification. In Phase 2, a laboratory-scale flow reactor was designed, fabricated, and used to assess the efficacy of the electrochemical method under flowing conditions. Results show that under proposed operating conditions for the Liquid Pathway Gen3 Pilot Plant, the electrochemical method is significantly more effective at removing impurities than alternative chemical and thermal methods, and that the electrochemical method produces less harmful byproducts. A key advance made in the course of this project was the development of a 2-electrode method for electrochemical purification that is more scalable than previously developed 3 electrode methods. This novel method is based on Magnesium (Mg) electrowinning. A provisional patent based on this invention has been submitted (USPTO Application No. 63/480,355). Additional key advances made during this project include assessment of the effect of dissimilar alloys on corrosion, kinetic and thermodynamic evaluation of thermolysis reactions of impurities within the molten salt, characterization of byproducts of purification reactions, and generation of IP focused on isolating value-added products using molten salt-based electrochemistry that could be deployed to valorize the process (USPTO Application No. 63/478,806). Ultimately, this project represented a step toward feasibility of Liquid Pathway Gen3 CSP. The method developed under this project could significantly reduce capital expenses and operating costs and increase plant profitability by enabling use of less expensive alloys, decreasing maintenance, and increasing plant longevity. Key focus areas for follow-on work have been identified as 1) evaluation of the efficacy of the electrochemical method under turbulent conditions in a larger flow system, such as the FASTR loop, 2) development of methods for removal of purification byproducts, 3) modeling pilot and industrial scale performance of electrochemical salt purification during plant operation and 4) further assessment of the effect of impurities on salt vapor phase.

14 SOLAR ENERGY↗
DOE OSTI2024

Scalable, Infiltration-Free Ceramic Matrix Composite Manufacturing for Molten Salt Receiver (SIF-CMC)

Ceramic Matrix Composite (CMC) with high thermomechanical properties is a promising material class for Concentrated Solar Power but current use is limited by a long and tedious manufacturing process with high costs and poor scalability. SIF-CMC provides a novel way to simplify the manufacturing process by dramatically increasing the char yield of the matrix from polymer to ceramic, which makes the CMC affordable and scalable.

Wei, Junhua↗
DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗
DOE OSTI2024

Dual-Image Color Normalization to Enable High-Performance Concentrating Solar Optical Metrology

Concentrating Solar Power (CSP) requires precision mirrors, and these in turn require metrology systems to measure their optical slope. In this project we studied a color-based approach to the correspondence problem, which is the association of points on an optical target with their corresponding points seen in a reflection. This is a core problem in deflectometry-based metrology, and a color solution would enable important new capabilities. We modeled color as a vector in the [R,G,B] space measured by a digital camera, and explored a dual-image approach to compensate for inevitable changes in illumination color. Through a series of experiments including color target design and dual-image setups both indoors and outdoors, we collected reference/measurement image pairs for a variety of configurations and light conditions. We then analyzed the resulting image pairs by selecting example [R,G,B] pixels in the reference image, and seeking matching [R,G,B] pixels in the measurement image. Modulating a tolerance threshold enabled us to assess both match reliability and match ambiguity, and for some configurations, orthorectification enabled us to assess match accuracy. Using direct-direct imaging, we demonstrated color correspondence achieving average match accuracy values of 0.004 h, where h is the height of the color pattern. We found that wide-area two-dimensional and linear one-dimensional color targets outperformed hybrid linear/lateral gradient targets in the cases studied. Introducing a mirror degraded performance under our current techniques, and we did not have time to evaluate whether matches could be reliably achieved despite varying light conditions. Nonetheless, our results thus far are promising.

14 SOLAR ENERGY↗