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DOE OSTI2023

Annual Technology Baseline: The 2023 Electricity Update

Consistent cost and performance data for various electricity generation technologies can be difficult to find and may change frequently for certain technologies. With the Annual Technology Baseline (ATB), the National Renewable Energy Laboratory annually provides an organized and centralized set of such cost and performance data. The ATB uses the best information from the Department of Energy national laboratories' renewable energy analysts. The ATB has been reviewed by experts and it includes the following electricity generation and storage technologies: land-based wind, offshore wind, distributed wind, utility-scale solar photovoltaics (PV), commercial-scale solar PV, residential-scale solar PV, concentrating solar power, geothermal power, hydropower, utility-scale battery storage, commercial battery storage, residential battery storage, pumped storage hydropower, coal, and natural gas. EIA data for nuclear and conventional biopower are included for reference. This webinar presentation introduces the 2023 update to the ATB Electricity data and documentation.

capacity factor↗
DOE OSTI2023

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

The submission is a two-page extended abstract. 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.

14 SOLAR ENERGY↗
DOE OSTI2023

High Temperature Ternary Chloride Molten Salt Pump

This work investigates the design criteria considering thermal, structural, and material selection of a ternary chloride (MgCl2-NaCl-KCl) molten salt pump that is capable of running at temperatures above 720 °C. In this work, preliminary testing of salt-wetted hydrodynamic bearings was done to investigate different material pairings including Colmonoy grades, Stellite grades, and a novel Nickel Tungsten Carbide alloy (HybrimetTM NiWC3b) used as a High Velocity Oxygen Fuel (HVOF) coating. The coating has shown to withstand the corrosive nature of the molten salt. The pump wetted components are made of Inconel 625 and features a carbon ring seal (CIRPAC Seal) flooded with a N2 gas flow on the overhead to keep salt vapors from interacting with the external ambient air. A comprehensive pump test program has been completed. Over 90 hours run time pumping hot chloride salts at temperatures up to 720 °C in which enough data was captured to produce performance curves at 3 different operating speeds. This research showcases a promising design for use in the Concentrated Solar Power (CSP) Gen 3 liquid-pathway and sets the ground for further development and use of the HybrimetTM NiWC3b as a competitive alternative to available superalloys.

14 SOLAR ENERGY↗
DOE OSTI2024

Dynamic Wind Loading on CSP Collectors Caused by Turbulent Wind Fluctuations: Insights from a 2-Year Field Campaign

Concentrating Solar Power (CSP) is a promising solar technology for electricity generation with thermal energy storage and with the additional benefit of industrial heat production. Wind loading on CSP collector structures, such as parabolic troughs or heliostats, is one of the primary drivers of their structural design costs. In particular, dynamic wind loading is a major source of uncertainty in the collector design process, which heavily relies on wind tunnel testing. In the field, the turbulent nature of the incoming wind creates fluctuating loads (support structure loads and resulting mirror deflections) on the collectors, with impacts on fatigue lifetime and optical performance. As is well known, wind tunnel tests cannot entirely reproduce the complex turbulent wind conditions typically observed at full-scale plants. To shed light on this topic, NREL initiated a field campaign at the operational Nevada Solar One (NSO) powerplant that uses parabolic troughs as solar collectors. The aim of the project is a detailed characterization of prevailing wind and turbulence conditions and resulting operational loads on parabolic troughs. We use the published 2-year dataset of high-resolution combined wind and structural loads measurements [1] to characterize the dynamic structural wind response. For quantifying dynamic wind loading, we apply the concept of admittance functions, which are spectral transfer functions that couple the turbulent wind to resulting structural loads (aerodynamic admittance), and to the structural response (mechanical admittance). In practice, aerodynamic admittance describes which turbulent eddy sizes are effective in creating structural loads. The mechanical admittance describes in which frequency ranges these loads are reinforced or dampened by the structure. While these functions are an established concept in civil engineering, their recent application to a single full-scale heliostat [2] proved their broader applicability to CSP collectors. Here, we present a characterization of admittance functions for full-scale parabolic trough collectors and show how wind characteristics (mean wind speed and direction, turbulent kinetic energy, turbulent length scales), the sun-tracking trough angle, and row position alter the admittance functions. Further, we study to which extent the admittance functions are universal for a specific trough geometry and how our findings compare to reported heliostat results. References [1] https://data.openei.org/submissions/5938. [2] Blume, K., Roger, M., and Pitz-Paal, R. 2023b. "Simplified analytical model to describe wind loads and wind-induced tracking deviations of heliostats." Solar Energy, 256, 96-109. https://doi.org/10.1016/j.solener.2023.03.055.

admittance functions↗
DOE OSTI2024

Experimental and Computational Validation of a Novel Particle Flow Control Valve for CSP Systems

Particle-based Concentrated Solar Power (CSP) systems most often utilize the state-of-the art slide gate mechanism for particle flow control. The slide-gate was found to have a sensitivity of 0.354 g/s-mm, a measure of mass flow rate over actuation position [1]. Particle-based CSP developers have noted that the slide gate is conducive to particle lodging, leaking, and difficulty actuating under particle pressure as well as differential expansion of the gate from thermal cycling. The goal of this work is to design, develop and test a novel particle flow control device that can operate without any hindrance from these shortcomings.

14 SOLAR ENERGY↗
DOE OSTI2024

Demonstration and Automation of Reflected Target Optical Measurement for Heliostats

Accurate optical surfaces are a primary driver of concentrated solar power plant performance. Errors in pointing and tracking mirrors, the canting of individual mirror facets, and the surface slope of the mirror itself can be caused by errors during assembly, transportation, wind loading, gravity, and many other sources. The tools that exist to measure these error sources today largely rely on fringe deflectometry (SOFAST, QDec, others), or photogrammetry with targets attached to the mirror surface. Since 2022, NREL has been developing a measurement method called the Reflected Target Non-intrusive Assessment (ReTNA) system. This system differs from most established methods in that we perform deflectometry with a pattern of coded targets, identified in space with photogrammetry. Reflected target systems have several advantages over traditional fringe deflectometry systems. Firstly, they can be operated in bright or ambient lighting, a challenge for fringe systems that use a projector and screen. Reflected target systems also can use a much lighter and less expensive target than projector-based systems. Lastly, 2D slope measurement can be solved from a single image, which leads to several advantages for accommodating faster measurements and smaller sized targets. These advantages make ReTNA particularly well-suited for applications where there are space or lighting constraints, like performing heliostat quality assurance on an assembly line. It's also useful when a lightweight, flexible system is needed, like for heliostat developers to quickly measure a new heliostat design at different orientations, to observe gravitational effects on the mirror surface shape. In the last year, significant improvements were made to this tool to make it more useful for these applications. These improvements were focused around validation of the ReTNA measurement system, and automation of the setup and measurement process. First, we present an improved ReTNA layout, for use on the heliostat assembly line. Next, we detail the various changes to the ReTNA software and computer vision methods to automate data collection in this new setup, and lessons learned from this process. The goal with this new setup is to perform a full heliostat surface characterization without removing the mirror from the assembly line. Lastly, we share results from several ReTNA validation studies undertaken over the last year. These include repeated ReTNA measurement on demonstration mirror facets, comparisons with other optical measurement tools, and some studies aimed at quantifying the uncertainty of ReTNA measurement under various constraints (mirror-target spacing, camera resolution, etc.). These results are compared with 2024 HelioCon performance targets, and our planned next steps for the ReTNA measurement system are presented.

CSP↗
DOE OSTI2024

Analysis of Gaps in Techno-Economic Analysis to Advance Heliostat Technologies for Concentrating Solar-Thermal Power

The Heliostat Consortium (HelioCon) was launched in 2021 to advance heliostat technology. One of its first efforts was to do a detailed analysis of gaps in technology and capabilities in the heliostat industry and complete a roadmap study describing high-priority gaps. HelioCon gathered gaps through a series of outreach activities with representatives and experts from industries and research institutes. Here, this paper discusses the gap analysis for the techno-economic analysis (TEA) topic. One of the main objectives of the TEA topic is to relate the cost and performance of heliostats and heliostat components to the overall system performance. In this study, we limit the scope of this topic to the heliostat field, tower, and receiver and do not consider downstream applications or uses of thermal energy. We conducted a thorough review of existing models and compiled a list of the state of the art in open-source tools currently available to researchers. We collected an initial list of gaps for the TEA of heliostats from industry developers and experts. Each gap is briefly described, and the heliostat development cycle stages that the gap impacts are indicated. We ranked the initial list of TEA gaps into tiers depending on their potential impact. For TEA, most of the gaps identified are related to developing models or data. Strictly speaking, none of these gaps are essential for heliostat development, but all would aid in the heliostat development process.

14 SOLAR ENERGY↗
DOE OSTI2024

A Planar-Cavity Receiver Configuration for High-Temperature Solar Thermal Processes: Preprint

Next generation concentrating solar thermal power (CSP) and novel solar thermochemical systems using concentrating solar thermal (CST) energy require high operating temperatures exceeding those of traditional nitrate-salt CSP systems. Particle-based systems are attractive for next-generation CSP and CST applications owing to high-temperature stability of inert silica- or alumina-based particulate materials, the lack of low-temperature freezing concerns that limit molten salt and/or molten metal heat transfer media, and cost-effective thermal storage using low-cost particulate and containment materials. Open-cavity falling particle receivers have many potential advantages, but face challenges pertaining to scalability, thermal loss, and particle loss through the open aperture, and are infeasible for chemical processes that require a low-oxygen ambient environment. Enclosed receiver configurations can be scalable, avoid particle loss when heating particles, and have potential for future chemical processes; however, particle-based heat transfer media provide substantially lower heat transfer rates than liquid media, and thus enclosed particle receiver designs require novel configurations to limit surface temperatures under the high incident solar flux concentrations necessary for high receiver thermal efficiency at high temperature. This paper introduces the novel planar-cavity enclosed particle receiver configuration in which arrays of planar surfaces are arranged into sub-vertical cavities. Large angles between the panel surface normal vectors and the aperture surface normal allow the incoming solar beam to distribute along the panel walls. Correspondingly, a high incident solar flux concentration at the cavity aperture produces substantially lower absorbed solar flux concentration on any panel wall. Sets of individual vertical cavities can be arranged to form a scalable receiver configuration.

cavity receiver↗
DOE OSTI2026

Performance Evaluation of an Additively Manufactured ultra-High Operating Temperature SiC Solar-Thermal Air Receiver (HOTSSTAR) Test Module

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal and solar power systems. GE Aerospace Research in collaboration with Heliogen Inc and Sandia National Laboratories (SNL) is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. HOTSSTAR goal is to demonstrate SiC receiver with air exit temperatures up to 1100oC. We discuss fabrication and on-sun test results of a prototype 50kWth test module. The receiver architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around central absorber. These components were fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the thermo-mechanical reliability of SiC test articles in thermal gradient/ shock environment of the application, the components were laminated with GE’s MI SiC CMC. A dedicated test facility was constructed at SNL Solar Tower to evaluate the operational performance of HOTSSTAR module under solar fluxes >200 W/cm2. We report on our final 50kW test module fabrication, integration at the test facility at Sandia, and discuss on-sun test results. We compare the performance of HOTSSTAR module relative to our model predictions.

14 SOLAR ENERGY↗
DOE OSTI2020

Integration of a Concentrating Solar Steam Topping Turbine to an Existing Geothermal Binary Power Plant (CRADA CRD-17-700 Final Report)

U.S. Geothermal Inc. is a publicly traded leading renewable energy company focused on the development, production, and sale of electricity from geothermal energy with operating generation facilities at Raft River, Idaho; San Emidio, Nevada; and Neal Hot Springs, Oregon. (U.S. Geothermal was acquired by Ormat Technologies, Inc. since the execution of this project). This project will evaluate the integration of a concentrating solar steam topping cycle with a geothermal bottoming binary cycle. This hybrid plant configuration will enable high efficiency conversion of the solar heat to electrical power, while simultaneously increasing the power output of the bottoming cycle. Such a design has the potential to reduce the cost of electrical power from concentrating solar power (CSP) and geothermal plants, and a viable design could be deployed at existing geothermal plants that have experienced resource productivity decline as well as in greenfield projects. This analysis will examine US Geothermal’s Raft River power plant for implementation of this concept. INL and NREL have previously collaborated in the analysis of geo-solar hybrid power plants. These two labs will again work together to model the solar field, steam-topping, and geothermal bottoming cycles in order to investigate the performance of the proposed cycle. This analysis will provide US Geothermal with technical information including equipment specifications and estimated power generation necessary to advance the concept toward implementation. A successful project outcome has two parts: One would be for US Geothermal to have a process flow diagram (heat and mass balance), and performance parameters for the major pieces of equipment. US Geothermal could then use this information evaluate the techno-economic feasibility of the hybrid power cycle, and serve as the basis for subsequent detailed equipment design, purchase, and installation of the cycle. The second would be for the developed solution to be published by DOE for use by other geothermal developers both to retrofit underperforming plants and to lower the LCOE of new developments.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Benchmarking of Solar Irradiance Nowcast Performance Derived from All-Sky Imagers

Fluctuations of the incoming solar irradiance impact the power generation from photovoltaic and concentrating solar thermal power plants. Accurate solar nowcasting becomes necessary to detect these sudden changes of generated power and to provide the desired information for optimal exploitation of solar systems. In the framework of the International Energy Agency's Photovoltaic Power Systems Program Task 16, a benchmarking exercise has been conducted relying on a bouquet of solar nowcasting methodologies by all-sky imagers (ASI). In this paper, four ASI systems nowcast the Global Horizontal Irradiance (GHI) with a time forecast ranging from 1 to 20 min during 28 days with variable cloud conditions spanning from September to November 2019 in southern Spain. All ASIs demonstrated their ability to accurately nowcast GHI, with RMSE ranging from 6.9% to 18.1%. Under cloudy conditions, all ASIs' nowcasts outperform the persistence models. Under clear skies, three ASIs are better than persistence. Discrepancies in the observed nowcasting performance become larger at increasing forecast horizons. The findings of this study highlight the feasibility of ASIs to reliably nowcast GHI at different sky conditions, time intervals and horizons. Such nowcasts can be used either to estimate solar power at distant times or detect sudden GHI fluctuations.

all-sky imagers↗
DOE OSTI2021

Simulation of the supercritical CO 2 recompression Brayton power cycle with a high-temperature regenerator

The supercritical carbon dioxide (sCO 2 ) recompression Brayton cycle promises higher efficiency and lower capital cost than traditional steam Rankine power cycles. However, achieving high efficiency requires large, highly effective recuperators. Regenerators may be a low-cost alternative to printed circuit and micro-tube heat exchangers for recuperation in sCO 2 power cycles. Regenerators are a periodic heat exchanger in which thermal energy is extracted from the hot stream, stored in solid media, and then released to the cold stream at a later time. Fixed bed regenerators with valves to direct fluid are the preferred method for implementing regenerators in power cycles, but the inherently transient nature of these systems has not been characterized for this application. This study presents the simulation of a high-temperature regenerator within a 10 MWe sCO 2 recompression Brayton cycle. A transient, one-dimensional regenerator model presented in a previous study is used to simulate the regenerator. Dynamic heat exchanger models are also developed for the precooler, low-temperature recuperator, and primary heat exchanger, and the compressors and the turbine are modeled with off-design performance maps. We assess two regenerator-valve design options; one for fast switching, and one for reduced flow rate fluctuations. System simulation finds that both designs see significant fluctuations in turbomachinery flow rate, turbomachinery and system power, and regenerator discharge process outlet temperature. While designing the regenerator-valve subsystem for lower fluctuations is possible, the regenerator cold discharge temperature and net power still fluctuate by ±77.6°C and 6%, respectively. Increasing buffer volume is not effective at sufficiently reducing these fluctuations, but adding a packed bed in between the regenerator and the primary heat exchanger can reduce regenerator discharge process outlet temperature fluctuations to 6.4°C. Further reductions could be possible by increasing the size of this packed bed.

42 ENGINEERING↗
DOE OSTI2024

Development of High Temperature (>700°C) Molten Salt Pump Technology for Generation 3 Solar Power Tower Systems

Bearings are required for long-shafted pumps historically used in concentrating solar thermal power applications. For molten chloride salts, bearings for such service conditions are not commercially available, nor has a design been demonstrated to work. Therefore, a project was sponsored by the Department of Energy’s Solar Energy Technologies Office for the development and demonstration of a submerged bearing for use in chloride salt pumps. This project’s tasks covered the tribological testing of candidate materials and the design, fabrication, testing, and post-test analysis of full-scale salt-compatible bearings. This work expands upon previous work. The effects of potential particulate in the salt were investigated through tribological bench testing. Through 11 tests, the MgO particulate size and concentration in a molten chloride salt were varied, and the effects on friction, wear rate, and wear characteristics were recorded. Novel journal bearings for chloride salt service were designed and fabricated based on these results. The bearings were of a relevant scale (i.e., for a 1.5 in. pump shaft) to demonstrate the technology with respect to further scale-up. The bearings were made of Haynes 244 and Yttria Partially Stabilized Zirconia. A custom bearing test rig, salt tanks, and associated infrastructure (e.g., heaters, tanks, transfer lines, gas flow control) were designed, procured, and installed. A few issues were encountered in the system fabrication process, resulting in delay of the project schedule. The system was successfully fabricated and assembled. Heating, cover gas, and pump motor systems were integrated into the control logic. This progress of the bearing test system represents a significant step forward towards demonstrating this promising technology. Nevertheless, the project ended before testing of the full-scale bearings could be performed.

14 SOLAR ENERGY↗
DOE OSTI2024

Design of Modular Test Facility for Particle/sCO2 Heat Exchanger Evaluation

Heliogen has designed a 1.3 MW particle and supercritical carbon dioxide (sCO2) test loop to retire technical and manufacturing risks. The data from this facility will be used to validate near commercial-scale particle heat exchanger modules. The heat exchanger is scaled to capture all features of the full-scale modules. Testing will be conducted with CARBOBEAD HSP 16/30, a larger particle size than other recent testing. The system was designed to ASME codes with the constraint that sCO2 piping and other major components are stainless steels.

14 SOLAR ENERGY↗
DOE OSTI2023

Factors Influencing Propensity for Stress Relaxation Cracking in Inconel® Alloy 740H® and Practical Guidance for Applications

Inconel® alloy 740H® (UNS N07740) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. In recent years, advanced energy systems such as supercritical CO2 power cycles have utilized alloy 740H in large demonstration projects driven by the requirement for higher fluid temperatures and pressures. Stress relaxation cracking (SRxC) following post-weld heat-treatment (PWHT), also known as strain age cracking (SAC), has been identified in a limited number of weldments during these industrial builds resulting in focused research to further clarify factors influencing this cracking tendency. This paper will summarize some of the findings from shop and field fabrication leading to successful welds and characteristics of observed SRxC. Laboratory experiments supported by microstructural characterization will be presented to highlight the importance of variables such as strain, material starting condition, and PWHT temperatures. Finally, the results will be summarized within the context of practical guidance for industry to successfully weld the material in boiler, heat exchanger, and piping applications.

14 SOLAR ENERGY↗
DOE OSTI2020

Concentrating photovoltaic retrofit for existing parabolic trough solar collectors: Design, experiments, and levelized cost of electricity

Photovoltaics and concentrating solar thermal power are two ways for generating electricity from sunlight, albeit through different methods. Parabolic trough style powerplants represent 3.6 GW of electricity production, but many of these plants are aging and being replaced with photovoltaics. An alternative option that could be employed to leverage the sunk capital cost associated with the primary optics would be the design of a pure photovoltaic retrofit working within the existing plant architecture. Here, a secondary optical concentrator is designed to use the existing primary optics of a parabolic trough type solar thermal powerplant. The design is a v-shaped secondary concentrator resulting in a predicted concentration ratio on a 20 mm wide target of 94. The concentrating photovoltaic receiver for retrofit of an RP-3 based parabolic trough has been constructed using multi-junction concentrator photovoltaic cells and experimentally demonstrated here for the first time. Calculated performance of the cells based on cell specifications should result in 31% efficiency at 85 °C. On-sun efficiencies were measured at an average value of 21% with operational temperatures between 55 and 120 °C. Levelized cost of electricity calculations predict the system to have the potential to be below 7¢/kWh based on predicted efficiencies and 13¢/kWh based on the measured values at cell costs of $5/cm 2 .

14 SOLAR ENERGY↗
DOE OSTI2024

Impact of Temperature and Optical Error on the Combined Optical and Thermal Efficiency of Solar Tower Systems for Industrial Process Heat: Preprint

Concentrating solar thermal (CST) power towers can provide high flux concentrations at commercial scale. As a result, CST towers exhibit potential for high-temperature solar industrial process heat (SIPH) applications. However, at higher operating temperatures, thermal radiation losses can be significant. This study explores the trade-off between thermal and optical losses for SIPH applications using a collection of three case studies at operating temperatures that range from 900-1,550 degrees C. We assume blackbody radiation to represent the thermal losses at the receiver and we use ray tracing to estimate the optical losses. The results show the impact of process temperature on the maximum attainable system efficiency, as well as the higher flux concentration requirements as the temperature increases.

concentrating solar power↗
DOE OSTI2024

HELIOCOMM: Wireless Controls State-of-the-Art Report

This report introduces the concept of wireless controls in heliostat-based concentrating solar thermal power (CSP) systems. Specifically, the need for wireless communications to be implemented within the heliostat-based CSP systems is identified versus the existing approaches that follow wireline connections which suffer from high installation, operation, and maintenance cost. Furthermore, this report analyzes the most recent advances in the field of developing wireless controls in heliostat-based CSP systems, which are highlighted to be in their infancy given the primitive wireless networking solutions that they currently utilize and test. The main contribution of this report is the introduction of a novel HELIOCOMM system that supports the wireless controls in heliostat-based CSP systems by exploiting the next generation networking technology of integrated access and backhaul. Furthermore, the proposed HELIOCOMM system performs an artificial intelligent clustering approach of the heliostats and clusterhead selection and develops an entropy-based routing model to enable the heliostats to communicate with the central station by considering their energy availability and network traffic. Also, towards efficiently exploiting the limited resources in the developed wireless communication system, a resource allocation module is introduced that performs the maximization of the energy efficiency of each heliostat by minimizing its corresponding experienced end-to-end latency to communicate with the central station, while performing an intelligent bandwidth splitting in the access and backhaul wireless links. The overall architecture is presented, and its individual building components are discussed in detail.

14 SOLAR ENERGY↗