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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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The utilization of solar energy for electrical power production was studied. Efforts underway on the central receiver solar thermal power system are presented. Preliminary designs are included of pilot plant utilizing large numbers of heliostats in a collector field. Safety hazards are also discussed, as well as the most beneficial location of such a plant within the United States.
Materials for high-temperature use reviewed. Report discusses characteristics of ceramics and assesses potential of candidate materials in solar receivers. Design requirements presented, including those for receiver with fluid exit temperatures up to 1,425 degrees C.
Solar thermal energy can be effectively collected, transported, stored, and utilized by means of a chemical storage and transport system employing the reversible SO2 oxidation reaction. A solar chemical receiver for SO3 thermal decomposition to SO2 and oxygen was analyzed. Bench tests of a ten foot section of a receiver module were conducted with dissociated sulfuric acid (SO3 and H2O) in an electrical furnace. Measured percent conversion of SO3 was 85% of the equilibrium value. Methods were developed to fabricate and assemble a complete receiver module. These methods included applying an aluminide coating to certain exposed surfaces, assembling concentric tubes with a wire spacer, applying a platinum catalyst to the tubing wall, and coiling the entire assembly into the desired configuration.
Method for mathematical modeling of reflection and absorption of solar radiation in solar-energy receiver derived by extending gray-body script-factor method to solar spectrum.
High temperature solar dynamic Brayton and Stirling receivers are investigated as candidate electrical power generating systems for future LEO missions. These receivers are smaller and more efficient than conventional receivers, and they offer less structural complexity and fewer thermal stress problems. Use of the advanced Direct Absorption Storage Receiver allows many of the problems associated with working with high-volumetric-change phase-change materials to be avoided. A specific mass reduction of about 1/3 with respect to the baseline receiver has been realized.
Solar energy harnessed through concentrating solar power (CSP) systems offers a promising path to sustainable energy production, with the efficiency and longevity of these systems relying on key components like solar receivers. This study analyzes the thermomechanical behavior of an innovative enclosed light-trapping solar receiver optimized for particle heating applications. The receiver utilizes sheet metal alloys to form enclosed cavities that reflect and trap incoming solar flux, as well as enclosed channels that contain fluidized particle beds absorbing solar heat. Finite element analysis (FEA) is applied to predict the receiver's thermomechanical performance under extreme solar flux conditions. Temperature distributions from a thermal model simulating a multi-panel assembly at steady state are input into the FEA thermomechanical model for stress analysis. A key aspect of the analysis focuses on evaluating creep-fatigue damage, with a design target of achieving a 30- year service life. Various stress relief techniques are also proposed to extend the receiver's service life. The results highlight the significant impact of the particle-to-wall heat transfer coefficients (HTCs), ranging from 800 W/m2*K to 1400 W/m2*K. The 800 W/m2*K case shows a maximum von Mises stress of 164 MPa, while the 1400 W/m2*K case reduces it to 150 MPa. The creep life increases from 4,000 hrs in the 800 W/m2*K case to over 100,000 hrs in the 1400 W/m2*K case with Inconel 740H used, indicating that higher HTCs reduce stress and extend lifespan. This research advances the design of high-efficiency, low-stress solar receivers for particle-based thermal energy storage in CSP and industrial heating applications.
Here, this paper introduces srlife, a tool for estimating the structural service life of concentrating solar power (CSP) receivers operating at high temperatures. Supporting both metallic and ceramic receiver designs, srlife is available as open-source software at https://github.com/applied-material-modeling/srlife and can be installed via the PyPi package manager (https://pypi.org). Given basic receiver geometry and incident heat flux, the tool performs thermohydraulic and structural analysis and estimates the life of a receiver. Designed for easy integration into a software stack, including solar field and levelized cost analysis, the tool can be utilized for optimizing receiver designs to meet service life and economic targets. This paper is Part I in a two-part series. Part I discusses the analysis process used to estimate the life of metallic receivers, along with a description of the required input data. Additionally, several heuristics applied within srlife can reduce analysis time significantly while maintaining accurate life estimations for metallic receivers when compared to full analyses. Several examples demonstrating the utility of srlife in receiver design are also discussed. Part II focuses on the life estimation of ceramic receivers, using time-dependent reliability analysis and various ceramic failure models implemented in srlife.
To maximize thermal efficiency, the National Renewable Energy Laboratory (NREL) has proposed a light-trapping cavity-planar receiver design intended to capture energy from reradiating surfaces. This system implements a macroscale light trapping mechanism induced by panels with triangular channels, this mechanism allows for elevated temperatures on the receiver panels and in turn the temperature of the HTF; using this design coupled with the implementation of a fluidized particle flow as the HTF, it can be expected for some components to reach a peak working temperature of nearly 1000 degrees C cyclically throughout each day-night cycle. While these temperatures correlate to higher efficiency of the CSP tower they also demand intense thermomechanical properties from the materials used to make the receiver panels. In this analysis, we will list our assumptions to provide clarity on the significance of our calculation. This cost analysis will be conducted using a combination of both case study data and surveying industry to determine costs that are relevant to the current market trends. This analysis represents an early attempt to establish the Capital Expenditures required for a CSP tower of such design to determine the feasibility of implementing such a system in the industry.
This work was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technologies Office Award Number 35928. The objective of the proposed effort was to develop and optimize additive manufacturing technologies for low-cost fabrication of high-temperature receivers using MAX phase-based materials (Ti 3 SiC 2 and Ti 3 AlC 2 ). MAX phase materials are a group of ternary metal carbides and nitrides where M stands for an early transition metal element, A is a group 13–16 element, and X is C and/or N. In Phase 1, the binder jetting additive manufacturing process was used to synthesize and characterize the Ti 3 SiC 2 MAX phase material. The typical process involved first producing a TiC preform using binder jetting followed by infiltration of the preform with silicon melt to form Ti 3 SiC 2 in situ. The reaction-infiltrated samples showed formation of MAX phase in the sample core; however, the surface showed cracking. Various process conditions—cooling rates, hold times, Si proportion, etc.—were varied to minimize the surface cracking. The fabricated MAX phase core was characterized by microstructure analysis and evaluations of mechanical properties such as hardness and thermal shock. In Phase 2, the focus included fabrication of Ti 3 SiC 2 MAX phase materials by spark plasma sintering (SPS) and synthesis of Ti 3 AlC 2 MAX phase materials by the Al melt infiltration process. It is expected that Al infiltration will not cause sample cracking, since Al does not expand during solidification. In addition, other processing approaches were investigated to fabricate the MAX phase materials, such as SPS with a graphite bedding approach for producing short-length Ti 3 AlC 2 MAX phase tubes for demonstration of prototypical Concentrating Solar Power receiver tubes. Fabricated samples underwent thermo-mechanical testing to validate the materials for the solar receiver application at temperatures >1000°C. In Phase 3, the effort focused on the development and optimization of the Ti-Al-C MAX phase composite material using the Al melt infiltration approach. We started with optimization of precursor powders and making preform structures by either pressing them in a die or using the binder jetting additive manufacturing process followed by Al melt infiltration. In addition, we investigated the formation of preform structures by cold isostatic pressing followed by Al melt infiltration for making Ti-Al-C MAX phase composite. Thermo-mechanical characterizations, such as creep, strength, and thermal shock, were conducted to establish the structures’ performance.
Advanced space power systems that use solar energy and Brayton or Stirling heat engines require thermal energy storage (TES) systems to operate continuously through periods of shade. The receiver storage units, key elements in both Brayton and Stirling systems, are designed to use the latent heat of fusion of phase-change materials (PCMs). The power systems under current consideration for near-future National Aeronautics and Space Administration space missions require working fluid temperatures in the 1100 to 1400 K range. The PCMs under current investigation that gave liquid temperatures within this range are the fluoride family of salts. However, these salts have low thermal conductivity, which causes large temperature gradients in the storage systems. Improvements can be obtained, however, with the use of thermal conductivity enhancements or metallic PCMs. In fact, if suitable containment materials can be found, the use of metallic PCMs would virtually eliminate the orbit associated temperature variations in TES systems. The high thermal conductivity and generally low volume change on melting of germanium and alloys based on silicon make them attractive for storage of thermal energy in space power systems. An approach to solving the containment problem, involving both chemical and physical compatibility, preparation of NiSi/NiSi2, and initial results for containment of germanium and NiSi/NiSi2, are presented.
The effects of elevated-temperature vacuum and elevated-temperature atomic oxygen exposure on the mass, surface chemistry, surface morphology, and optical properties of Haynes 188, a possible heat receiver material for space-based solar dynamic power systems, have been studied. Pristine and surface modified Haynes 188 were exposed to vacuum less than or equal to 10 exp -6 torr at 820 C for 5215.5 h, and to atomic oxygen in an air plasma asher at 34 and 827 C for fluences up to 5.6 x 10 exp 21 atoms/sq cm. Results obtained indicate that vacuum heat treatment caused surface morphology and chemistry changes with corresponding optical property changes. Atomic oxygen exposure caused optical property changes which diminished with time. Mass changes are considered to be negligible for both exposures.
The tracking mechanism for a point-focusing concentrator may be subject to failure. If this should occur, the solar image will travel across the aperture plate, and it may also impinge on the adjacent support structure. Such an event is called 'sun walk-off'. The present investigation is concerned with the transient response of different aperture plate materials to the intense heating produced in a typical walk-off situation for parabolic dish concentrators. Receivers for two solar module systems are considered, including a high-temperature receiver that utilizes a 2-milliradian (mrad) concentrator, and a lower-temperature receiver which is coupled with a 4-mrad concentrator. It is found that during a walk-off situation the solar image travels in a straight line in the radial direction. The results obtained for a copper aperture plate were disappointing. It appears that passive metallic plates without cooling or other protective support cannot withstand the intense heating.
A technology demonstration of a Dish Stirling solar thermal electric system can be accomplished earlier and at a much lower cost than previous planning had indicated by employing technical solutions that allow already existing hardware, with minimum modifications, to be integrated into a total system with a minimum of development. The DSSR operates with a modified United Stirling p-40 engine/alternator and the JPL Test Bed Concentrator as a completely integrated solar thermal electric system having a design output of 25 kWe. The system is augmented by fossil fuel combustion which ensures a continuous electrical output under all environmental conditions. Technical and economic studies by government and industry in the United States and abroad identify the Dish Stirling solar electric system as the most appropriate, efficient and economical method for conversion of solar energy to electricity in applications when the electrical demand is 10 MWe and less.
3D-printing technology was applied to fabricate novel solar thermal collection tubes that have internal heat transfer enhancement fins and external surfaces with high solar absorptivity and low emissivity due to the ability to use different materials in one tube. Helical fins were selected to introduce circumferential flow and thus minimize the circumferential temperature difference of the tube that receives sunlight on one side. The structures of the helical fins were previously optimized from computational fluid dynamics (CFD) analysis with the objective of low entropy production rate by looking for high heat transfer coefficient and relatively lower pressure loss. High-temperature alloy, Inconel-718, was used to 3D print the tubes, which can resist corrosion for the potential application of molten chloride salts as heat transfer fluid. Experimental tests were carried out using water as the heat transfer fluid with the high heat flux provided by a tubular furnace heater. The tested Reynolds number ranges from 3.9 × 10 3 to 6.1 × 10 4 . Heat transfer coefficients of up to 2.8 times that of the smooth tube could be obtained with the expense of increased pressure loss compared to that of the smooth tube. The total system entropy generation can be significantly reduced due to the benefit of heat transfer enhancement that is greater than the expenses of the increased pressure loss. The experimental results of the 3D-printed heat transfer tubes confirmed the CFD-based results of fin optimization. Furthermore, the novel heat transfer tube is recommended for application in concentrating solar power systems.
As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.
Design intended for high-temperature service. Proposed ceramic-tube and header heat exchangers used for solar-concentrating collector operating in 25- to 150-KW power range at temperatures between 2,000 degrees and 3,000 degrees F (1,095 degrees and 1,650 degrees C).
Due to variations in solar insolation, it may be necessary or desirable to operate solar energy systems continuously in off-design conditions. Design of solar energy systems should maximize system efficiency at the design point and throughout the range of operational solar insolation. The solar power system considered in this study consists of a point-focusing concentrator, a cavity receiver, an open cycle gas turbine engine, and a heat regenerator. A computer simulation model was developed to predict off-design system performance. Results showing system efficiency and associated subsystems interface requirements are presented for various turbine inlet temperatures and engine speeds.
Design under uncertainty has significantly grown in research developments during the past decade. Additionally, machine learning (ML) and explainable ML (XML) have offered various opportunities to provide reliable predictable models. The current article investigates the use of finite element modeling (FEM), ML and XML predictions, and uncertain-based design of carbon-carbon (C-C) composites for use in ultra-high temperatures. A C-C composite concentrating solar power (CSP) as a microvascular receiver is considered as a case study. These C-C composites are fiber composites with directly integrated carbonized microchannels to form a lightweight, high-absorptivity material that includes an embedded microvascular network of channels. The topology of these microchannels is engineered to optimize heat transfer to a supercritical carbon dioxide (sCO2) heat transfer fluid. The mechanical characterization of C-C composites is highly challenging. Thus, designing every component made of C-C composites for ultra-high temperature applications needs an uncertainty-based analysis. As a part of a comprehensive project on the development of a novel carbonized microvascular C-C composite, this paper explores C-C composite sensitivity analysis, FEM, ML prediction, and XML analysis. The resulting composite can then be carbonized and coated with an oxidation-resistant coating to form a thermally efficient and mechanically robust C-C composite. An ANSYS 3-D-FE model was used to analyze the CSP’s stress/strain. To consider the variability in the mechanical and thermal properties of C-C composites, various mechanical properties are considered as the ANSYS FEM’s input. A synthetic dataset from 730 ANSYS runs was produced to feed into the ML and XML algorithms for uncertainty analysis and prediction. The ML and XML algorithms could accurately predict the CSP stresses/strains.