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DOE OSTI2022

Development of Cast Valve Bodies For High Temperature Service

Gen 3 Concentrating Solar-Thermal Power (CSP) system components are required to operate at 750°C - 800°C to achieve the Sunshot target of 6 cents/kWh. Haynes ® 282 and IN ® 740H are preferred alloys for the construction of these components due to their high tensile and creep strengths for service at temperatures greater than 750°C. There is significant motivation to lower the cost of materials and components so that the capital costs can be minimized. One approach to reduce costs is to fabricate castings at the lowest possible cost. To obtain the lowest cost in castings, there is a significant need to maximize yields in castings by decreasing rejects due to casting defects and to minimize wastage in material lost in the gating systems. However, very little work has been performed to develop cast products using Haynes ® 282. Although preliminary work has established the feasibility of casting Haynes ® 282 using investment and sand casting, there are no commercial cast components available. In particular, there is significant interest in the development of casting design and process technology for the fabrication of components such as valve bodies using Haynes ® 282.

14 SOLAR ENERGY↗
DOE OSTI2023

Utility-Scale Solar, 2023 Edition: Empirical Trends in Deployment, Technology, Cost, Performance, PPA Pricing, and Value in the United States [Slides]

Berkeley Lab’s “Utility-Scale Solar, 2023 Edition” presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC (PV plants of 5 MWAC or less, including residential rooftop systems, are covered separately in Berkeley Lab’s companion annual report, Tracking the Sun). Highlights of this year’s update include: -10.4 GWAC of new utility-scale PV capacity came online in 2022, bringing cumulative installed capacity to more than 61.7 GWAC across 46 states. -94% of all new utility-scale PV capacity added in 2022 uses single-axis tracking. -Median installed project costs declined to $\$1.32$/WAC (or $\$1.07$/WDC) in 2022. -Plant-level capacity factors vary widely, from 9% to 35% (on an AC basis), with a sample median of 24%. The report explores drivers of this variation. -Utility-scale PV’s LCOE fell to $\$39$/MWh in 2022 ($\$29$/MWh if factoring in the federal investment tax credit, or ITC). -PPA prices have largely followed the decline in solar’s LCOE over time, but have recently stagnated and even moved slightly higher. Prices from a sample of recent contracts average around $\$20-30$/MWh (levelized) in the West and $\$30-40$/MWh elsewhere in the continental US. -In 2022, solar’s average market value (defined in the report to include only energy and capacity value) rose by 40% to $\$71$/MWh and exceeded average wholesale prices in 4 of the 7 ISOs/RTOs and 11 of 18 other balancing authorities analyzed. -Adding battery storage is one way to increase the value of solar. Our public data file tracks metadata and PPA prices from ~100 PV+battery hybrid projects that are already online or that have secured offtake arrangements. -the end of 2022, there were at least 947 GW of utility-scale solar power capacity within the interconnection queues across the nation, 456 GW of which include batteries. For more information, and to explore related interactive data visualizations, go to utilityscalesolar.lbl.gov.

14 SOLAR ENERGY↗
DOE OSTI2024

Utility-Scale Solar, 2024 Edition: Empirical Trends in Deployment, Technology, Cost, Performance, PPA Pricing, and Value in the United States [Slides]

Berkeley Lab’s “Utility-Scale Solar, 2024 Edition” presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC (PV plants of 5 MWAC or less, including residential rooftop systems, are covered separately in Berkeley Lab’s companion annual report, Tracking the Sun). Key findings from this year’s report include: -18.5 GWAC of new utility-scale PV capacity came online in 2023, bringing cumulative installed capacity to more than 80.2 GWAC across 47 states. Installed costs continued to fall in 2023. Relative to 2022, capacity-weighted averages decreased by 8% to -$\$1.43$/WAC (or $\$1.08$/WDC). Costs, based on a 7.1 GWAC sample of 76 plants completed in 2023, have fallen by 75% (averaging 10% annually) since 2010. Plant-level capacity factors vary widely, from 6% to 36% (on an AC basis), with a sample median of 24%. -Levelized cost of energy (LCOE) of new 2023 projects increased slightly to $\$46$/MWh prior to the application of tax credits but continued to fall to $\$31$/MWh when accounting for federal incentives. PPA prices have largely followed the decline in solar’s LCOE over time, but newly signed longer-term PPA prices have increased since 2021, to an average of $\$35$/MWh (levelized, in 2023 dollars). -Solar’s average energy and capacity value (i.e., ability to offset costs of other power generation sources) across the U.S. was $\$45$/MWh in 2023. Solar’s average market value was lowest in CAISO ($\$27$/MWh), the market with the greatest solar generation share, and highest in ERCOT ($\$67$/MWh). -Newer solar projects had greater market value in 2023 than their generation costs, yielding $\$1.1$ billion in benefits. Projects built in 2022 delivered on average $\$15$/MWh more market value than their costs in 2023. -Solar’s combined value from wholesale electricity markets, public health and climate damage reduction were greater than generation costs and incentives, yielding $\$13.7$ billion in net benefits in 2023. We estimate U.S. health benefits of $\$24$/MWh and reduced global climate damages of $\$101$/MWh. -Adding battery storage is one way to increase the value of solar. Deployment of 52 new PV+battery hybrid plants set a record with 5.3 GW installed in 2023. Our public data file tracks metadata and PPA prices from more than 100 PV+battery hybrid projects that are already online or that have secured offtake arrangements. -Looking ahead, a massive pipeline of at least 1,085 GW of solar capacity dominates the nation’s interconnection queues at the end of 2023. Nearly 571 GW, or 53%, of that total was paired with a battery – in CAISO it was a staggering 98%. Historically only 10% of the requested solar capacity is built. -For more information, and to explore related interactive data visualizations, go to utilityscalesolar.lbl.gov.

14 SOLAR ENERGY↗
DOE OSTI2023

Utility-Scale Solar, 2023 Edition: Analysis of Empirical Plant-level Data from U.S. Ground-mounted PV, PV+battery, and CSP Plants (exceeding 5 MWAC)

Berkeley Labs "Utility-Scale Solar", 2023 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2022, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, and interconnection queue data.

analysis↗
DOE OSTI2022

Utility-Scale Solar, 2022 Edition: Analysis of Empirical Plant-level Data from U.S. Ground-mounted PV, PV+battery, and CSP Plants (exceeding 5 MWAC)

Berkeley Labs "Utility-Scale Solar", 2022 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2021, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, and interconnection queue data.

2022↗
DOE OSTI2024

Utility-Scale Solar, 2024 Edition: Analysis of Empirical Plant-level Data from U.S. Ground-mounted PV, PV+battery, and CSP Plants (exceeding 5 MWAC)

Berkeley Labs "Utility-Scale Solar", 2024 Edition presents analysis of empirical plant-level data from the U.S. fleet of ground-mounted photovoltaic (PV), PV+battery, and concentrating solar-thermal power (CSP) plants with capacities exceeding 5 MWAC. While focused on key developments in 2023, this report explores trends in deployment, technology, capital and operating costs, capacity factors, the levelized cost of solar energy (LCOE), power purchase agreement (PPA) prices, wholesale market value, net value, and interconnection queue data.

analysis↗
DOE OSTI2024

Technoeconomic Analysis of a Solar Thermochemical Fuel Production Process Using a Packed-Bed Redox Reactor

The production of sustainable liquid fuels is paramount in decarbonization of difficult to abate sectors such as the aviation and maritime sectors. Solar thermochemical fuel production is a promising pathway to produce such fuels using concentrated solar thermal (CST) power driving high-temperature redox reactions, coupled with a gas-to-liquid process. In this work we present a preliminary technoeconomic analysis of a solar fuels plant, utilizing a new fixed-bed countercurrent redox reactor and combining both CST and photovoltaic arrays to supply the required energy.

ENERGY STORAGE,HYDROGEN,SOLAR ENERGY↗
DOE OSTI2024

Studying Wind Loading on CSP Collectors to Improve Performance and Reliability

Electricity generation through Concentrating Solar-thermal Power (CSP) adds the advantage of thermal energy storage and heat production. CSP collector costs constitute nearly one-third of total plant costs. Managing wind loading, especially dynamic wind loading caused by the turbulent wind flow, is a significant design challenge. Traditional collector designs rely on wind tunnel experiments and numerical simulations, which do not fully capture dynamic effects. Here, we provide an overview of NREL's activities on wind loading on CSP collectors, aiming to improve their reliability and cost-efficiency. We present insights from field measurements at operational parabolic trough and power-tower CSP plants. Over two years, we measured turbulent wind fields and resulting structural loads in a parabolic trough plant, revealing wind, turbulence, and collector field interactions. Similar measurements are ongoing at the Crescent Dunes heliostat field. These campaigns show how atmospheric turbulence, wind direction, and collector orientation affect dynamic wind loading. Upwind collector structures can generate turbulent structures, causing fluctuating loads at downstream collectors, impacting fatigue lifetime and optical efficiency. Preliminary results indicate that interior collectors experience higher turning moments than those at the edges, suggesting higher drive wear. At Crescent Dunes, we use instrumented heliostats at the field's edge and interior to study the translation of turbulent wind to dynamic structural loads. The campaign is still ongoing, and we will present first findings. Another focus of our work is tying the experimental wind loading findings to optical performance of the collectors, using simulation tools. For example, we derive torsional errors of the parabolic troughs - the angular offset from the sun position along a collector row. This error is impacted by wind-induced mirror deformations. Future work will focus on continuing the measurement efforts and combining them with computational fluid dynamic simulations. By providing detailed field measurements and validated models, our efforts aim to enhance understanding of wind loading on CSP collectors, improving their structural integrity and optical performance.

CSP↗
DOE OSTI2023

Integrated Micro‐Scale Concentrating Photovoltaics: A Scalable Path Toward High‐Efficiency, Low‐Cost Solar Power

The global energy market is seeing increases in the electricity demand of a couple of percentage points annually. The photovoltaic (PV) industry is also growing rapidly every year. One of the PV technologies is concentrator photovoltaics (CPV). CPV uses high‐efficiency multijunction solar cells and optics to concentrate sunlight, thereby significantly reducing the amount of semiconductor material needed. Yet, due to the high upfont manufacturing cost of CPV, it currently does not offer a competitive price against silicon PV. With this a new branch is introduced to the industry, micro‐CPV, which can be broadly explained as the miniaturization of the solar cells and optical components. The motivation for micro‐CPV is lowering the cost by decreasing the material volume and enabling new system architectures and high‐throughput manufacturing methods, while still maintaining high electrical efficiencies, taking advantage of a lower thermal load, shorter optical paths, lower resistive losses, and lower material volumes. Herein, a comprehensive review of the technological advances is presented, key synergies between micro‐CPV and other industries sharing similar challenges are identified, exemplified by micro‐light emitting diodes display manufacturing. New assembly process development in these industries will facilitate commercial adoption of micro‐CPV with continued miniaturization while driving down the cost.

Jost, Norman↗
DOE OSTI2024

Techno-Economic Analysis of Greenfield Geothermal Hybrid Power Plants using a Solar or Natural Gas Steam Topping Cycle

The relatively low generation costs associated with wind, solar photovoltaic (PV), and natural-gas power plants make it challenging for geothermal power plants to produce and sell the power that has the reliability and sustainability characteristics that are greatly needed in U.S. power markets. This is especially true for geothermal resources with low-to-medium temperatures, which results in relatively low-thermal efficiency and generation costs that are higher than those for wind, solar PV, and natural gas. This analysis evaluates solar thermal- and natural-gas combustion waste heat recovery-based topping cycle hybridization of geothermal binary power plants. This approach provides several benefits that may allow geothermal power plants to generate power at more competitive costs. First, the addition of solar thermal energy or natural-gas combustion waste heat input to a geothermal power plant provides additional heat input that can be converted to electrical power. Second, the temperature level of the heat obtained from concentrating solar collectors or natural-gas combustion exhaust is higher than that of geothermal heat, which provides opportunities for improving the efficiency of the conversion of thermal energy to electrical power. Third, the ease with which solar thermal systems integrate with energy storage and the flexibility of natural gas means power generation can occur during peak demand periods. The hybrid cycles are compared to equivalently sized, co-located, independent geothermal, concentrating solar, and/or natural-gas power plants. The hybrid cycle tends to produce slightly more power than the standalone plants combined. However, the hybrid plant Levelized Cost of Energy (LCOE) is slightly higher than the LCOE of the combined standalone power plants for each of the case study locations investigated. Using the steam-topping cycle, organic Rankine cycle (ORC)-bottoming cycle hybrid plant design to combine a solar thermal resource and low- temperature geothermal resource (<120 degrees C) leads to a hybrid plant with a lower LCOE than a standalone geothermal-only system. Thus, hybrid plants may enable the economic development of geothermal resources in locations with low geothermal resource temperatures. However, in areas with higher geothermal resource temperatures (>120 degrees C), the geothermal-only plant has a lower LCOE than the hybrid cycle and thus could be developed without the need for solar heat addition. iv A geothermal-natural-gas reciprocating engine hybrid plant was evaluated for an Elk Hills, California case study location. The Elk Hills case study analysis indicates that when the natural-gas engine operates for more than 12 hours per day the hybrid plant can produce power at an LCOE lower than a standalone geothermal plant, and comparable to that of the standalone natural-gas reciprocating engine, while also reducing the carbon intensity of the power generated relative to the standalone natural-gas engine. This may represent a scenario in which the hybrid plant provides an opportunity for the deployment of a low-temperature geothermal resource that otherwise may have an LCOE too high to develop and operate as a standalone resource, while also reducing the carbon intensity of natural-gas generation sources. A "triple-hybrid" plant that combines natural gas, solar thermal, thermal energy storage, and geothermal was also investigated. A natural-gas combustion turbine (NGCT) is added to the geothermal-solar hybrid such that the hot exhaust gas from the gas turbine provides an alternative source of heat to the steam turbine of the hybrid cycle. Analysis results suggest that the triple-hybrid plant has a significantly higher energy generation and revenue than a standalone NGCT or the original geothermal-solar hybrid. The triple-hybrid design benefits most from using a smaller solar field so that the solar energy can be dispatched at the most valuable times available. The triple-hybrid plant also has a lower LCOE than the standalone NGCT. The triple-hybrid plant was evaluated making simple assumptions about the dispatch profile of the gas cycle, and more nuanced and realistic dispatching schedules should be analyzed in future work.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Hybrid Natural Gas Geothermal Combined Cycle Power Plant Analysis

Low temperature geothermal resources, including those associated with oil and gas production, are an underutilized source of low carbon energy. The present work investigates coupling of low-temperature geothermal resources with concentrating solar and/or natural gas energy sources to increase the number of locations at which power generation from low temperature geothermal resources would be technically and economically viable. Stand-alone and hybrid geothermal power cycles are simulated using SimTech IPSEpro process modeling software. Design point strategies for a hybrid power cycle that may operate with either a single heat source or two simultaneous heat input sources are considered. Additionally, off-design power plant operation is investigated to consider the impacts of the heat source availability and ambient temperature variations. The off-design analysis utilizes a modeling tool that predicts power plant performance at each time step as a function of topping cycle heat input (from gas or solar), bottoming cycle heat input (from geothermal), and ambient temperature. Addition of a steam topping cycle to an organic Rankine cycle geothermal power plant provides opportunities to increase the efficiency and power output relative to a stand-alone geothermal power plant. Additionally, use of the waste heat from gas turbine power generation in a geothermal bottoming cycle provides opportunities to increase the amount of power generation associated with each unit of carbon dioxide emitted. This paper will describe the hybrid plant configuration evaluated, discuss the predicted power cycle performance, and compare with stand-alone natural gas and geothermal power generation cases. The power cycle investigated is expected to be applicable for use with conventional hydrothermal resources as well as with geologic thermal energy storage applications and/or enhanced geothermal systems. The steam topping cycle could use a concentrated solar heat source for fully renewable hybrid plant configuration. A plant initially constructed with a natural gas topping cycle heat source could be converted to a solar heat source part way though the power cycle operational life to achieve life cycle carbon emission reductions.

concentrating solar power↗
DOE OSTI2024

Evaluation of Additively Manufactured Monolithic SiC and SiC-Matrix Ceramic Matrix Composites for Concentrating Solar Receiver Applications - Fabrication and Testing of Receiver Design Feature Specimens in a Simulating Lab Test via Laser Heating

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. We report the results of our study of the effective heat transfer characteristics of several candidate SiC structure motifs, or feature geometries, which are fabricated via additive manufacturing. The SiC structure motifs studied include different permutations of three-dimensional periodic lattices and defined shapes. A solar-thermal simulating laboratory test setup is constructed using a 4kW CO2 laser system with beam shaping optics to apply concurrent radiative heating power on one face of 2”-diameter cylindrical feature specimens, representing the structure motifs of interest for receiver element design, while flowing through the sample as heat transfer fluid. Using the test setup, simulative test conditions representative of a concentrated solar flux of up to ~2000 suns could be achieved in the lab tests under varying air flow through the test structure. A simple 1D numerical analysis scheme is developed to extract an effective or compound heat transfer coefficient representative of the test structure under steady-state heat flow conditions. The test results and their use to guide the selection and optimization of SiC material and structure motifs for the receiver element design fabrication are discussed.

14 SOLAR ENERGY↗
DOE OSTI2024

Evaluation of Thermal & Mechanical Properties of Additively Manufactured Monolithic SiC for Solar Receiver Applications

Increasing the operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. State-of-the-art SiC volumetric concentrating solar air receivers such as the honeycomb design have successfully demonstrated in field exit air temperatures approaching 800oC. However, a successful application of CST systems for the decarbonization of heat reliant industrial sectors requires significant increases in the temperature capability of SiC receiver technology. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Research in collaboration with Heliogen Holdings Inc, is engaged in the development of an ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and demonstrate a techno-economically viable SiC air receiver technology that can achieve exit air temperatures up to 1100oC for CST applications. We report and discuss the results of our testing and evaluation of thermal and mechanical properties of reaction-bonded SiC fabricated via binder jet printing to support the receiver component design, development, and analyses.

14 SOLAR ENERGY↗
DOE OSTI2024

Thermo-Mechanical Modeling and Evaluation of the Cracking Response of Additively Manufactured Monolithic SiC Lattice Structures Subjected to Laser Heating

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. The state-of-the-art SiC volumetric concentrating solar air receivers such as honeycomb design have been demonstrated in field tests to achieve exit air temperatures approaching 800oC. However, successful application of CST systems for decarbonization requires significant increase in temperature capability of SiC receiver technology. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Research in collaboration with Heliogen Holdings Inc, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to design and to demonstrate a techno-economically viable SiC air receiver technology to achieve exit air temperature of 1100oC for CST applications. This report summarizes the learnings of a computational study on additively manufactured SiC lattice structures subjected to laser heating. The results from this study aim to help guide the design of a SiC receiver through a better understanding of lattice structure geometric parameters and their implications on the cracking response of the structure. In the study, a heat flux was applied to the surface of a 2”-diameter cylindrical lattice structure to simulate a 4kW CO2 laser. The resulting temperature distribution was applied to a structural model to approximate the stress distribution within the lattice structure and a Weibull analysis was performed to gain insight into the probability of failure and to evaluate the cracking response of the structure. With this approach, the influence of lattice density on temperature, stress, and probability of failure was explored for two different lattice beam spacings. A discussion on modeling assumptions, a comparison with experimental results, and an evaluation of the lattice cracking response is provided.

14 SOLAR ENERGY↗
DOE OSTI2024

Demonstration of a multi-channel fluidized bed particle–supercritical carbon dioxide heat exchanger for concentrating solar applications

High-temperature thermal energy storage in oxide particles at temperatures above 600°C can couple concentrated solar energy with high-efficiency thermal power cycles to provide dispatchable solar-driven electricity. Challenges remain in developing cost-effective primary heat exchangers, which require expensive alloys, to extract the high-temperature thermal energy from the particles to power cycle fluids, such as supercritical CO 2 (sCO 2 ) in recuperated Brayton cycles. To explore one pathway for cost-effective, high-temperature particle heat exchangers, the current study demonstrates a shell-and-plate, particle–sCO 2 heat exchanger with narrow- channel fluidized beds coupled with micro-channel sCO 2 flows in the heat exchanger walls. This study evaluates the feasibility of multiple parallel, narrow-channel fluidized beds in shell-and-plate particle–sCO 2 HXs, to achieve high bed-wall heat fluxes at elevated temperatures. A reduced-order model simulates the narrow- channel, fluidized-bed particle–sCO 2 heat exchanger to design the fluidized bed geometry, in terms of depth, height, and number of channels,for a nominal 40-kWth heat exchanger at particle and sCO 2 inlet temperatures up to 600 °C and 400 °C respectively. The resulting shell-and-plate heat exchanger design operates with bubbling fluidization of the downward-flowing oxide particles to enhance bed-wall heat transfer. The heat exchanger core is fabricated with etched sCO 2 micro-channels in thin wall plates that are diffusion bonded to spacer frames to form the shell-and-plate structure with 12 parallel, fluidized bed channels, 10.4 mm deep. The heat exchanger is tested at the National Solar Thermal Test Facility at Sandia National Laboratories with CARBOBEAD HSP particles at design particle flow rates of 0.20 kg s –1 and inlet temperatures up to 525 °C. Results show that fluidization across multiple parallel channel beds can maintain uniform particle inventory with a common freeboard zone above the heat exchanger core. Bubbling fluidization improves particle–wall heat transfer coefficients but also increases axial dispersion of particle thermal energy, which lowers the log- mean temperature difference such that total heat transfer remains relatively constant to within ±10% over a broad range of fluidization gas velocities. The axial dispersion required particle and sCO 2 flow rates to be increased by 25% over model-designed conditions to achieve the targeted 40 kWth, which indicates the importance of incorporating axial dispersion into heat exchanger design models and of deploying bed structures to suppress it. Furthermore, this study demonstrates the feasibility and preferred fluidizing gas conditions for particle heat exchangers for releasing high-temperature thermal energy storage systems.

14 SOLAR ENERGY↗
DOE OSTI2025

Design, Fabrication and On-Sun Performance Evaluation of SiC Receiver Feature Specimens for CST Applications Using Additively Manufactured SiC Materials

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Successful development of CST systems to generate heat for industrial applications requires significant increase in temperature capability and techno-economically viability of the receiver systems. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Aerospace Research in collaboration with Heliogen Holdings Inc and Sandia National Lab, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to demonstrate SiC receiver with air exit temperatures up to 1100 oC and high thermal efficiencies. We report design, fabrication and on-sun test results of SiC components of a prototype 50kW (thermal) HOTSSTAR module. The receiver module architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around a SiC center absorber. The SiC components are fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the reliability and to minimize the risk of cracking damage of SiC test articles in thermal gradient and thermal shock environment of the application, the components were laminated with GE’s MI SiC-SiC CMC. Following extensive design and lab test analyses, selected SiC component designs are tested at Heliogen Lancaster Solar field under highly concentrated solar fluxes around 2000 suns to assess the thermal performance characteristics under realistic field conditions. We report on the test results and compare the thermal performances of different HOTSSTAR SiC absorbers. Finally, we discuss fabrication and initial assembly of a 50kW prototype test module in preparation of on-sun field tests to assess the performance of our final design.

CST, CSP, high temperature, air receiver, SiC, add↗
DOE OSTI2026

Thermomechanical analysis and modeling of a high-temperature light trapping planar cavity solar receiver

The development of durable particle-based high-temperature solar receivers is critical for advancing concentrating solar-thermal (CST) technologies to enable high-efficiency power generation and industrial process heat. Here, this study presents a computational framework to evaluate the thermomechanical performance of a proposed enclosed light-trapping planar cavity receiver designed for particle-based thermal energy systems. The receiver incorporates absorptive cavities and fluidized particle-bed channels to enhance heat capture and reduce thermal losses. Finite element analysis (FEA) is employed to assess stress, strain, and creep-fatigue behavior under concentrated solar flux using realistic thermal boundary conditions derived from coupled system models and experimental assembly parameters. The analysis investigates the influence of particle-to-wall heat transfer coefficients (HTC) ranging from 800 to 1800 W/m 2 .K on the thermomechanical response of six candidate high-temperature alloys: Alloy 740H, Alloy 282, Alloy 617, 316H, Alloy 230, and 800H. Results show that increasing HTC reduces thermal gradients, leading to lower stresses and strains and extended minimum predicted creep life. While all materials satisfy fatigue life requirements under the investigated conditions, significant differences in creep resistance are observed. Alloy 740H consistently exhibits the longest minimum predicted creep life and the most favorable durability margins, followed by Alloy 282, with the remaining materials showing reduced creep resistance under identical loading. The reported creep lives are conservative lower-bound estimates intended for comparative material evaluation. This framework highlights the critical roles of material selection and geometry optimization in improving mechanical durability and reliability of solar-thermal receivers, forming a foundation for future experimental validation and design optimization.

14 SOLAR ENERGY↗
DOE OSTI2020

Ceramic encapsulated metal phase change material for high temperature thermal energy storage

Thermal energy storage (TES) is a broad-based technology for reducing CO₂ emissions and advancing concentrating solar, fossil, and nuclear power through improvements in efficiency and economics. Phase change materials (PCMs) are of interest as TES media because of their ability to store large amounts of heat in relatively small volumes. The volume expansion during a phase change, typically between a solid and liquid, can cause breakage of protective coatings. This paper reports on the fabrication of a ceramic encapsulated metal (CEM) high temperature TES technology using a rotary calcining furnace and a fluidized bed chemical vapor deposition coating technique. Aluminum beads were chosen as the PCM because Al has a high melting point (660 °C), low cost, high heat of fusion, and an ability to form a thin, strong alumina layer capable of supporting the Al melt for subsequent processing. Quite remarkably, this study shows that 1 mm diameter Al can be fluidized up to at least 1500 °C in an appropriate atmosphere while maintaining a spheroid geometry. This allowed for producing a first of a kind CEM whereby Al particles were encapsulated in pyro-carbon (PyC) and high purity, dense chemical vapor deposited SiC. The CEM with a PyC only coating was exposed to thermal cycling to test the performance with a differential scanning calorimeter; the melting point and latent heat were measured to be 648.4 ± 2.8 °C and 293.3 ± 6.2 J/g respectively. It was demonstrated that the CEM design is possible to produce, laying the foundation for manufacturing of high temperature, tunable, TES media.

25 ENERGY STORAGE↗