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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Heat Transfer of an Integrated Counterflow Ceramic Heat Exchanger

The ceramic-based heat exchanger is one of the leading contenders for high-efficiency concentrating solar power plants using a molten salt heat transfer fluid and a supercritical carbon dioxide Brayton power cycle operating at temperatures above 700 °C due to the excellent resistance of ceramics to corrosion, oxidation, erosion, creep, and fouling. In the present study, the thermal performance of a ceramic silicon carbide prototype heat exchanger, with semi-elliptical heat transfer channels, integrated header channels, and a counterflow configuration fabricated by using binder jetting additive manufacturing, was experimentally investigated. Experimental heat transfer tests of the prototype were conducted at high temperatures and under various test fluid flow rates and inlet temperatures. The experimental heat transfer rates compared favorably with simulation predictions.

Yu, Wenhua (ORCID:0000000219457014)↗
DOE OSTI2023

CSP Design Study for Sandia National Laboratories and Kirtland Air Force Base

This report provides a design study to produce 100% carbon-free electricity for Sandia NM and Kirtland Air Force Base (KAFB) using concentrating solar power (CSP). CSP plant designs of 50 MW and 100 MW are assessed to meet the electricity needs of Sandia NM and/or KAFB. Probabilistic modeling is performed to evaluate inherent uncertainties in performance and cost parameters on total construction costs and the levelized cost of electricity. Estimated annual electricity production was ~200 – 300 GWh for the 50 MW plant and ~400 – 700 GWh for the 100 MW plant. The overnight construction costs ranged between ~$300M - $400M for the 50 MW CSP plant and between ~$500M - $800M for the 100 MW CSP plant. The heliostat field was the most significant subsystem cost, followed by the thermal energy storage, power cycle, and fixed operation and maintenance costs. Other considerations such as land availability and permitting, funding options, and interconnections are discussed.

Ho, Clifford K.↗
DOE OSTI2023

Investigating Various Failure Models on Commercial Silicon Carbide

Structures and components made from ceramic materials are often brittle and can fail by the unstable growth of existing flaws such as voids and cracks. There have been several failure criteria developed for ceramics, in the past and they are broadly categorized based on their dependency on crack geometry. The present work implements eight failure criteria using an open-source software package – srlife, which predicts the lifetime or failure probability of concentrated solar power (CSP) structural components. The present work also checks the viability of building a ceramic CSP receiver, by analyzing the reliability predictions from srlife for a SiC ceramic. The reliability predictions for a biaxial loading problem indicated the Shetty Mixed-Mode criterion gives the most conservative predictions. Whereas, in case of the CSP receiver, the predictions show that the co-planar strain energy criterion gives the most conservative predictions as it is agnostic towards the type of stress, and therefore, is not recommended to be used designing ceramic receivers.

Chaugule, Pawan (ORCID:0000000275706572)↗
DOE OSTI2023

Particle Receiver Models for Systems Analysis

Particle receivers are gaining importance in the field of Concentrating Solar Power (CSP) due to the high temperature that particles can achieve without degradation. Several researchers are studying the potential of this technology by means of system analyses, which need simple and light models of the system. This study presents two simple models for the particle receiver. The simplest model is a correlation obtained by fitting the results calculated with a more complex receiver model simulated in CFD. The other model is a 1D model, which is benchmarked against the same CFD results. Although both models achieve high coefficient of determination, R2, when compared to CFD results, the 1D model seems to provide more accurate results (especially during sunsets and sunrises). Both models are integrated into a tecno-economic model developed in previous work. The LCOE obtained with the 1D model is between 7% and 10% greater than the one obtained with the correlation.

González-Portillo, Luis F. (ORCID:0000000348643825↗
DOE OSTI2023

Cyclic Thermal and Structural Testing of a Hot Particle Storage Bin

Thermal energy storage is a key element in concentrating solar energy systems. In 2017 a Roadmap toward a third-generation system that could meet the SunSHOT goals of 0.06 $/kWe recommended increasing temperatures to > 700° C for heat transfer media to in-crease thermal efficiencies and lower levelized costs of heat. In 2021, the U.S. Department of Energy selected the particle pathway, G3P3, to build a 1 MWt prototype solar tower with 6 MWh thermal energy storage at the NSTTF in Albuquerque, NM. Of the primary components, the falling particle receiver, and particle-to-sCO2 heat exchanger have been demonstrated at the 250 kWt capacity. The storage component is now being demonstrated as part of the G3P3-USA and G3P3-KSA pilot plants. Storage bin liner materials have been demonstrated by KSU in 2016 and 2019. A flowing particle storage container was demonstrated in 2020 by KSU. The testing presented in this work will be the first to test the particle to wall interactions with mono-lithic refractory insulation, and to validate a transient thermal transport model with the unique kinetics of bulk solids in funnel-flow where cooler particles near the walls flow inward toward a hot central flow channel. This work will also de-risk and characterize the specific design of the G3P3-USA storage bin.

Sment, Jeremy↗
DOE OSTI2023

Design of a Continuous Electrochemical Purification Reactor for Corrosion Mitigation in Molten Chloride Salt Systems

The utility of molten chloride salts in concentrating solar power (CSP) is dependent on the ability to maintain low corrosive impurities. Without proper purification, the corrosion rates of containment alloys exceed the industry standard of corrosion—under 20 μm/year. An extensive body of literature focuses on the initial purification stage of molten chloride salts. However, occurrences such as maintenance, leaks, and so forth expose the salt to the atmosphere and reintroduce impurities. Therefore, it is critical to develop a purification strategy that can control impurity levels during CSP plant operation. Here we present the design and fabrication of a purification vessel to continuously remove impurities out of flowing molten salt.

Witteman, Liam↗
DOE OSTI2023

Summary Paper: An Initial Heliostat Supply Chain Analysis

This paper summarizes the prior analysis, key findings, and recommendations from the published report titled “Initial Heliostat Supply Chain Analysis” [1]. 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 commodity materials can be sourced in the domestic market where power plant will be constructed. Although specialty components are required for CSP solar fields —including mirror panels used for heliostat applications—these specialty components constitute about 30-50% of total system installed costs [2]. Only a few companies and countries, including the United States, have developed the capacity to supply such specialty components. The U.S. heliostat supply chain at present is comprised of few companies (e.g., CSP developers), component suppliers, and is its infancy. By 2035, with current and aggressive solar photovoltaic (PV) capacity expansions, there is the potential for 500,000–1,500,000 direct and indirect jobs in the areas of manufacturing, installation and development, and operations and maintenance (O&M) [3]. Utilizing the CSP capacity estimations the recent NREL report [4], the construction of 39 gigawatts (GW) of CSP (assuming mainly power tower) in the U.S. could lead to approximately 195,000 manufacturing, construction, and O&M jobs. This does not include the longer-term jobs and economic impact (e.g., taxes from plant operations staff) from operating the plants once constructed. It is recommended that further CSP component and system supply chain analysis and modelling be undertaken.

Kurup, Parthiv (ORCID:0000000217356703)↗
DOE OSTI2023

Equivalent Breakeven Installed Cost: A Tradeoff-Informed Measure for Technoeconomic Analysis of Candidate Heliostat Improvements

Technoeconomic analysis (TEA) is commonly used to determine economic viability of power-generating technologies, including concentrating solar power (CSP) and thermal (CST) production plants. Levelized cost of electricity (LCOE) and analogous measures provide an estimate of long-term costs for operating power plants over their designed lifetimes by accounting for revenues and costs in a time-discounted manner. While these measures are effective when assessing a technology’s total lifecycle costs and productivity under various designs, TEA of candidate incremental technology improvements from the lens of LCOE can be limited when required investment and LCOE impacts are small. In this work, we propose a novel metric for TEA of a plant component technology that recasts relative changes in levelized system costs into component-specific capital cost budgets. This measure, which we refer to as the equivalent breakeven installed cost, is the maximum budget for the technology component that leads to improved levelized costs. We illustrate the usefulness of this metric using the example of candidate heliostat improvements for a CSP tower plant. Here, the results suggest that a reduction in mirror washing costs yield a total plant O&M cost of $37/kWe-yr, which is a breakeven proposition if the average reflectance is reduced from 0.90 to 0.85 as a result of the cost savings.

Zolan, Alexander (ORCID:0000000326017604)↗
DOE OSTI2023

Modelling and Optimizing CSP-PV Hybrid Systems Using the Hybrid Optimization and Performance Platform (HOPP)

The hybridization of concentrating solar power (CSP) with thermal energy storage (TES), photovoltaics (PV), and electrochemical battery energy storage systems (BESS) has the potential to provide continuous, high-capacity-factor energy production at a lower cost than a PV-BESS or CSP with TES alone. Because of the system complexity of CSP technology, it is challenging to evaluate the technological and financial performance of a CSP-PV hybrid system without detailed modeling of annual operations. To address this challenge, we have developed a modeling framework for evaluating the performance and financial viability of CSP systems hybridized with PV and BESS technologies. This modeling effort incorporates CSP tower and trough configurations into an existing modeling tool recently developed by NREL, the Hybrid Optimization and Performance Platform (HOPP). This paper provides a brief overview of our methodology, as well as an example case study. CSP with TES hybridized with PV provides the best benefit-to-cost ratio compared to the other simulated technology combinations. However, for the conditions considered, this configuration only increases the benefit-to-cost ratio by about 1% compared to the CSP with TES configuration. The PV-BESS system provides the lowest benefit-to-cost ratio compared to the other configurations explored because of the relatively low capacity credit received by the system.

Hamilton, William (ORCID:0000000244654239)↗
DOE OSTI2023

High Temperature Ternary Chloride Molten Salt Pump

A ternary chloride (MgCl2-NaCl-KCl) molten salt pump has been developed to operate up to 720°C. The design is the result of a thermal, structural and material study of critical components. The vertical overhung pump incorporates first of a kind salt-wetted hydrodynamic bearings. Several bearing material pairings were tested which include: colmonoy grades, stellite grades, and a novel NiWC-based alloy (i.e. HybrimetTM NiWC3b) used as a High Velocity Oxygen Fuel (HVOF) coating. The coating withstands the corrosion effects of the molten salt, and is also used to protect a 316L stainless steel pump reservoir. The pump bowl assembly components are made of Inconel 625. A Nitrogen flushed carbon ring seal is used to keep salt vapors from interacting with external ambient air. Preliminary testing shows a promising pump design for use in the Concentrating Solar Power Gen 3 systems and sets the ground for further development of the HybrimetTM NiWC3b as a competitive alternative to available superalloys.

Handy-Cardenas, Lewis (ORCID:0009000744006972)↗
DOE OSTI2024

Time-Dependent Failure Assessment of Ceramic Receivers

The outlet temperature targets for Gen 3 Concentrating Solar Power (CSP) systems pose a significant challenge to the structural reliability of high temperature metallic components, including those manufactured from nickel-based superalloys. Advanced ceramics present a potential solution due to their excellent high-temperature strength. However, accurate assessment of ceramic components requires an entirely different approach compared to metallic components. This paper describes the implementation of time-dependent reliability analysis of ceramic components in srlife – an open-source software package for estimating the life of high temperature CSP components. This new capability will allow high temperature CSP designers to make fair comparisons between competing metallic and ceramic designs and accurately assess the performance of different ceramic materials for CSP receivers and other components. The current version of the tool is available at https://github.com/Argonne-National-Laboratory/srlife.

Barua, Bipul (ORCID:0000000247184113)↗
DOE OSTI2024

Modeling Dense Particle Flow in Multistage and Obstructed Flow Receivers Using High Fidelity Simulations

Particles are a leading contender for next-generation, concentrating solar power technologies, and the design of the particle receiver is critical to minimize the levelized cost of electricity. Falling particle receivers (FPRs) are a viable receiver concept, but many new designs feature complex particle obstructions that include dense discrete phase flows. This creates additional challenges for modeling as particle-to-particle interactions (i.e., collisions) and particle drag become more complex. To improve upon existing modeling strategies, a CFD-DEM simulation capability was created by coupling two independent codes: Sierra/Fuego and LAMMPS. A suitable receiver model was then defined using a traditional continuum-based model for the air and a granular model for the particle curtain. A sensitivity study was executed using this model to determine the relevance of different granular model inputs on important quantities of interest in obstructed flow FPRs: the particle velocity and curtain opacity. The study showed that the granular model inputs had little effect on the particle velocity magnitude and curtain opacity after an obstruction.

Mills, Brantley↗
DOE OSTI2026

Development and Validation of Low-Cost, High-Reflectance Composite CSP Facets: SIPS Final Report

This work investigates the various challenges associated with developing heliostat structural composite facets using 1 mm glass mirrors. Such facets are desirable for Concentrating Solar Power because 1 mm glass mirrors provide an absolute increase in reflectivity of 2-3 % over the industry standard of 4 mm glass mirrors. Prototypes of paraboloid composite facets with 1 mm glass mirrors were constructed that have a root mean square slope error on the order of 2 mrad while achieving greater than 96% reflectivity. These facets were constructed using a low-quality aluminum mold and a bill of materials that show potential to achieve cost parity with existing 4 mm glass mirrors supported by structural steel. The facets produced were able to survive up to 50 mm hail ball impacts and were robust against accelerated environmental cycling designed to expose durability concerns. Further work is needed to develop a scalable and cost-effective manufacturing process with a similar bill of materials.

14 SOLAR ENERGY↗
DOE OSTI2026

Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) Tool, for Indoor Optical Analysis of Heliostats

Under HelioCon, NLR began developing a new optical measurement system, called Reflected Target Non-Intrusive Assessment (ReTNA). ReTNA has shown promise towards addressing metrology gaps for heliostat used in concentrated solar thermal (CST) plant. This project is focused on advancing this measurement system from the laboratory into industry, where it can provide valuable information for heliostat developers during research, development, and qualification of a heliostat design, and be used for quality assurance during heliostat manufacture. Over the course of this project, ReTNA was deployed at several commercial heliostat facilities. The system developed and deployed with the primary project partner, Solar Dynamics LLC, is described in detail. The report discusses each project Milestone, the ending status, the achieved value, and how these Milestones improve and qualify the ReTNA measurement tool. Finally, the final report covers the market advancements, path forward, commercial successes, and lessons learned. Final Technical report for TCF Base Technology-Specific project TCF-23-20118, Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) tool, for indoor optical analysis of Heliostats.

14 SOLAR ENERGY↗
DOE OSTI2026

Testing and Validation of Wireless Communication Architecture for Heliostat Fields: SIPS Final Report

This work focuses on the development and testing of a low-cost wireless communication system for heliostat fields, enabling significant capital costs reductions for concentrating solar thermal systems. Outputs of this work include a working demonstration of a multi-node communication system, clear reporting of system performance, and technical documentation of system development and architecture for reproducibility. Through this process, an open-source repository was created for manufacturing hardware at ~$30/heliostat. The system includes software for cybersecurity, achieving sub-second communication latencies and derisking of hardware for eventual scale-up to tens of thousands of heliostats. While the system is not currently off-the-shelf ready, there is now a clearly defined pathway for scaling up and completing the commercial development process.

14 SOLAR ENERGY↗
DOE OSTI2026

EXERGETIC: De-Risking Next-Generation Resilient Geothermal Hybrids via At-Scale Evaluation Using Virtual Emulation Digital Twin Environment for Efficient Operation

The DOE-GTO-funded project, award number 5.1.2.12, entitled "EXERGETIC - De-risking Next Generation Resilient Geothermal Hybrids via at-Scale Evaluation Using a Virtual Emulation Digital Twin Environment for Efficient Operation," advances the solution to these challenges by developing and validating a geothermal co-emulation environment implemented at the National Laboratory of the Rockies (NLR)'s Advanced Research on Integrated Energy Systems (ARIES) platform. This framework enables the de-risking of next-generation geothermal and geothermal hybrid systems through high-fidelity modeling, real-time digital emulation, advanced control strategies, and techno-economic assessment. The project focused on geothermal hybrid configurations that integrate geothermal power plants with concentrated solar power and underground thermal energy storage, enabling enhanced efficiency, flexibility, and grid support capabilities. The main goal of this project was the development of a geothermal digital co-emulation environment to demonstrate the technical and economic value of geothermal hybrid systems and their contribution to grid stability and flexibility. The EXERGETIC framework combined physics-based models, controls, and real assets at ARIES, including digital real-time simulators (DRTS), a 20-MW-scale controllable grid interface (CGI), and a 2-MW conventional generator. Detailed transient models were developed for the key subsystems of a hybrid geothermal plant, including parabolic trough solar collectors, reservoir thermal energy storage (RTES), and a binary Organic Rankine Cycle (ORC) power plant. The ORC model explicitly captured thermal inertia and off-design operation and integrated control strategies to dynamically respond to electric load profiles. The models were validated against published experimental and numerical studies, demonstrating strong agreement and confirming the accuracy and robustness of the modeling approach. The resulting digital twin represents geothermal-solar-storage systems at multiple scales (1 MW to 100 MW) and enables realistic emulation of grid-connected operation. The control architecture allows the geothermal resource to provide stable baseload generation, while solar and stored thermal energy supply flexible, dispatchable support during periods of high demand or variable grid conditions. A key contribution of the EXERGETIC project is the demonstration that geothermal hybrid systems can be designed to be active grid assets rather than passive baseload generators. Using the ARIES platform, the digital twin was evaluated under multiple grid scenarios, including load following, voltage support at the distribution level, and frequency response at the transmission level. Results show that hybrid geothermal systems can respond effectively to dynamic grid conditions, providing inertia-like behavior, primary frequency support, and voltage regulation through coordinated control. In addition to the performance and grid services capability analysis of geothermal and hybrid geothermal systems, the EXERGETIC project also focused on scalability and techno-economic analysis of geothermal hybrid plants. In particular, for the scalability analysis, machine-learning (ML)-based surrogate models were trained using data generated from the geothermal digital twin under different grid-connected scenarios and plant capacities. These ML models demonstrated strong interpolation and extrapolation capabilities across plant sizes, accurately reproducing both steady-state and transient responses with very low errors. Regarding the techno-economic analysis, plant performance results were integrated with cost models for hybrid geothermal systems, and the levelized cost of electricity (LCOE) was used as the main economic metric to evaluate system performance across a range of system capacities, solar shares, solar multiples, and storage durations. Results indicate that economies of scale significantly reduce geothermal LCOE as plant capacity increases, with large-scale systems (25-100 MW) achieving substantially lower costs than small plants. Hybridization with solar thermal energy and storage further improves economic performance by increasing capacity utilization and enabling flexible dispatch. In addition, thermal storage plays a critical role in reducing LCOE by maximizing geothermal, solar, and stored energy resources. In summary, the results from this project demonstrate that geothermal hybrid systems represent a promising alternative for increasing the energy conversion efficiency of geothermal technologies, contributing to the preservation of geothermal resources, and supporting the transition of geothermal plants from traditional baseload resources into flexible, resilient, and cost-competitive energy conversion technologies.

15 GEOTHERMAL ENERGY↗
NASA NTRS1976

Third Working Meeting on Gallium Arsenide Solar Cells

Research results are reported for GaAs Schottky barrier solar cells, GaAlAs/GaAs heteroface solar cells, and GaAlAs graded band gap solar cells. Related materials studies are presented. A systems study for GaAs and Si solar concentrator systems is given.

Walker, G. H.↗
NASA NTRS1976

A comparison of GaAs and Si hybrid solar power systems

An analytical comparison of energy output from various silicon and gallium arsenide hybrid solar power systems, producing electric power and also thermal power for heating or cooling, is made. System performance indices in terms of capital cost, peak power, total power output, and electric power were evaluated. Limiting values for annual energy production from GaAs and Si solar concentrator systems were estimated to be 2 cents and 6.8 cents per kWh for GaAs concentrator systems and between 2.5 cents and 11 cents per kWh for Si concentrator systems.

Heinbockel, J. H.↗