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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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This document outlines criteria for an “acceptable” measurement or dataset of thermophysical properties of Gen3 CSP materials to be included in an online database and the accompanying supporting information.
This document describe multiple-measurement uncertainty analysis that is implemented to the thermophysical properties measurement or dataset of Gen3 CSP materials curated in an online database (http://gen3csp.gatech.edu/). This uncertainty analysis is based on a textbook method, that follows the American National Standard Institute/American Society of Mechanical Engineering (ANSI/ASME) Power Test Codes (PTC) 19.1 Test Uncertainty and NIST Technical Note 1297. It is also consistent with the international guidelines established by the International Organization for Standardization (ISO).
Pumped thermal energy storage (PTES) is a storage system that stores electricity in thermal reservoirs. In this project, methods of integrating PTES with concentrating solar power (CSP) systems were investigated and their feasibility evaluated. Hybrid "solar-PTES" devices can provide both flexible renewable power generation as well as a variety of electricity storage services. Techno-economic models of PTES and solar-PTES were developed and used to assess their performance, cost, and commercial viability. Systems were optimized using multi-objective optimization techniques. The value that these storage devices provide to the grid was estimated using production cost modelling. Key advances made in this project include the development of detailed techno-economic models that improve state-of-the-art assessments of these technologies. Off-design models were developed and used in grid-analysis models. This work describes for the first time how PTES and solar-PTES behave over a range of operating points and assesses the value that these systems can provide to the electrical grid. Feedback was obtained from experts in the field, which clarified key technological and economic barriers that must be addressed to improve the feasibility of these devices.
Through this DOE funded 3.5-year research project, feasibility of fabricating supercritical carbon dioxide (sCO2) turbine components by powder metallurgy (PM) based near-net-shape (NNS) hot isostatic pressing (HIP) was demonstrated in a turbine nozzle ring, a turbine casing with Haynes 282 powder, and a bimetallic pipe with Haynes 282 and SS415 powder. As-HIP microstructure of various powders and HIP processing conditions was studied to downselect a condition for the prototype components. Tensile strength and low cycle fatigue (LCF) capability of PM HIP 282 was found to be superior to cast 282, despite a debit in creep stress capability that could be mitigated by component design modification. Near-Net-shape with minimal post machining was achieved by modeling the non-uniform shrinkage during HIP cycle and designing the HIP tooling to meet dimensional targets. The prototypes of turbine nozzle ring and bimetallic pipe were successful in achieving overall dimension, microstructure, and properties, despite dimensional tolerance affected by chemical milling rate. The prototype of a 1700lbs turbine casing was partially successful in achieving dimension, microstructure in as-HIP state, and providing consistent mechanical properties, however, cracking issue during post heat treatment required further investigation. The estimated manufacturing cost using NNS HIP was a ~50% reduction compared to forging with extensive machining, which translated into ~$100/kWe CAPEX cost reduction for concentrated solar power (CSP) power block.
In turbomachinery, internal leakage flow accounts for up to 3% of the total thermodynamic cycle energy loss. Tradeoff must be made between the sealing efficiency (smaller clearance) and the friction and wear issues for interfering with the shaft (larger clearance). This ORNL-Danfoss joint effort developed a novel hybrid seal composed of carbon nanotube (CNT)-coated metal meshes. The CNT growth process was based on a self-catalyzing chemical vapor deposition and these multiwall CNTs were well aligned with high crystallinity. This hybrid material structure takes advantage of the CNT’s low-friction nature and uses the metal mesh as an extendable backbone. Full-scale experimental seals were designed, fabricated, and optimized for sealing performance and durability. The CNT-coated metal mesh seal demonstrated superior gas sealing efficiency to the baseline labyrinth seal and significantly improved shaft surface protection compared with the state-of-the-art superalloy brush seal on the static rig and full-scale compressor dynamometer tests. The CNT-metal mesh seal is low-cost and scalable and can potentially benefit wide applications, including CSP and other power generation, marine, automotive, and HVAC.
The National Renewable Energy Laboratory, Missouri University of Science and Technology (MS&T), Massachusetts Institute of Technology (MIT), and Colorado School of Mines (CSM) collaborated to design, develop, and test a material concept at bench scale which will be used to achieve a ceramic-to-metal (C2M) joint between a selected metal HTF loop material and a selected ceramic material used by the Gen3 CSP technology pathway. The final joint assembly will need to possess sufficient mechanical properties to withstand static high-temperature (650 degrees-700 degrees C) and high-pressure (20 MPa) and thermal cycling (between 650 degrees C and 100 degrees C) conditions. The material concept consists of three key components: (1) a ceramic matrix composite (CMC) that serves as a compliant transition material aiming to mitigate the stresses due to the mismatch of coefficient of thermal expansion (CTE) from a direct ceramic-to-metal joint, (2) a metal-end joint utilizing a multi-principal element alloy (MPEA) with changing percentage of particle loading to bond the candidate metal to the CMC, and (3) a ceramic-end joint utilizing a glass ceramic to bond the candidate ceramic to the CMC.
Short and sweet three-minute presentation on CSP metrology techniques
The overarching goal of this project is to come up with an innovative joining solution for integration of SiC ceramic to structural materials such as stainless steels (SS)/Ni-base alloys, where intimate metallurgical bonding between SiC ceramic and the structural metallic alloy is demonstrated at the interface. Implementation of a simple, yet robust joining method would help in increasing the application space of SiC in a high-temperature CSP (concentrated solar power) plant, especially in the receiver section. This research goal has been achieved by creating a functionally graded material (FGM) interface between SiC and the selected structural material with the help of powder metallurgy (PM) approach and demonstrate intimate metallurgical bonding between monolithic RB-SiC and 316L stainless steel alloy blanks.
The Multi-layered Thermal Energy Storage (TES) tank consists of three regions–top and bottom part is packed with suitable Phase Change Materials (PCM) and low-cost pebbles are placed in the middle region, whereas entire tank portion is filled by solid fillers in Single-layered tank system. For a storage tank operating between 563 and 663 K with bed dimensions of 12 and 14.38 m using Solar salt as Heat Transfer Fluid (HTF), it is observed that the duration of discharge for multi-layered tank is 5.32 h whereas it is 4.19 h for single-layered tank with a Reynolds number of 10. The effect of intermediate melting temperature range of PCMs are also analyzed by taking PCMs with sharp as well as intermediate melting ranges. Further, comparison of single and multi-layered systems is carried out by analyzing the temperature profiles and width of both PCM layers. The width of top and bottom PCM layers of tank is varied from 0 to 30% to analyze its effect on the discharging duration. It is observed that multi-layered system provides extra discharge of 1 h with introduction of PCM at top and bottom with a width of 10%. Discharge duration increases with increase in PCM width whereas the percentage increase in duration of discharge with increase in PCM width is comparatively less. It is also seen that PCMs with sharp melting point performs better compared to one having intermediate range of melting temperatures. Multi-layered configuration concept offers best possibilities as integration to CSP plants with desired efficiency.
The operating characteristics (power-current, beam divergence, etc.) and reliability assessment of high-power CSP lasers is discussed. The emission wavelength of these lasers was optimized at 860 to 880 nm. The operational characteristics of a new laser, the inverse channel substrate planar (ICSP) laser, grown by metalorganic chemical vapor deposition (MOCVD), is discussed and the reliability assessment of this laser is reported. The highlights of this study include a reduction in the threshold current value for the laser to 15 mA and a degradation rate of less than 2 kW/hr for the lasers operating at 60 mW of peak output power.
This paper reviews the accelerated thermal cycling test methods that are currently used by industry to characterize the interconnect reliability of commercial-off-the-shelf (COTS) ball grid array (BGA) and chip scale package (CSP) assemblies. Acceleration induced failure mechanisms varied from conventional surface mount (SM) failures for CSPs. Examples of unrealistic life projections for other CSPs are also presented. The cumulative cycles to failure for ceramic BGA assemblies performed under different conditions, including plots of their two Weibull parameters, are presented. The results are for cycles in the range of -30 C to 100 C, -55 C to 100 C, and -55 C to 125 C. Failure mechanisms as well as cycles to failure for thermal shock and thermal cycling conditions in the range of -55 C to 125 C were compared. Projection to other temperature cycling ranges using a modified Coffin-Manson relationship is also presented.
This paper will compare three different CSP concepts as well as their assembly reliability.
Systems, methods and apparatus are provided through which in some embodiments, automata learning algorithms and techniques are implemented to generate a more complete set of scenarios for requirements based programming. More specifically, a CSP-based, syntax-oriented model construction, which requires the support of a theorem prover, is complemented by model extrapolation, via automata learning. This may support the systematic completion of the requirements, the nature of the requirement being partial, which provides focus on the most prominent scenarios. This may generalize requirement skeletons by extrapolation and may indicate by way of automatically generated traces where the requirement specification is too loose and additional information is required.
Hyperlight Regions of Interest and Contamination Characteristics in these regions. Hyperlight LFR CSP Contamination Testbed
Particle based concentrated solar power plants are increasingly being considered as an alternative to molten salts. Although these particle based systems provide the inherent safety and enhanced lifetime from reduced corrosion compared to molten salt systems, they bring in complexities associated with surface erosion from falling particle impact and sliding motion along the surfaces. Past research on particle related erosion has been limited to high velocity applications and doesn’t necessarily coincide with the operating conditions in CSP systems. In our work, we evaluate characterize the rate of erosion for particles and containment materials at 800ºC. Three different types of erosion resulting from a) impact of solid particles on receiver, particle storage, and heat exchanger walls; b) abrasion erosion from particle sliding motion along walls; and c) attrition erosion as the particles breakdown from particle-to-particle contact and particle-to-wall interactions are evaluated and compared across a varied spectrum of particle and containment material spectrum. From the results, It is noted that temperature plays a key role in the rate of erosion experienced by any material. With the increase in temperature, materials become more ductile and are more readily sheared away from particle impinging or sliding motion. Furthermore, the particles themselves have higher susceptibility to breakdown which also lowers particle thermal absorptance and thus efficiency as heat transfer fluid.
This poster presents a novel modular, scalability receiver design for various Concentrating Solar Thermal (CST)-Concentrating Solar Power (CSP) applications and scale of economics.
Package/die stacking technology enhances most aspects of electronic systems such as size, weight, speed, yield, and power consumption.
This study examines the differences in direct normal irradiance (DNI) in two versions of the National Solar Radiation Database (NSRDB) produced by the National Renewable Energy Laboratory (NREL). NSRDB V3 of the NSRDB includes significant changes to various parts of the radiative transfer model and inputs to the model compared to NSRDB V2. The changes in NSRDB V3 resulted in lower uncertainty than NSRDB V2. The study quantified the uncertainty and the spatial and temporal variability under clear-sky conditions. The uncertainty estimation was performed using a standardized method, The Guide to the Expression of Uncertainty in Measurement (GUM). The evaluation of the accuracy of the NSRDB was conducted using high-quality ground-measurements for seven National Oceanic and Atmospheric Administration Surface Radiation Budget Network (SURFRAD) stations for 1998-2015.