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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 19 records

Dynamic modeling of heat pipe integrated thermal battery latent heat storage system experiment validation

A heat pipe integrated thermal battery system has been constructed to investigate a high-temperature latent heat thermal energy storage technology that takes advantage of near isothermal operation of latent heat storage and heat pipes to potentially enable high-energy isothermal heat storage. A dynamic model constructed in Modelica has been validated, showing errors between 2.5 °C–39.7 °C across 10-h to 47-h simulations against experiment results, showing good prediction capability of experiment output, especially against phase change time. Model calibrations showing vessel heat-up capability of 3 kW and heat pipes combining to provide 600 W each during experiment operation validate experiment circumstances including reduced material loading and reduced power capability. The experiment configuration uses an Al-Mg-Zn eutectic metal as the storage material, heated via heat tape wrapped around the vessel and guide tubes to bring the system to operation range (>400 °C) and to simulate charging heat exchange, respectively, with heat rejection occurring through the surfaces of the material and facilitated via guide tubes with less insulation wrapping. The model is available in the open-source repository HYBRID on Github.

25 - ENERGY STORAGE↗

Atomistic insights into the synergistic effects of tensile strain and hydroxyl group on increasing the thermal conductivity of monohydric alcohols as latent heat storage materials

The low thermal conductivity of linear monohydric alcohols significantly limits their performance when used as latent heat storage materials. It was found that imposing certain mechanical strains on nanomaterials with highly ordered structures can lead to appreciable thermal conductivity enhancement. To explore the potential of enhancing the intrinsic thermal conductivity of monohydric alcohols, a simplified ideal crystal model was employed for molecular arrangement in this work. The variation of atomistic heat transfer as a function of tensile strains was exploited by non-equilibrium molecular dynamics simulations. Furthermore, the influence of stretching on the vibration density of states and the corresponding molecular morphology were revealed. The results suggested that the thermal conductivity of monohydric alcohols with such simplified ideal crystalline structures can increase by about 170 % at the strain of 0.1. The distance between neighboring interfaces was found to determine the energy of inter-molecular interactions at the crystal grain boundaries. The hydrogen bonds energy has not reached the critical value when increasing tensile strains from 0 to 0.1. In contrast, the strongest van der Walls interactions for alkanes were obtained at the strain of 0.06 where the interfacial distances of alkanes have achieved their equilibrium distances. In addition, the interfacial heat transfer coefficient of ideal crystal monohydric alcohols at hydroxyl interfaces was found to be threefold than that between methyl interfaces, in consistent with the strength of inter-molecular interactions between functional groups at the interfaces.

36 MATERIALS SCIENCE↗

High-Temperature Latent Heat Storage System using Transportable Heat Pipes for Versatile Integration with Emerging Microreactors

With the growing interest in the development of micro nuclear reactors and their application to microgrid, high-temperature thermal energy storage (TES) has also been receiving great attention as a technology to reinforce the energy utilization and profitability of this class of reactors. Given the importance and research needs of the TES technology, a research project is underway at Idaho National Laboratory (INL) to develop high-temperature TES that can be easily interfaced with emerging micro nuclear reactors. Currently under development is the Heat pipe-Integrated Thermal Battery (HITB), a novel latent heat storage design that enables flexible and robust integration with any design of currently considered micro nuclear reactors. The development of detailed design based on the proposed TES concept, HITB, requires not only development and validation of modeling and simulation capabilities, but also research that spans thermal performance analysis, component- and system-scale design optimization, and experimental demonstrations including high-temperature feasibility testing. The current research efforts (and plans) are divided into the following four areas: (i) Thermal and structural modeling and analysis at both system- and component-scales for evaluating performance and conducting design optimization, (ii) Small-scale experimental demonstrations for the key components of the proposed HITB design, (iii) Modelica-based dynamic model development for developing a control strategy under dynamic operation within integrated energy systems configuration, (iv) Integrated experimental testing and demonstration. This paper introduces the overall research efforts that have been and are being conducted to develop and demonstrate the novel design of the high-temperature latent heat storage device, HITB. The key design features, ongoing research efforts including the development of modeling and simulation capabilities, small-scale demonstrations of the HITB’s key functionalities prior to scaled-up experimental demonstration, are discussed. Then, this paper concludes with a remark on the future research plans for this project.

25 ENERGY STORAGE↗

Performance Investigation of High-temperature Latent Heat Storage for Integration with Advanced Nuclear Reactors

Integrating thermal energy storage (TES) with advanced nuclear reactors enhances the flexible use of nuclear energy, facilitating its expansion beyond conventional electricity generation. High-temperature TES, capable of storing heat above 400 degree C, emerges as a vital carbon-free energy solution for decarbonizing industrial sector, especially when combined with low-emission energy sources like advanced nuclear reactors. Idaho National Laboratory (INL) has recently developed a novel design for high-temperature latent heat storage system, called Heat pipe Integrated Thermal Battery (HITB), and efforts are underway to experimentally demonstrate the concept. HITB employs liquid-metal heat pipes to establish thermal linkage between TES and nuclear systems without direct fluid exchange, minimizing the potential risk of the integrated systems such as cross-contamination. HITB is designed to achieve high charging and discharging efficiency as well as high energy storage density by employing metal alloys as Phase Change Material (PCM). Initial proof-of-concept experiments are being undertaken using an aluminum alloy (Al59%-Mg35%-Zn6%). This paper discusses current progress of the HITB project at INL, seeking to develop high-temperature TES for versatile integration with advanced nuclear reactors, and shares insights from the performance evaluations via numerical modeling and analysis.

25 ENERGY STORAGE↗

Nature-inspired lotus-shaped fins combined with hybrid nanoparticles and metal foam for high-performance latent heat thermal energy storage

Latent heat thermal energy storage (LHTES) systems play a critical role in renewable energy integration by providing high energy density and nearly isothermal operation during phase transitions. However, their performance is often limited by slow melting/charging rates, which motivates the search for enhanced heat transfer designs. This study investigates the melting behavior of RT-82 phase change material (PCM) using novel lotus-shaped fins combined with copper metal foam and conductive graphene nanoparticles and carbon nanotubes. A two-dimensional enthalpy-porosity model in ANSYS Fluent was developed to simulate the charging/melting process, capturing non-thermal equilibrium between the foam and PCM/nano-PCM. In this study, effects of fin geometry, nanoparticle concentration, and foam porosity on melting dynamics and cost-performance trade-offs were investigated. Results showed that natural convection accelerated melting by ~12% compared to conduction-only scenarios. Optimized lotus-shaped fins with higher fin density (T3F4 and T3F10) achieved up to 63% faster melting relative to sparse configurations. Graphene nanoparticles improved thermal conductivity, with a 6% volume fraction, by reducing melting time by ~6.9%, while their combination with 75% porosity foam achieved a maximum reduction in the melting time of ~51% compared to pure PCM. Cost-performance analysis identified T3F4 as the most balanced design, offering rapid thermal response without excessive material costs, while moderate-density designs like T3S6 provided economical alternatives with acceptable performance. These results highlight the performance enhancement that can be achieved by integrating bio-inspired fins, nanoparticles, and foams, into compact and efficient LHTES for solar heating, building thermal management, and industrial waste-heat recovery applications.

25 ENERGY STORAGE↗

Risks and Benefits of Pressurized Water Reactor Coupling to Energy Storage and Water Desalination

This research explored potential options to improve nuclear pressurized water reactors’ (PWRs) operational flexibility through integration with thermal energy storage (TES) and water desalination technologies. Benefits and challenges of TES technologies were reviewed, which includes sensible heat storage systems, latent heat storage systems, and thermochemical storage systems. Water desalination technologies were reviewed and compared, which includes multi-stage flash, reverse osmosis, and multi-effect distillation. The multi-effect distillation technology was selected to be coupled with a generic PWR. Risk of this cogeneration was quantified using the probabilistic risk assessment (PRA) methodology. Results suggest that nuclear-desalination cogeneration can be done safely because the additional risk to the PWR is trivial, and even in certain cases the PWR risk is decreased. This cogeneration operation is expected to improve efficiency of thermal utilization and the nuclear plant’s revenues. In summary, this study supports the potential of nuclear-desalination cogeneration systems to address water scarcity while optimizing nuclear energy use and managing safety.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Corrosion evaluation of metal foams in eutectic molten salts for high temperature latent heat energy storage application

High-temperature Thermal Energy Storage (TES) has drawn great attention as a technology that can increase the role and profitability of micro nuclear reactors in the decentralized clean energy market. Various research needs have been proposed by Idaho National Laboratory (INL) in "the Integrated Energy Systems: 2020 Roadmap" with the goal of utilizing the high temperature of 550 degrees or more generated in the 4th generation reactor to industrial purposes from the standpoint of integrated energy systems [1]. With the recent development of the 4th generation nuclear power plant, including micro nuclear reactor, there is a great deal of interest in researching how to efficiently couple a heat source to an industrial process through thermal processing. Texas A&M University (TAMU) and INL are currently collaborating to develop a novel latent heat storage design called HITB (Heat pipe-Integrated Thermal Battery). As part of the small-scale experimental demonstration research for HITB, a study for storage medium selection was conducted at TAMU. Eutectic salts have attracted interest as high-temperature heat storage medium for HITB. Especially, chloride molten salts and fluoride molten salts are considered promising candidates due to their high melting temperature, thermal stability, and high latent heat of fusion. Since eutectic salts have poor thermal conductivity in general, it is critical to distribute materials with high thermal conductivity evenly to facilitate the charging and discharging of heat. In this study, metal foam was considered in the HITB system to overcome the poor heat transfer characteristics of eutectic salts. In order to improve heat transfer, it is necessary to study materials with high thermal conductivity, corrosion resistant to molten salts, such as fins, extended surfaces, particles, microcapsulation, or foam structure. Porous structure of copper or aluminum can increase heat transfer area, form a thermal transfer network, and increase the effective thermal conductivity of thermal storage medium [2]. Since the melting temperature is required to be at least 450? in the current HITB design, various eutectic salts are being considered. FLiNaK and FLiBe, which are famous for fluoride salts, are good candidates, but due to the sharp rise in the price of LiF recently, they are excluded for economic reasons to be applied to large-capacity thermal energy storage. On the other hand, chloride salts are very cheap and easy to obtain, have a high melting temperature, and have a high latent heat of fusion, so they are recently in the spotlight as a phase change material. However, because of the hygroscopic nature of chloride salts, HCl gas due to impurity is easy to be released and is particularly vulnerable to corrosion. Chloride eutectic salts have been tested and suggested for metal alloys that are particularly resistant to corrosion, such as SS304, SS316, Hastelloy, Inconel 625, Incoloy 800H, which has low thermal conductivity, and is very expensive [3-6]. Porous materials with high thermal conductivity such as copper and aluminum have been tested for stability in fluids such as paraffin or water as metal foam or metal fin structures, but high temperature corrosion tests were not performed on various eutectic salts yet. Therefore, this study investigated the high temperature corrosion characteristics of metal alloys, such as C10100 foam, C10100 plate, 6101 alloy foam, and SS316 plate, while immersed in the candidate eutectic salts. A total of 20 tests for SS316 coupons and 10 tests for C10100 coupons were performed to ensure the repeatability of the present measurements. Since it is difficult to completely remove the salt inside metal foam due to the complex inner structure of the metal foam, only the surface condition was observed with a microscopy and scanning electron microscopy (SEM) image, except for measuring the corrosion rate and average mass loss.

25 ENERGY STORAGE↗

A fast reduced model for a shell-and-tube based latent heat thermal energy storage heat exchanger and its application for cost optimal design by nonlinear programming

Numerical simulation of latent heat thermal energy storage (LHTES) systems plays a fundamental role in studying the physical process and guiding the engineering design. Discretization of the PDEs describing the nonlinear solidification/melting process of phase change materials (PCMs) leads to a large-scale complex dynamics system, where the system behavior depends on a set of parameters. In a design setting, repeated model evaluations are required over the set of parameters results in significant computational burden. In this paper, an explicit analytic solution was built for the propagation of the solidification front in a cylindrical coordinate. The analytic solution approach is further employed to develop a low computational reduced model (RM) as a module for a shell-and-tube based LHTES heat exchanger. The levelized Cost of Energy (LCOE) is used as a design metric and the RM model is used to apply system-level constraints in the nonlinear programming formulation that facilitates efficient global optimal design of the PCM properties, flow conditions and tube geometries. The use of LCOE as the design metric prevents over design of the heat transfer rate and also establishes a fair ground for evaluation of different thermal storage technologies and their integrated applications with other systems. Optimal results showed that a higher effectiveness results in a higher LCOE; the velocity of the HTF and the length of the channel are highly correlated with each other; both larger PCM latent energy and conductivity result in lower LCOE.

25 ENERGY STORAGE↗

Guidelines for Phase Change Material Selection Based on a Holistic System Model

Concentrating solar power (CSP) has potential to increase the amount of renewable energy on electric grids and reduce global carbon emissions, in particular because of its capability to incorporate inexpensive thermal energy storage. To realize this potential, development of latent heat storage with phase change materials (PCMs) is attractive because of its high energy density and low material cost. Research in this area has identified many promising materials, and has developed effective storage system designs that could be used to deploy PCMs. However, the field has lacked a rigorous methodology to select the optimal material for a particular CSP system. To address this need, here we present a holistic model that evaluates all important influences of PCM properties on the performance and cost of an entire CSP plant. We apply this model to over 100 of the most widely considered candidate materials, including both salts and metals. We quantify the relative value of each PCM property, and identify leading materials for application in CSP systems. This method and our results may aid future efforts to develop latent heat storage by providing a more informed view of how material selection impacts an entire CSP system.

14 SOLAR ENERGY↗

Powdermet CRADA for VELOCITI Voucher (CRADA Final Report)

NLR shall develop a model of an electric thermal energy storage (ETES) system in the System Advisor Model (SAM) framework that uses a salt and particle slurry developed by PowderMet as the thermal energy storage medium. The ETES shall consist of a recuperated sCO 2 Brayton cycle using 2-tank indirect thermal energy storage and an electric heater for heat input. The salt slurry uses chloride salt and operates at a maximum temperature of 500-720°C. The ETES uses dry air cooling. The salt slurry will be modeled as a sensible heat storage medium and as a latent heat storage medium. NLR will use the model to do parametric analysis of the factors affecting the performance (ex., round trip efficiency) of the ETES system. NLR will work with PowderMet to estimate the costs of system components and total system costs, with the levelized cost of electricity (LCOE) as the primary cost metric.

14 SOLAR ENERGY↗

Evaluation of Formate Salt PCM’s for Latent Heat Thermal Energy Storage

This work examines formate salts as potential phase change materials (PCMs) for middle-high temperature (≤250 °C) latent heat thermal energy storage applications. The thermophysical properties of three formate salts were characterized: pure sodium formate and binary blends of sodium/potassium formate and sodium/calcium formate. The stability of formate PCM’s was evaluated by thermal cycling using differential scanning calorimetry where sodium formate and sodium/potassium formate appeared stable over 600 cycles, while sodium/calcium formate exhibited a monotonic decrease in heat of fusion over the test period. A longer test with sodium formate led to gas release and decomposition of the salt. FTIR analysis of the PCM showed degradation of formate to oxalate. T-history experiments with 50-g PCM quantities demonstrated a bulk supercooling of only 2–3 °C for these salts. Thermal conductivity enhancement of over 700% was achieved by embedding aluminum in the solid PCM. Finally, mild carbon steel was immersed in molten sodium formate for up to 2000 h. Sodium formate was found to be non-corrosive, as calculated by mass loss and confirmed by cross-sectional high-resolution microscopy. FTIR analysis of the PCM after 2000 h shows oxidation at the free surface, while the bulk PCM remained unchanged, further indicating a need to protect the formate from atmospheric exposure when used as a PCM.phase change materials; formate salts; latent heat thermal energy storage; thermal cycling; supercooling; thermal conductivity enhancement; corrosion

25 ENERGY STORAGE↗

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Numerical Evaluation of Effective Thermal Conductivity of PCM with Metal Foam Incorporating Buoyancy Effects for Thermal Energy Storage

The thermal energy storage (TES) system has the capability to efficiently preserve thermal energy directly derived from the energy source, minimizing any conversion losses. Especially latent heat storage offers distinct advantages, including a substantial increase in energy storage density and minimization of temperature fluctuations within the plants. However, the phase change material (PCM) employed in latent heat storage has low thermal conductivity. Consequently, various studies are being conducted to enhance heat transfer. One approach to enhance heat transfer involves utilizing metal foam to maximize the heat transfer area. However, modeling metal foam with its intricate structure is a challenging task in numerical analysis. For this reason, ongoing research focuses on simplifying the modeling of metal foam. Nevertheless, fully encompassing all the characteristics of actual metal foam proves to be a challenging task for the simplified analytical model. The objective of this paper is to interpret the simple lattice metal foam analysis model from the perspective of behavior induced by buoyancy. When comparing the analysis results of solid PCM and liquid PCM with the same thermal conductivity under changes in porosity and gravity direction, we conducted an analysis to discern the trends in effective thermal conductivity that are overestimated due to convection. In the analysis, a constant heat flux of 10 kW and a constant surface boundary condition of 350 K were applied, and a sensitivity study regarding the mesh was conducted. The results indicate that, from the perspective of gravity in the simple lattice model, the solid analysis yields an effective thermal conductivity 29-47% higher compared to the liquid analysis. Additionally, as porosity increases, there is an observed increase of 24-33% in effective thermal conductivity.

25 ENERGY STORAGE↗

Atomistic insights into the heat conductance across the interfaces between erythritol and different metals: A non-equilibrium molecular dynamics study

The heat conductance across the interface between a phase change material (PCM) and the metal shell is important for thermal design of latent heat storage systems. Non-equilibrium molecular dynamics simulations were carried out in this work to unravel, at the atomistic level, the interfacial heat conductance mechanisms between erythritol (the most promising medium-temperature polyol PCM) and two different metals (i.e., copper and aluminum). The interfacial contact ratio was introduced as a parameter to represent different contact conditions at the interfaces, for example, different surface roughness levels of the metals. It was found that with the increase of interfacial contact ratio, the temperature difference between the erythritol/metal interfaces decreases, whereas the interfacial heat transfer coefficient increases gradually. At the perfect contact condition, i.e., the interfacial contact ratio reaches 100%, the interfacial heat transfer coefficients across the erythritol/Cu and erythritol/Al interfaces were predicted to be 398 ± 26 MW/m 2 K and 544 ± 11 MW/m 2 K, respectively. The interfacial heat conductance of erythritol/Al is better than that of erythritol/Cu. The mismatch of atomic spectral density across the interfaces between erythritol and the two metals was analyzed and distinguished. These results could guide the selection of packaging materials and the thermal design of erythritol-based latent heat storage systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Evaluation and selection of eutectic salts combined with metal foams for applications in high-temperature latent heat thermal energy storage

This study presents a systematic process for selecting eutectic salts for use in latent heat thermal energy storage (LHTES), and provides experimental evidence regarding their performance. One primary goal was to identify the most suitable eutectic salt for use with metallic foams over a temperature range of 450 °C–500 °C. Twenty-one eutectic salts were preselected for comparison. Here, the performance and cost-effectiveness of each were evaluated based on the Ragone relation, enabling a fair comparison of each salt's heat storage capacity and power density relative to cost. As a result, MgCl-NaCl, CaCl 2 -NaCl, and FLiNaK were selected as the most promising candidates. Subsequently, experiments were performed to demonstrate the compatibility of the selected salts with metal foams while the copper and aluminum foams were immersed in the salts at 550 °C for 120 h. Combining C10100 (copper alloy) foam with CaCl 2 -NaCl was observed to generate the least surface corrosion due to oxidation. The charge/discharge performance and thermal stability of CaCl 2 -NaCl, both with and without the copper foam, were also tested to confirm the feasibility of this combination. The capsule with the copper foam showed enhanced performance (a 13 % reduced discharge rate) in comparison to the capsule without copper foam. The melting point of the CaCl 2 -NaCl remained unchanged for 300-h duration of the cyclic melting/solidification experiments, and no thermal stability issues were observed.

25 ENERGY STORAGE↗

Stable salt hydrate-based thermal energy storage materials

A phase change material composition for latent heat storage is provided. In one embodiment, the phase change material includes a salt hydrate having a melting temperature (Tm) of from 1° C. to 100° C. as determined in accordance with ASTM E793. The phase change material further includes a stabilizing matrix including a polysaccharide selected from the group of a nanocellulose, a sulfonated polysaccharide, a starch, a glycogen, a chitin, and combinations thereof. A composite article including the phase change material composition is also provided.

Li, Yuzhan↗