Thermochemical air separation to produce high-purity N2 was demonstrated in a vertical tube reactor via a two-step reduction–oxidation cycle with an A-site substituted perovskite Ba0.15Sr0.85FeO3–δ (BSF1585). BSF1585 particles were synthesized and characterized in terms of their chemical, morphological, and thermophysical properties. A thermodynamic cycle model and sensitivity analysis using computational heat and mass transfer models of the reactor were used to select the system operating parameters for a concentrating solar thermal-driven process. Thermal reduction up to 800 °C in air and temperature-swing air separation from 800 °C to minimum temperatures between 400 and 600 °C were performed in the reactor containing a 35 g packed bed of BSF1585. The reactor was characterized for dispersion, and air separation was characterized via mass spectrometry. Gas measurements indicated that the reactor produced N2 with O2 impurity concentrations as low as 0.02 % for > 30 min of operation. A parametric study of air flow rates suggested that differences in observed and thermodynamically predicted O2 impurities were due to imperfect gas transport in the bed. Temperature swing reduction/oxidation cycling experiments between 800 and 400 °C in air were conducted with no statistically significant degradation in N2 purity over 50 cycles.
Falling particle receivers are a promising receiver design to couple with particle-based concentrating solar power to help meet future levelized cost of electricity targets in next generation systems. The thermal performance of receivers is critical to the economics of the overall system, and accurate models of particle receivers are necessary to predict the performance in all conditions. A model validation study was performed using falling particle receiver data recently collected at the National Solar Thermal Test Facility at Sandia National Laboratories. The particle outlet temperature, the thermal efficiency of the receiver, and the wind speed and direction around the receiver were measured in 26 steady-state experiments and compared to a corresponding receiver model. The results of this study showed improved agreement with the experimental data over past validation efforts but did not fully meet all predefined validation metrics. Future model improvements were identified to continue to strengthen the modeling capabilities.
A comprehensive control strategy is necessary to safely and effectively operate particle based concentrating solar power (CSP) technologies. Particle based CSP with thermal energy storage (TES) is an emerging technology with potential to decarbonize power and process heat applications. The high-temperature nature of particle based CSP technologies and daily solar transients present challenges for system control to prevent equipment damage and ensure operator safety. An operational controls strategy for a tower based particle CSP system during steady state and transient conditions with safety interlocks is described in this paper. Control of a solar heated particle recirculation loop, TES, and a supercritical carbon dioxide (sCO2) cooling loop designed to reject 1 MW of thermal power are considered and associated operational limitations and their influence on control strategy are discussed.
Solar Thermal Ammonia Production has potential to produce green ammonia using CSP, air, and water. Air separation to purify N2 was successfully demonstrated with BSF1585 in packed bed reactor; on-sun reduction reactor under construction. Metal nitrides (MNy) were successfully synthesized and characterized under both ambient and pressurized conditions. Co3Mo3N shown to successfully produce NH3 when exposed to pure H2 at pressures between 5 – 20 bar 600 – 750 °C. Ambient reaction experiments imply there may be a catalytic aspect as well. Technoeconomic and systems analyses show a path towards scale-up.
Particle heat exchangers are a critical enabling technology for next generation concentrating solar power (CSP) plants that use supercritical carbon dioxide (sCO2) as a working fluid. This report covers the design, manufacturing and testing of a prototype particle-to-sCO2 heat exchanger targeting thermal performance levels required to meet commercial scale cost targets. In addition, the the design and assembly of integrated particle and sCO2 flow loops for heat exchanger performance testing are detailed. The prototype heat exchanger was tested to particle inlet temperatures of 500 °C at 17 MPa which resulted in overall heat transfer coefficients of approximately 300 W/m2-K at the design point and cases using high approach temperature with peak values as high as 400 W/m2-K
This report documents the results and conclusions of a recent project to understand the technoeconomics of utility-scale, particle-based concentrating solar power (CSP) facilities leveraging unique operational strategies. This project included two primary objectives. The first project objective was to build confidence in the modeling approaches applied to falling particle receivers (FPRs) including the effect s of wind. The second project objective was to create the necessary modeling capability to adequately predict and maximize the annual performance of utility-scale, particle-based CSP plants under anticipated conditions with and without active heliostat control. Results of an extensive model validation study provided the strongest evidence to date for the modeling strategies typically applied to FPRs, albeit at smaller receiver scales. This modeling strategy was then applied in a parametric study of candidate utility-scale FPRs, including both free-falling and multistage FPR concepts, to develop reduced order models for predicting the receiver thermal efficiency under anticipated environmental and operating conditions. Multistage FPRs were found to significantly improve receiver performance at utility-scales. These reduced order models were then leveraged in a sophisticated technoeconomic analysis to optimize utility-scale , particle-based CSP plants considering the potential of active heliostat control. In summary, active heliostat control did not show significant performance benefits to future utility-scale CSP systems though some benefit may still be realized in FPR designs with wide acceptance angles and/or with lower concentration ratios. Using the latest FPR technologies available, the levelized-cost of electricity was quantified for particle-based CSP facilities with nominal powers ranging from 5 MWe up to 100 MWe with many viable designs having costs < 0.06 $/kWh and local minimums occurring between ~25–35 MWe.
This paper summarizes the evolution of the Gen 3 Particle Pilot Plant (G3P3) receiver design with the goal of reducing heat losses and increasing thermal efficiencies. New features that were investigated included aperture covers and shrouds, active airflow, multistage catch-and-release devices (stairs), and optimization of receiver cavity geometry. Simulations and ground-based testing showed that a reduced receiver volume and aperture shroud could reduce advective heat losses by ∼40 - 50%, and stairs could increase opacity and reduce backwall temperatures. The reduced volume receiver and stairs were selected for on-sun testing, and receiver efficiencies up to 80 - 90% were achieved in the current test campaign. The receiver thermal efficiency generally increased as a function of incident power and particle mass flow rates. In addition, particle outlet temperatures were maintained to within ±10 °C of a prescribed setpoint temperature up to ∼700 °C using a PID controller that adjusted the particle mass flow rate into the receiver in response to the measured particle outlet temperatures.
Particle-based heat transfer materials used in concentrating solar power systems benefit from gravity-fed arrangements such as vertically integrated components inside the receiver tower which can eliminate the need for conveyance machinery. However, the amount of particles required for commercial scale systems near 100 MWe can require towers with very thick walls that must be built with high-strength concrete. Cost models for particle-based receiver towers with internal particle storage are being developed in this work and compared to well-established cost models that have been used to estimate tower costs for molten salt systems with external storage tanks. New cost models were developed to accommodate the high-temperature applications required for CSP. Further research is needed to directly compare costs between tower-integrated and external storage. For now, a method is proposed to superimpose increased storage costs with existing molten salt CSP towers. For instances where suitable materials are unavailable or do not meet the structural requirements, ground based storage bins must be used in concert with mechanical conveyance systems. Ground based storage vessels have been shown to be consistent with low thermal energy storage cost and heat loss goals. Ground based storage vessels are well-established in industry.
Levelized costs of electricity (LCOE) approaching the U.S. Department of Energy Solar Energy Technologies Office 2030 goal of 0.05 $/kWh may be achievable using Brayton power cycles that use supercritical CO2 as the working fluid and flowing solid particles with temperatures >700° C as the heat transfer media. The handling and conveyance of bulk solid particles at these temperatures in an insulated environment is a critical technical challenge that must be solved for this approach to be used. A design study was conducted at the National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories in Albuquerque, NM, with the objective of identifying the technical readiness level, performance limits, capital and O&M costs, and expected thermal losses of particle handling and conveyance components in a particle-based CSP plant. Key findings indicated that chutes can be a low-cost option for particle handling but uncertainties in tower costs make it difficult to know whether they can be cost effective in areas above the receiver if tower heights must then be increased. Skips and high temperature particle conveyance technology are available for moving particles up to 640° C. This limits the use of mechanical conveyance above the heat exchanger and suggests vertical integration of the hot storage bin and heat exchanger to facilitate direct gravity fed handling of particles.
The U.S. Department of Energy Solar Energy Technologies Office initiated the Generation 3 Concentrating Solar Power (CSP) program to achieve higher operating temperatures (>700 °C) to enable next-generation CSP high-temperature power cycles such as the supercritical CO2 (sCO2) Brayton Cycle. Three teams were selected to pursue high-temperature gas, liquid, and solid pathways for the heat-transfer media. Phases 1 and 2, which lasted from 2018 – 2020, consisted of design, modeling, and testing activities to further de-risk each of the technologies and develop a design for construction, commissioning, and operation of a pilot-scale facility in Phase 3 (2021 – 2024). This report summarizes the activities in Phases 1 and 2 for the solid-particle pathway led by Sandia National Laboratories. In Phases 1 and 2, Sandia successfully de-risked key elements of the proposed Gen 3 Particle Pilot Plant (G3P3) by improving the design, operation, and performance of key particle component technologies including the receiver, storage bins, particle-to-sCO2 heat exchanger, particle lift, and data acquisition and controls. Modeling and testing of critical components have led to optimized designs that meet desired performance metrics. Detailed drawings, piping and instrumentation diagrams, and process flow diagrams were generated for the integrated system, and structural analyses of the assembled tower structure were performed to demonstrate compliance with relevant codes and standards. Instrumentation and control systems of key subsystems were also demonstrated. Together with Bridgers & Paxton, Bohannan Huston, and Sandia Facilities, we have completed a 100% G3P3 tower design package with stamped engineering drawings suitable for construction bid in Phase 3.