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Innovative Application of Maintenance-Free Phase-Change Thermal Energy Storage for Dish Engine Solar Power Generation
DOE SunShot CSP Review
April 24, 2013
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Project Title: Innovative Application of Maintenance-Free Phase-Change Thermal Energy Storage for Dish-Engine Solar Power Generation
Awardee: Infinia Corporation
Principal Investigator: Songgang Qiu
Presenter: Maury White
Subcontractors: Applied Research Lab, Penn State University
Thermacore, Inc.
Project Period: 09/30/08 – 08/30/12 (Phase 1 and Phase 2)
PROJECT OVERVIEW
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Background & Project Description
Objectives and Goals
System Design
Eutectic Salt Selection
Dish Concentrator Design Modification
Demonstrator Prototype Design
Thermal Energy Storage (TES) Module Design
TES Module Support/Attachment Design
TES System Testing
Test Setup / Analysis
Results
Accomplishments, Conclusions, & Path Forward
PRESENTATION OUTLINE
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BACKGROUND & PROJECT DESCRIPTION
The baseline TES approach for most Trough and Central Receiver Systems uses sensible heat capacity of molten salt
This necessitates power converter operation over a range of temperatures which reduces integrated efficiency
Freezing of molten salt needs to be avoided
Phase Change Materials (PCM) provide a large increase in energy storage density by using latent heat of fusion for TES
Infinia implemented an innovative approach of directly integrating a hermetically-sealed maintenance-free eutectic salt PCM storage module with a dish Stirling system
This is believed to be the first ever TES system suitable for dish engine applications
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Develop hermetically sealed, maintenance-free, phase-change thermal energy storage for dish-engine solar power generation
Demonstrate the practicality of integrating TES modules with a dish Stirling engine
These objectives support DOE goals to increase the use of CSP in the USA and the 2020 Levelized Cost of Energy (LCOE) goal of 5¢/kWh
Increased energy production per system module
Low capital cost solution for TES
Low maintenance solution
Reduced CSP system cost due to relaxed optical requirements
Provide dispatchability for solar power generation
OBJECTIVES & GOALS
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OVERVIEW
SYSTEM DESIGN
Project Innovation: Dish Stirling Thermal Energy Storage (TES) using
NaF/NaCl eutectic salt Phase Change Material (PCM) with both latent and sensible heat storage
Component Design : Eutectic Salt Selection
Dish Concentrator Design Modification
Demonstrator Prototype Design
TES Module Design
TES Module Support Design
Challenges/Goals: Heat Pipe Wick Limitations, Low Salt Conductivity
Improved Capacity Factors for Dish/Stirling CSP
Reduced Levelized Cost of Electricity (LCOE)
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83 candidate PCM salts investigated
Prioritized selection criteria:
– Melting temperature
– Cost
– Latent heat
– Specific heat
Sodium chloride – sodium fluoride eutectic selected: NaCl (65)/NaF (35)
– Melt Temp: 675 °C
– Cost: $0.50/kg
– Heat of fusion: 700 kJ/kg
– Specific heat: 1.3 kJ/kg/°C
– Density: 1970 kg/m3
Eutectic Salt Selection
SYSTEM DESIGN
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Modified Boom-arm to support additional weight and CG change
Dish Concentrator Design Modification
SYSTEM DESIGN
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20% Larger Dish 2 Dimensional Flux Distribution Plot
SYSTEM DESIGN
Dish Concentrator Design Modification
Oversized dish to provide simultaneous heat for TES and engine
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PCM volume is sized to generate 3kWh net electric power from TES; about 35 kg PCM
When solar energy is available, the heat pipe system is designed to permit simultaneous operation of the engine and charging of the salt
SYSTEM DESIGN
Demonstrator Prototype Design
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SYSTEM DESIGN
Thermal Energy Storage (TES) Module Design
TES module incorporates solar absorber and is welded to engine heater head
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SYSTEM DESIGN
Thermal Energy Storage (TES) Module Design Modified engine shroud and TES concept for integration with engine heater head
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SYSTEM DESIGN
Thermal Energy Storage (TES) Module Design
TES module integration with heater head: photo (left), mode concept (right)
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Heat pipe wick analysis by Thermacore
SYSTEM DESIGN
Thermal Energy Storage (TES) Module Design
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SYSTEM DESIGN
TES Module Support Design Requires thermal and vibration isolation
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SYSTEM DESIGN
TES Module Support Design
TES module support structure required extensive design and analysis
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TES SYSTEM TESTING
TES Test Setup
The engine/TES module was tested in the lab with the axis in both vertical and horizontal orientations.
Heat was supplied using an induction heater with a ceramic susceptor, which in turn delivered radiant heat energy to the receiver portion of the TES module.
Conventional Test Stand
Modified TES Test Stand
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Integrated TES Test Results, Vertical Mounting
TES SYSTEM TESTING
Testing with the engine at the top (high noon case) is the worst orientation for returning sodium condensate to the evaporator by capillary pumping against gravity to the heater head heat pipe vapor chamber, then back down the central heat pipe to the receiver.
Heat pipe wick limitations limited heat input to about 2.8 kW, which was inadequate to run the engine with minimal output and fully melt salt
Test Results – Axis Vertical
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Integrated TES Test Results, Horizontal mounting
TES SYSTEM TESTING
Test Results – Axis Horizontal
Converting the test stand to a horizontal orientation was done as a diagnostic tool. The salt was fully melted and operation on TES after removing heat input successfully extracted 1.32 kWh of engine electrical output, which is 44% of the design target.
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Accomplishments Basic functionality of the TES/engine system was successfully demonstrated in the laboratory. This was a technology breakthrough, although performance fell short of targets. Major repairs due to two breaches of the absorber by artifacts of the initial direct induction heater prevented more comprehensive testing.
Conclusions Heat pipe wick to return sodium condensate is inadequate in current design when the TES module is in its gravity-adverse (vertical) orientation.
Salt conductivity enhancement or closer heat pipe spacing would be beneficial.
Path Forward Further testing with the existing unit would provide more comprehensive data. Upgrading the sodium heat pipe network through analysis, redesign and demonstration should provide significant improvement.
ACCOMPLISHMENTS, CONCLUSIONS, & PATH FORWARD
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US Headquarters
1840 Terminal Drive
Richland, WA 99354
www.infiniacorp.com
Thank you