Publications

Sandia National Laboratories has been tasked to operate and maintain the National Solar Thermal Test Facility (NSTTF) located in Kirtland Airforce Base near Albuquerque, NM. The NSTTF provides established test platforms and experienced researchers and technologists in the field of Concentrating Solar Technologies (CST) and Concentrating Solar Power (CSP). This three-year project seeks to maintain the NSTTF for development, testing, and application of new CSP technologies that are instrumental in advancing the state-of-the-art in support of SunShot and Generation 3 CSP technology goals. In turn, these technologies will form the foundation of the global CSP industry and continue to advance the technology to new levels of efficiency, higher temperatures, lower costs, lower risk, and higher reliability. The NSTTF provides established test platforms and highly experienced researchers and technologists in the CSP field.

A new generation of concentrating solar power (CSP) technologies is under development to provide dispatchable renewable power generation and reduce the levelized cost of electricity (LCOE) to 6 cents/kWh by leveraging heat transfer fluids (HTFs) capable of operation at higher temperatures and coupling with higher efficiency power conversion cycles. The U.S. Department of Energy (DOE) has funded three pathways for Generation 3 CSP (Gen3CSP) technology development to leverage solid, liquid, and gaseous HTFs to transfer heat to a supercritical carbon dioxide (sCO2) Brayton cycle. This paper presents the design and off-design capabilities of a 1 MWth sCO2 test system that can provide sCO2 coolant to the primary heat exchangers (PHX) coupling the high-Temperature HTFs to the sCO2 working fluid of the power cycle. This system will demonstrate design, performance, lifetime, and operability at a scale relevant to commercial CSP. A dense-phase high-pressure canned motor pump is used to supply up to 5.3 kg/s of sCO2 flow to the primary heat exchanger at pressures up to 250 bar and temperatures up to 715 °C with ambient air as the ultimate heat sink. Key component requirements for this system are presented in this paper.

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This report describes the design, development, and testing of a prototype 100 kWt particle-to-supercritical CO₂ (sCO2) heat exchanger. An analytic hierarchy process was implemented to compare and evaluate alternative heat-exchanger designs (fluidized bed, shell-and-plate moving packed bed, and shell-and-tube moving packed bed) that could meet the high pressure (≥ 20 MPa) and high temperature (≥ 700 °C) operational requirements associated with sCO2 power cycles. Cost, heat-transfer coefficient, structural reliability, manufacturability, parasitics and heat losses, scalability, compatibility, erosion and corrosion, transient operation, and inspection ease were considered in the evaluation. A 100 kWt shell-and-plate design was selected for construction and integration with Sandia’s falling particle receiver system that heats the particles using concentrated sunlight. Sandia worked with industry to design and construct the moving packed-bed shell-and-plate heat exchanger. Tests were performed to evaluate its performance using both electrical heating and concentrated sunlight to heat the particles. Overall heat transfer coefficients at off-design conditions (reduced operating temperatures and only three stainless steel banks in the counter-crossflow heat exchanger) were measured to be approximately ~25 - 70 W/m²-K, significantly lower than simulated values of >100 W/m²-K. Tests using the falling particle receiver to heat the particles with concentrated sunlight yielded overall heat transfer coefficients of ~35 – 80 W/m²-K with four banks (including a nickel-alloy bank above the three stainless steel banks). The overall heat transfer coefficient was observed to decrease with increasing particle inlet temperatures, which contrasted the results of simulations that showed an increase in heat transfer coefficient with temperature due to increased effective particle-bed thermal conductivity from radiation. The likely cause of the discrepancy was particle-flow maldistributions and funnel flow within the heat exchanger caused by internal ledges and cross-bracing, which could have been exacerbated by increased particle-wall friction at higher temperatures. Additional heat loss at higher temperatures may also contribute to a lower overall heat-transfer coefficient. Design challenges including pressure drop, particle and sCO2 flow maldistribution, and reduced heat transfer coefficient are discussed with approaches for mitigation in future designs. Lessons learned regarding instrumentation, performance characterization, and operation of particle components and sCO2 flow loops are also discussed. Finally, a 200 MWt commercial-scale shell-and-plate heat-exchanger design based on the concepts investigated in this report is proposed.

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Concentrating Solar Power (CSP) plants have the potential to provide dispatchable renewable power generation to support the baseload need currently supplied primarily by coal and nuclear plants and peaking power capability to reduce the use of natural gas for load following. However, these plants have had difficulty achieving widespread use due to the low cost of combined photovoltaic and battery systems capable of providing similar services to the electricity grid. A new generation of CSP technologies must be developed to reduce the levelized cost of electricity (LCOE) to 6 cents/kWh by leveraging heat transfer fluids (HTF) capable of operation at higher temperatures and coupling with higher efficiency power conversion cycles. Three promising pathways for Generation 3 CSP (Gen3CSP) technology development have been funded by the U.S. Department of Energy (DOE) leveraging solid, liquid, and gaseous HTFs to transfer heat to a supercritical carbon dioxide (sCO2) Brayton cycle. The primary heat exchangers (PHX) necessary to couple these high-temperature HTFs to sCO2 are an essential new technology that must be demonstrated at a scale relevant to commercial CSP to validate design expectations for performance, lifetime, and operability. The demonstration of these PHXs need a reliable 1 MWth-scale sCO2 test system that can provide sCO2 coolant to the PHX in a compact package suitable for installation near any Gen3CSP thermal storage system. This paper outlines the final design of such a system including the expected operating range and off-design capabilities. The system uses a dense-phase high pressure canned motor pump as the sCO2 circulator and ambient air as the ultimate heat sink operating at pressures up to 250 bar and temperatures up to 715 °C with capability to supply up to 5.3 kg/s of sCO2 flow to the primary heat exchanger. Key component requirements for this system have been frozen and procurement is underway. The expected completion date for heated acceptance testing of this system is September of 2020. This system is also capable of being upgraded through the addition of a turbo-compressor and turbo-generator to operate as a complete sCO2 Brayton cycle with power generation in order to demonstrate an integrated solar to sCO2 power pilot plant and understand transient interactions between the thermal storage system, sCO2 turbomachinery, and ambient air temperature. In addition, this upgrade would provide experience with plant operating considerations including balancing charging the thermal storage system with generating and dispatching power to the electrical grid. A roadmap for this upgrade will be discussed including limitations and requirements for the necessary turbomachinery.