Publications

The National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories New Mexico (SNL/NM) developed this Life Cycle Management Plan (LCMP) to document its process for executing, monitoring, controlling and closing-out Phase 3 of the Gen 3 Particle Pilot Plant (G3P3). This plan serves as a resource for stakeholders who wish to be knowledgeable of project objectives and how they will be accomplished.

This report summarizes the needs, challenges, and opportunities associated with carbon-free energy and energy storage for manufacturing and industrial decarbonization. Energy needs and challenges for different manufacturing and industrial sectors (e.g., cement/steel production, chemicals, materials synthesis) are identified. Key issues for industry include the need for large, continuous on-site capacity (tens to hundreds of megawatts), compatibility with existing infrastructure, cost, and safety. Energy storage technologies that can potentially address these needs, which include electrochemical, thermal, and chemical energy storage, are presented along with key challenges, gaps, and integration issues. Analysis tools to value energy storage technologies in the context of manufacturing and industrial decarbonizations are also presented. Material is drawn from the Energy Storage for Manufacturing and Industrial Decarbonization (Energy StorM) Workshop, held February 8 - 9, 2022. The objective was to identify research opportunities and needs for the U.S. Department of Energy as part of its Energy Storage Grand Challenge program.

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 MW_e up to 100 MW_e with many viable designs having costs < 0.06 $/kWh and local minimums occurring between ~25–35 MW_e.

Falling particle receivers have the potential to increase the maximum operating temperature of CSP systems by directly heating a solid particle heat transfer fluid. Particle abrasion in FPR systems can generate dust which can escape out of open receiver designs. The characterization and capture of this dust can help mitigate health risks and increase the optical and thermal efficiency of the receiver. Particle fines were generated and captured by fluidizing a bed of nominally sized particles and filtering out the entrained particulate from the air exiting the bed. Particle fine size distribution, composition, and rate of generation was found for a specific mass of fluidized particles using optical microscopy, SEM, XRD, and aerosol sampling equipment to better inform dust filtration in falling particle receiver systems.

The design, modeling, and integration of high-temperature particle storage bins is a critical component of Gen. 3 concentrated solar power (CSP). Particle storage bins control the temperature and flow rates throughout the particle circulatory system, so having a fundamental understanding of their transient thermal behavior is highly advantageous for the design and multi-level control of future CSP systems. This paper provides contributions to this understanding by presenting a semi-analytic method for modeling the transient thermal behavior of bulk particle bins. The model is verified with experiments and a baseline CFD model and then used to make conclusions about the dominant heat transfer modes in bulk particle bins and the general transient thermal performance of related systems.

Computational Fluid Dynamics modeling of two different high-temperature particle lifting systems was done in order to be able to capture the thermal behavior of these systems. The two lifting mechanism modeled were a closed bucket elevator that carries the particles up a shaft with a conveyor belt of buckets, and a skip hoist that goes through a cycle of loading, lifting, unloading, and lowering. Both of the modeled systems were subject to a validation process, where the bucket elevator was compared to IR images taken of a real bucket elevator in use under high temperature conditions, and the skip hoist was compared to a 1-D MATLAB model using the heat equation. Both models showed reasonable validation results, and therefore an insulation thickness study was done on both models in order to show the capability of using Computational Fluid Dynamics tools for analysis on these types of systems as a way to inform design decisions. The results were able to show the relationship between increased insulation and lower particle temperature loss of the systems and was able to do so for both steady state and transient results.

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.

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This report provides a study of the potential impacts of climate change on intermittent renewable energy resources, battery storage, and resource adequacy in Public Service Company of New Mexico’s Integrated Resource Plan for 2020 – 2040. Climate change models and available data were first evaluated to determine uncertainty and potential changes in solar irradiance, temperature, and wind speed in NM in the coming decades. These changes were then implemented in solar and wind energy models to determine impacts on renewable energy resources in NM. Results for the extreme climate-change scenario show that the projected wind power may decrease by ~13% due to projected decreases in wind speed. Projected solar power may decrease by ~4% due to decreases in irradiance and increases in temperature in NM. Uncertainty in these climate-induced changes in wind and solar resources was accommodated in probabilistic models assuming uniform distributions in the annual reductions in solar and wind resources. Uncertainty in battery storage performance was also evaluated based on increased temperature, capacity fade, and degradation in round-trip efficiency. The hourly energy balance was determined throughout the year given uncertainties in the renewable energy resources and energy storage. The loss of load expectation (LOLE) was evaluated for the 2040 No New Combustion portfolio and found to increase from 0 days/year to a median value of ~2 days/year due to potential reductions in renewable energy resources and battery storage performance and capacity. A rank-regression analyses revealed that battery round-trip efficiency was the most significant parameter that impacted LOLE, followed by solar resource, wind resource, and battery fade. An increase in battery storage capacity to ~25,000 – 30,000 MWh from a baseline value of ~14,000 MWh was required to reduce the median value of LOLE to ~0.2 days/year with consideration of potential climate impacts and battery degradation.

High - temperature particle receivers are being pursued to enable next - generation concentrating solar thermal power (CSP) systems that can achieve higher temperatures (> 700 C) to enable more efficient power cycles, lower overall system costs, and emerging CSP - based process - heat applications. The objective of this work was to develop characterization methods to quantify the particle and heat losses from the open aperture of the particle receiver. Novel camera - based imaging methods were developed and applied to both laboratory - scale and larger 1 MW t on - sun tests at the National Solar Thermal Test Facility in Albuquerque, New Mexico. Validation of the imaging methods was performed using gravimetric and calorimetric methods. In addition, conventional particle - sampling methods using volumetric particle - air samplers were applied to the on - sun tests to compare particle emission rates with regulatory standards for worker safety and pollution. Novel particle sampling methods using 3 - D printed tipping buckets and tethered balloons were also developed and applied to the on - sun particle - receiver tests. Finally, models were developed to simulate the impact of particle size and wind on particle emissions and concentrations as a function of location. Results showed that particle emissions and concentrations were well below regulatory standards for worker safety and pollution. In addition, estimated particle temperatures and advective heat losses from the camera - based imaging methods correlated well with measured values during the on - sun tests.

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Computational fluid dynamics (CFD) models were developed to simulate the impact of different ventilation scenarios on airborne exposure risks in a 72-passenger school bus. Scenarios and factors that were investigated included a moving vs. stationary bus, impacts of a heating unit within the bus, and impacts of alternative ventilation scenarios with different combinations of openings (e.g., windows, door, emergency hatch). Results of the simulations showed that when the bus was stationary, use of the heater increased receptor concentrations unless there was another opening. When the bus was moving, simulations with at least two sets of openings separated from each other in the forward and aft directions produced a through-flow condition that reduced concentrations via dilution from outside air by a factor of ten or more. A single opening in a moving bus generally increased concentrations throughout the cabin due to increased mixing with minimal ventilation. The cumulative exposure risk (time-averaged concentrations) was found to be inversely correlated to the air exchange rate. Stationary and moving-bus scenarios that yielded above ~20 air changes per hour resulted in the lowest cumulative exposures. Recommendations from this study were implemented in new safety and operating procedures by the Albuquerque Public Schools Transportation Center.

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.

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This report provides a design study to produce 100% carbon-free electricity for Sandia NM and Kirtland Air Force Base (KAFB) using concentrating solar power (CSP). Annual electricity requirements for both Sandia and KAFB are presented, along with specific load centers that consume a significant and continuous amount of energy. CSP plant designs of 50 MW and 100 MW are then discussed to meet the needs of Sandia NM and the combined electrical needs of both Sandia NM and KAFB. Probabilistic modeling is performed to evaluate inherent uncertainties in performance and cost parameters on total construction costs and the levelized cost of electricity. Total overnight construction costs are expected to range between ~$300M - $400M for the 50 MW CSP plant and between ~$500M - $800M for the 100 MW plant. Annual operations and maintenance (O&M) costs are estimated together with potential offsets in electrical costs and CO₂ emissions. Other considerations such as interconnections, land use and permitting, funding options, and potential agreements and partnerships with Public Service Company of New Mexico (PNM), Western Area Power Administration (WAPA), and other entities are also discussed.

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