Innovative Application of Maintenance-Free Phase-Change Thermal Energy Storage for Dish-Engine Solar Power Generation

Abstract

This final report summarizes the final results of the Phase II Innovative Application of Maintenance-Free Phase-Change Thermal Energy Storage for Dish-Engine Solar Power Generation project being performed by Infinia Corporation for the U.S. Department of Energy under contract DE-FC36-08GO18157 during the project period of September 1, 2009 - August 30, 2012. The primary objective of this project is to demonstrate the practicality of integrating thermal energy storage (TES) modules, using a suitable thermal salt phase-change material (PCM) as its medium, with a dish/Stirling engine; enabling the system to operate during cloud transients and to provide dispatchable power for 4 to 6 hours after sunset. A laboratory prototype designed to provide 3 kW-h of net electrical output was constructed and tested at Infinia's Ogden Headquarters. In the course of the testing, it was determined that the system's heat pipe network - used to transfer incoming heat from the solar receiver to both the Stirling generator heater head and to the phase change salt - did not perform to expectations. The heat pipes had limited capacity to deliver sufficient heat energy to the generator and salt mass while in a charging mode, which was highly dependent on the orientation of the device (vertical versus horizontal). In addition, the TES system was only able to extract about 30 to 40% of the expected amount of energy from the phase change salt once it was fully molten. However, the use of heat pipes to transfer heat energy to and from a thermal energy storage medium is a key technical innovation, and the project team feels that the limitations of the current device could be greatly improved with further development. A detailed study of manufacturing costs using the prototype TES module as a basis indicates that meeting DOE LCOE goals with this hardware requires significant efforts. Improvement can be made by implementing aggressive cost-down initiatives in design and materials, improving system performance by boosting efficiencies, and by refining cost estimates with vendor quotes in lieu of mass-based approaches. Although the prototype did not fully demonstrate performance and realize projected cost targets, the project team believes that these challenges can be overcome. The test data showed that the performance can be significantly improved by refining the heat pipe designs. However, the project objective for phase 3 is to design and test on sun the field ready systems, the project team feels that is necessary to further refine the prototype heat pipe design in the current prototype TES system before move on to field test units, Phase 3 continuation will not be pursued.