Abstract Concentrating solar thermal power coupled with thermal energy storage is considered as one of the leading technologies to address the decarbonization of the energy sector. The use of molten solar salt (60–40% b.w. NaNO3-KNO3) as heat transfer fluid and thermal storage medium is the current commercial practice, with alternative salt mixtures being under evaluation for the next-generation higher-temperature systems. The main drawback of the molten salts is their high freezing temperature; active means are required for preheating of- and to prevent salt from freezing in- the transfer lines. In this article we present experiences from the PROTEAS facility, where heating tapes as opposed to heating cables are used. The thermal energy losses from the transfer lines are evaluated and compared to those predicted by a one-dimensional heat transfer analysis. Thermal losses between 43 and 100 W/m are found at operating temperatures from 300 to 500 °C. A joint optimization of the capital and operational expenditure for heating tapes and insulation is performed, leading to the optimal insulation thickness and installed heat tracing capacity. Increasing the installed heat tracing capacity with respect to the minimum required to overcome thermal losses, leads to a reduction of the preheating time and, therefore, a reduction in the overall operational expenses of the system. In some situations, this was found to also lead to a reduction in the necessary insulation thickness. Simulations indicate that if the optimal insulation was used, a decrease of 10 and 15% in thermal losses and O&M expenditures, respectively, could be achieved.
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