THERMAL ENERGY STORAGE BLOCKS AND ASSOCIATED SUPPORT STRUCTURES

Abstract

Thermal energy storage blocks are heated by electrical heating elements to store energy from an intermittent electrical energy source. The energy is efficiently stored in the material from which the thermal energy storage blocks are formed. The thermal energy storage blocks have heat radiation cavities to allow efficient radiative heating, and fluid flow slots to allow efficient discharge of the energy stored in the blocks. Support structures, including support blocks and support slabs, for the thermal energy storage blocks provide physical support for assemblies of the thermal energy storage blocks, and provide thermal insulation of the thermal energy storage blocks from surrounding materials.

Description

Title of the invention: THERMAL ENERGY STORAGE BLOCKS AND ASSOCIATED SUPPORT STRUCTURES Prior art

[0001] This application claims priority, under the Paris Convention, over: United States Provisional Patent Application No. 63 / 459,540 filed on April 14, 2023, United States Provisional Patent Application No. 63 / 578,139 filed on August 22, 2023, United States Provisional Patent Application No. 63 / 626,501 filed on January 29, 2024, and United States Provisional Patent Application No. 63 / 623,523 filed on January 31, 2024. Technical field

[0002] The present disclosure relates to thermal energy storage blocks for use in thermal energy storage and utilization systems. More particularly, the present disclosure relates to an energy storage block that can store electrical energy in the form of thermal energy, usable for the supply of hot air, nitrogen, argon, carbon dioxide (CO2), water vapor, process gas, inert gas, hydrogen, or other heated fluids, for various applications, including the supply of heat for the generation of electricity. The present disclosure also relates to support structures for thermal energy storage blocks, including support blocks, sleepers, and slabs. These support structures can provide structural support and physical and thermal separation of the thermal energy storage blocks from surrounding structures. I. Thermal energy systems A. Variable renewable electricity

[0003] The combustion of fossil fuels has been used as a heat source in thermal electricity generation to provide heat and steam for purposes such as industrial heat. However, the use of fossil fuels has various problems and disadvantages, including global warming and pollution. Therefore, there is a need to shift from fossil fuels to clean and sustainable energy.

[0004] Variable renewable electricity sources (VREs), such as solar and wind power, have grown rapidly as their costs have decreased as the world has moved toward lower carbon emissions to mitigate climate change. But a major challenge with the use of VREs is, as their name suggests, their variability. The variable and intermittent nature of wind and solar power does not make these types of energy sources natural candidates for meeting the continuous energy demand of power grids, industrial processes, etc. Therefore, there is an unmet need for VRE storage to be able to supply energy efficiently and flexibly at different times.

[0005] Furthermore, the International Energy Agency reported that industrial energy use accounts for the largest portion of global energy use, and three-quarters of industrial energy is used as heat rather than electricity. Therefore, there is an unmet need for lower-cost energy storage systems and technologies that utilize VREs to provide energy for industrial processes, which can increase VREs and reduce the combustion of fossil fuels. B. Storage of energy in the form of heat

[0006] Thermal energy in industrial, commercial, and residential applications can be collected during one period, stored in a storage device, and released for its intended use during another period. Examples include storing energy as sensible heat in liquid reservoirs, including water, oils, and molten salts; sensible heat in solid media, including rock, sand, concrete, and refractory materials; latent heat in the phase change between the gas, liquid, and solid phases of metals, waxes, salts, and water; and thermochemical heat in reversible chemical reactions that can absorb and release heat over many repeated cycles; and media that can combine these effects, such as phase change materials incorporated or integrated into materials that store energy as sensible heat.Thermal energy can be stored in bulk underground, in the form of temperature or phase changes of subsurface materials, in confined media such as liquids or particulate solids, or in self-supporting solid materials.

[0007] Electrical energy storage devices such as batteries generally transfer energy via a flowing electric current. Some thermal energy storage devices similarly transfer energy into and out of the storage device using a single heat transfer approach, such as convective transfer via a liquid heat transfer medium. or circulating gases. These devices use "refractory" materials, which are resistant to high temperatures, for their energy storage medium. These materials can be arranged in configurations that allow the passage of air and combustion gases through large quantities of material.

[0008] Some thermal energy systems can, at system boundaries, absorb energy in one form, such as incident solar radiation or incoming electrical energy, and deliver output energy in a different form, such as heat carried by a liquid or gas. But thermal energy storage systems must also be able to provide storage economically. For sensible heat storage, the temperature range over which the bulk storage material—the "storage medium"—can be heated and cooled is an important determinant of the amount of energy that can be stored per unit of material. Thermal storage materials are limited in their operating temperatures by factors such as freezing, melting, softening, boiling, or thermally induced decomposition or deterioration, including chemical and mechanical effects.

[0009] Furthermore, different uses of thermal energy—different heating processes or industrial processes—require energy at different temperatures. Electrical energy storage devices, for example, can store and release electrical energy at any suitable voltage and efficiently convert that voltage up or down using active devices. On the other hand, converting low-temperature heat to higher temperatures is inherently expensive and inefficient. Therefore, a challenge of thermal energy storage devices is the cost-effective delivery of thermal energy with sufficient heat content and temperature to meet a given application.

[0010] Some thermal energy storage systems store heat in a liquid that flows from a "cold reservoir" through a heat exchange device to a "hot reservoir" during charging, and then from the hot reservoir to the cold reservoir during discharging, providing relatively isothermal conditions at the system outlet during discharging. Systems and methods for maintaining a sufficient outlet temperature while using less expensive solid media are needed.

[0011] Thermal energy storage systems generally have costs that are primarily related to their total energy storage capacity (how many MWh of energy are contained in the system) and their energy transfer rates (the MW of instantaneous energy entering or leaving the energy storage unit at any given time). In an energy storage unit, energy is transferred from an inlet to a storage medium and then transferred at another time from the storage medium to an outlet. The rate of heat transfer into and out of the storage medium is limited by factors such as the heat conductivity and capacity of the medium, the surface area over which the heat is transferred, and the temperature difference across that surface area. High charging rates are permitted due to high temperature differences between the heat source and the storage medium, large surface areas, and storage media with high heat capacity and / or high thermal conductivity.

[0012] Each of these factors can significantly increase the cost of an energy storage device. For example, larger heat exchange surfaces typically require 1) larger volumes of heat transfer fluids and 2) larger surface areas in heat exchangers, both of which are often expensive. Larger temperature differences require heat sources operating at relatively higher temperatures, which can lead to efficiency losses (e.g., radiant or convective cooling to the environment, or lower coefficient of performance of heat pumps) and cost increases (such as selecting and using materials resistant to higher temperatures).Media with higher thermal conductivity and heat capacity may also require the selection of higher performing materials or aggregates, which are expensive.

[0013] Another challenge of energy storage systems from ERV sources concerns charging rates. On a given day, an ERV source may only provide a small percentage of its energy during a brief period of the day, due to ambient conditions. For an energy storage system coupled to an ERV source and designed to deliver a continuous output, all of the delivered energy must be absorbed during the period when the incoming ERV is available. As a result, the maximum charging rate may be some multiple of the discharge rates (e.g., 3-5x), for example, in the case of a solar energy system, if the discharge period (during the night) is much longer than the charging period (during daylight). In this respect, the challenge of ERV storage is different from, for example, that of heat recovery devices, which typically absorb and release heat at similar rates.For ERV storage systems, designing units capable of charging efficiently at high rates is important and can be a greater determinant of total system cost than discharge rate. C. Problems and disadvantages of thermal energy storage

[0014] The approaches described above have various problems and drawbacks. Prior systems do not take into account several critical phenomena in the design, construction, and operation of thermal energy storage systems, and therefore do not facilitate the efficient construction and operation of such systems. More specifically, current designs fail to address "thermal runaway" and element failure due to non-uniform charging and discharging of thermal energy across a solid material assembly, including the design of charge, discharge, and unit controls to achieve and restore temperature equilibrium across large thermal storage material assemblies.

[0015] Thermal energy storage systems with integrated radiative charging and convective discharging are in principle vulnerable to "thermal runaway" or "heat runaway" effects. This phenomenon can result from imbalances, or even small imbalances, in local heating by the heating elements and cooling by the heat transfer fluid flow. Variations in heating rate and cooling rate, unless managed and mitigated, can lead to runaway temperatures that cause failures of the heating elements and / or deterioration of the refractory materials. Overheating leads to early failures of the heating elements and a reduction in the system life. In the case of a stack, for example, the blocks closest to the heating wire are heated more than the blocks further from the heating wire.Therefore, the wire failure rate is likely to increase, reducing the life of the heating element.

[0016] An effect that further aggravates thermal runaway is the thermal expansion of the air flowing through the air lines. The hot air expands further, generating a higher exit velocity for a given inlet flow, and thus a greater hydraulic pressure drop across the line, which can contribute to a further reduction in flow and decreased cooling during discharge. Thus, during successive heating and cooling cycles, progressively less local cooling may occur, resulting in even greater local overheating.

[0017] Efficient operation of heat delivery from thermal energy storage relies on continuous discharge, which is a particular challenge in systems that rely on ERV sources to charge the system. Solutions are required that can capture and store ERV energy efficiently and deliver the stored energy as needed to various uses, including a range of industrial applications, reliably and without interruption.

[0018] Prior systems do not adequately address issues associated with ERV energy sources, including variations arising from severe weather conditions such as storms, and longer-term supply variations arising from seasonal variations in ERV generation. In this regard, there is an unmet need in resilient technology in providing efficient control of energy storage system charging and discharging as part of smart storage management.Current designs do not adequately provide management that considers various factors, including medium- and short-term weather forecasts, VRE generation forecasts, and time-varying energy demand, which may be determined in whole or in part by considerations such as industrial process demand, grid energy demand, real-time electricity prices, wholesale electricity market capacity prices, utility resource adequacy value, and the carbon intensity of displaced energy supplies. What is needed is a system that can provide stored energy according to various demands, and that prioritizes by taking these factors into account, maximizing practical utility and economic efficiency.

[0019] There are various unmet needs regarding energy in general and, more specifically, thermal energy. From a general perspective, there is a need to transition from fossil fuels to clean and sustainable energy. There is also a need to store ERVs to deliver energy at different times to help meet society's energy needs. There is also a need for less expensive energy storage systems and technologies that allow ERVs to deliver energy to industrial processes, which could expand the use of ERVs and thus reduce the combustion of fossil fuels. There is also a desire to maintain a sufficient outlet temperature while using less expensive solid media.

[0020] Furthermore, there is a need to design ERV units that can be rapidly charged at low cost, that can deliver continuous and dispatchable energy according to the needs of various industrial applications despite variations in ERV supply, and that facilitate efficient control of the charging and discharging of the energy storage system. II. Intermittent energy storage

[0021] Fossil fuels have been the driving force of the global economy since the Industrial Revolution; however, humanity has discovered that not only is the supply of these energy resources limited, but also that burning fossil fuels to extract energy produces greenhouse gases and other pollutants that threaten ecosystems across the planet. Specifically, these systems are inherently inefficient in their use of energy locked up in chemical bonds because they emit countless tons of combustion gases hot through chimneys into our atmosphere, directly causing global warming, indirectly causing global warming through the effects of greenhouse gas emissions on planet Earth's increased absorption of sunlight, and also through the effects of pollutants contributing to the degradation of our planet, for example through the washing away of Earth's various ecosystems by acid rain.

[0022] Energy sources that address this problem, such as solar power, wind power, and tidal power, are being developed to meet our need for renewable energy sources that do not generate these harmful greenhouse gases. One drawback of renewable energy sources is that they are intermittent in nature. The sun does not always shine; the wind does not always blow; the tides do not always rise and fall. This has prevented these technologies from replacing fossil fuel sources, since industry requires electricity on demand, 24 hours a day, 365 days a year.

[0023] Therefore, there is a need to find a way to store the intermittent energy delivered by renewable energy sources in a closed circuit to meet the constant energy needs of industry without releasing heat and pollutants into the atmosphere. This has led to the development of green energy storage solutions, as well as systems and methods for storing and extracting heat from solid blocks structured in thermal energy storage units, as described herein.

[0024] One of the obstacles that stands between the initial design and development of thermal storage solutions and their actual implementation is the interfacing of these solutions with existing industrial equipment in order to utilize existing infrastructure and assets. Therefore, there is a need for systems for the modularization of such thermal energy storage units that can be combined in various ways to provide customized solutions that meet the individual needs for modernizing such fossil fuel power generation systems. Furthermore, there is a strong need to enable the evaluation of thermal energy storage units as a green energy alternative to existing fuel boiler systems, without redesigning and rebuilding existing industrial infrastructure.Along the same lines, there is a desperate need for systems that allow for easy switching from fossil fuel energy sources to variable renewable electricity sources to evaluate the latter as a replacement for existing fossil fuel energy sources. This would greatly contribute to achieving the global goals set in the Paris Climate Agreement, in particular a 45% reduction in greenhouse gas emissions by 2030, with a net-zero emissions target set for 2050. In particular, systems and processes . enabling the coupling of one or more thermal energy storage units to fuel-fired boiler systems are required, together with control systems that coordinate the operation of systems containing multiple thermal energy storage units. This coupling of two completely different energy sources allows this new sustainable technology to be reversibly evaluated for retrofitting or possible replacement of fossil fuel-based systems with a green energy source, while retaining the majority of the capital equipment already paid for and in service. III. Industrial applications of stored thermal energy

[0025] The steel industry accounts for up to 5% of total global greenhouse gas emissions due to its significant use of coal. The traditional steelmaking process using refined coal generates approximately two tonnes of carbon dioxide (CO2) per tonne of steel produced. Low-CO2 steelmaking and ironmaking solutions are being developed to reduce the amount of greenhouse gas emissions associated with the steel and iron industries.

[0026] One such solution involves direct reduction of iron (DRI), also known as sponge iron production. DRI is a key process step in one of the two major process routes for producing steel from iron oxide ore. DRI refers to a solid-state process that reduces iron oxides to metallic iron at temperatures below the melting point of iron. As part of the overall effort to reduce greenhouse gas emissions, DRI is becoming the preferred route for steel production due to its emission reduction potential not matched by the blast furnace route. While this is a step in the right direction, traditional DRI processes continue to rely on carbon-emitting sources to provide sufficient heat for the DRI process. Summary

[0027] According to a first aspect of the invention, there is provided a thermal energy storage block comprising: one or more thermal radiation cavities; and a first set of fluid flow slots extending from, and in fluid communication with, a first thermal radiation cavity of the one or more thermal radiation cavities, such that the first set of fluid flow slots and the first thermal radiation cavity together define fluid flow paths through the thermal energy storage block.

[0028] The thermal energy storage block may be formed from a thermal energy storage material, optionally including concrete.

[0029] The thermal energy storage block may further comprise one or more locking features on an external surface of the thermal energy storage block, wherein the one or more locking features are configured to be inserted into engagement with one or more corresponding locking features on another of said thermal energy storage blocks, thereby enabling a stacked arrangement.

[0030] The locking features may include protrusions and / or recesses.

[0031] One or more of the protrusions may be disposed on an upper surface of the thermal energy storage block, and one or more of the recesses may be disposed on a lower surface of the thermal energy storage block opposite the upper surface, and in which the recesses are formed or configured to receive the protrusions.

[0032] The fluid flow slots may be arranged in a first direction parallel to the upper surface and the lower surface of the thermal energy storage block.

[0033] The thermal energy storage block may also include a second set of fluid flow slots extending from, and in fluid communication with, a second thermal radiation cavity of the one or more thermal radiation cavities, such that the second set of fluid flow slots and the second thermal radiation cavity together define further fluid flow paths through the thermal energy storage block.

[0034] The thermal energy storage block may further include a third set of fluid flow slots extending from, and in fluid communication with, a third thermal radiation cavity of the one or more thermal radiation cavities, such that the third set of fluid flow slots and the third thermal radiation cavity together define further fluid flow paths through the thermal energy storage block.

[0035] At least one sidewall of the thermal energy storage block may be configured to define a partial thermal radiation cavity, such that, in use, another thermal radiation cavity is formed when the thermal energy storage block is adjacent another of said thermal energy storage blocks.

[0036] The at least one side wall may be recessed to define the partial radiation cavity.

[0037] The thermal energy storage block may further include a fourth set of fluid flow slots extending from, and in fluid communication with, the partial thermal radiation cavity, such that the fourth set of fluid flow slots and the partial thermal radiation cavity together define additional fluid flow paths through the thermal energy storage block.

[0038] Diagonally opposite portions of the thermal energy storage block may be recessed to define partial thermal radiation cavities, such that, in use, additional thermal radiation cavities are formed when the thermal energy storage block is placed adjacent to other thermal energy storage blocks.

[0039] The thermal radiation cavities may extend through a portion of the thermal energy storage block and the fluid circulation slots may extend through the remaining portion of the thermal energy storage block.

[0040] The thermal storage block may have a mosaic shape.

[0041] The mosaic shape may comprise an asymmetric shape or a rotationally symmetric shape of order two, optionally comprising a zigzag shape or a wave profile shape.

[0042] At least some of the fluid flow slots may have an opening of a different size and / or shape than some other fluid flow slots.

[0043] The thermal energy storage block may further comprise: an upper massive platform portion; and a lower massive base portion, wherein the fluid flow slots are arranged in a first direction parallel to the upper massive platform portion and the lower massive base portion, and wherein the thermal radiation cavity extends between the upper massive platform portion and the lower massive base portion in a second direction perpendicular to the first direction.

[0044] The thermal energy storage block may further comprise openings formed in the upper solid platform portion and / or in the lower solid base portion to facilitate the passage of air therethrough.

[0045] The thermal energy storage block may further include one or more integrated flanges for supporting heating elements adjacent to the one or more thermal radiation cavities.

[0046] In another aspect, there is provided a support block for the thermal energy storage block, the support block comprising: an upper platform portion; a base portion opposite the upper platform portion; a hollow channel between the upper platform portion and the base portion, the channel hollow defining a fluid flow path through the support block; and locking features disposed on the upper platform and on the lower side of the base portion of the support block and configured to engage the one or more locking features of the thermal energy storage block.

[0047] The support block may further include first and second opposing support walls extending between the upper platform portion and the base portion, wherein the hollow channel is defined by the upper platform portion, the base portion, and the first and second opposing support walls.

[0048] At least one side wall of the support block may be recessed, such that, in use, one or more additional hollow channels are formed when the support block is placed adjacent another of said support blocks, thereby defining one or more further fluid flow paths.

[0049] The locking features may include a plurality of protrusions on the upper platform portion and a plurality of recesses formed or configured to receive the protrusions on the lower side of the base portion.

[0050] The protrusions of the upper platform portion may be configured to engage the recesses in the lower surface of the thermal energy storage block, such that the support block is configured to support said thermal energy storage block thereon.

[0051] In another aspect, there is provided an assembly comprising the thermal energy storage block supported by the support block.

[0052] In another aspect, there is provided an assembly comprising a plurality of stacked thermal energy storage blocks, wherein the thermal energy storage blocks in a given layer of the stack are laterally offset from the thermal energy storage blocks in the layer below, such that recesses on the underside of a given block in the given layer are engaged by protrusions on a plurality of blocks in the layer below.

[0053] In another aspect, there is provided a generally parallelepiped-shaped thermal energy storage block, the block comprising: a plurality of fluid flow slots extending in a first direction through the block, the plurality of fluid flow slots defining fluid flow paths through the block; and at least one edge chamfered in a second direction generally perpendicular to the first direction such that, in use, the block is configured to abut at least one other of said blocks with the respective chamfered edges engaged to define a thermal radiation cavity.

[0054] The block may include two edges chamfered in the second direction, such that, in use, the block is configured to abut at least two other of said blocks with the respective chamfered edges engaged to define a heat radiation cavity between the blocks, the heat radiation cavity being in fluid communication with the fluid flow slots to define a fluid flow path therethrough.

[0055] The thermal energy storage may further include one or more integrated rims configured to support one or more heating elements.

[0056] In another aspect, there is provided a support slab for the thermal energy storage block, the support slab having a plurality of recessed bays formed in its upper surface, the recessed bays each being formed and configured to retain said thermal energy storage block therein, wherein the recessed bays are spaced apart from each other and formed in rows, and wherein the recessed bays in adjacent rows are offset, such that when said blocks are disposed in respective bays, the blocks form thermal radiation cavities therebetween.

[0057] The recessed bays in adjacent rows may be offset such that a recessed bay in a given row aligns with the center of a space between consecutive recessed bays in the adjacent row.

[0058] The support slab may further comprise a plurality of recessed bays formed in a lower surface, opposite the upper surface, said bays corresponding to the bays formed in the upper surface of the support slab, thereby allowing, in use, a stacked arrangement of thermal energy storage blocks with the support slab disposed between adjacent layers of the stack.

[0059] In another aspect, there is provided an assembly comprising a plurality of the thermal energy storage blocks, each disposed in a respective recessed bay on the support slab. Brief description of the drawings

[0060] The accompanying drawings are incorporated to provide a better understanding of this disclosure, and are incorporated herein as a part thereof. The drawings illustrate exemplary embodiments of this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0061] [Fig-1] [Fig.l] illustrates a schematic perspective view of a storage block thermal energy according to the implementation examples;

[0062] [Fig.2] [Fig.2] illustrates a perspective view of the bottom of the storage block thermal energy according to the implementation examples;

[0063] [Fig.3a] [Fig.3a] illustrates a front view of the thermal energy storage block according to the examples of realization;

[0064] [Fig.3b] [Fig.3b] illustrates a cross-sectional side view of the block of thermal energy storage according to the embodiment examples;

[0065] [Fig.4] [Fig.4] illustrates a plan view of the thermal energy storage block according to the examples of realization;

[0066] [Fig.5a] [Fig.5a] illustrates a side view of the thermal energy storage block according to the examples of realization;

[0067] [Fig.5b] [Fig.5b] illustrates a cross-sectional plan view of the block of thermal energy storage according to the embodiment examples;

[0068] [Fig.6a] [Fig.6a] illustrates a side view of the thermal energy storage block according to the examples of realization;

[0069] [Fig.6b] [Fig.6b] illustrates another cross-sectional plan view of the block of thermal energy storage according to the embodiment examples;

[0070] [Fig.7a] [Fig.7a] illustrates a side view of a stacked assembly of blocks of thermal energy storage according to the embodiment examples;

[0071] [Fig.7b] [Fig.7b] illustrates a cross-sectional view of a stacked assembly of thermal energy storage blocks according to the embodiment examples;

[0072] [Fig.7c] [Fig.7c] illustrates a close-up view of locking features of the thermal energy storage block according to the embodiment examples;

[0073] [Fig.7d] [Fig.7d] illustrates a plan view of a stacked assembly of thermal energy storage blocks according to the exemplary embodiments;

[0074] [Fig.7e] [Fig.7e] illustrates a perspective view of a stacked assembly of blocks thermal energy storage according to the embodiment examples;

[0075] [Fig.7f] [Fig.7f] illustrates a perspective view of a stacked assembly of thermal energy storage blocks including heating elements according to the exemplary embodiments;

[0076] [Fig.8] [Fig.8] illustrates a schematic perspective view of a storage block thermal energy according to the implementation examples;

[0077] [Fig.9a] [Fig.9a] illustrates a schematic perspective view of a block of thermal energy storage according to the embodiment examples;

[0078] [Fig.9b] [Fig.9b] illustrates a schematic perspective view of a block of thermal energy storage according to the embodiment examples;

[0079] [Fig.9c] [Fig.9c] illustrates a schematic perspective view of the underside of a thermal energy storage block according to the embodiment examples;

[0080] [Fig. 10a] [Fig. 10a] illustrates a schematic perspective view of a support block for a thermal energy storage block according to the exemplary embodiments;

[0081] [Fig. 10b] [Fig. 10b] illustrates a schematic perspective view of the underside of a support block for a thermal energy storage block according to the exemplary embodiments;

[0082] [Fig.lia] [Fig.lia] illustrates a front view of a support block for a block of thermal energy storage according to the embodiment examples;

[0083] [Fig. 11b] [Fig. 11b] illustrates a plan view of a support block for a block of thermal energy storage according to the embodiment examples;

[0084] [Fig.lia] [Fig.lia] illustrates a bottom view of a support block for a block thermal energy storage according to the embodiment examples;

[0085] [Fig. 12] [Fig. 12] illustrates a schematic perspective view of a block of thermal energy storage according to the embodiment examples;

[0086] [Fig. 13a] [Fig. 13a] illustrates a perspective view of an assembly of blocks of thermal energy storage arranged on support slabs according to the embodiment examples;

[0087] [Fig. 13b] [Fig. 13b] illustrates a perspective view of an assembly of blocks of thermal energy storage arranged on support slabs with heating elements according to the embodiment examples;

[0088] [Fig. 14] [Fig. 14] illustrates a cross-sectional perspective view of a assembly of thermal energy storage blocks arranged on support slabs according to the embodiment examples;

[0089] [Fig. 15] [Fig. 15] illustrates a plan view of an assembly of storage blocks thermal energy arranged on support slabs according to the embodiment examples;

[0090] [Fig. 16] [Fig. 16] illustrates a side view of a storage block assembly thermal energy arranged on support slabs according to the embodiment examples;

[0091] [Fig. 17a] [Fig. 17a] illustrates a schematic perspective view from one side upper part of a support slab for thermal energy storage blocks according to the embodiment examples;

[0092] [Fig. 17b] [Fig. 17b] illustrates a schematic perspective view of a lower side of a support slab for thermal energy storage blocks according to the embodiment examples. Detailed description

[0093] Aspects of the exemplary embodiments, as disclosed herein, relate to thermal energy storage blocks, as well as associated support slabs and support blocks, for use in thermal energy storage systems for various industrial applications.

[0094] The structure and shape of the blocks are configured for repeated heating and cooling for the purpose of energy storage. When implemented in a thermal energy storage system, the energy input is provided in the form of electrical energy, which heats wires, filaments, rods, or other solid conductive materials to emit radiant thermal energy. The energy output is in the form of heat delivered into a circulating gas introduced at a portion of a structure incorporating the blocks, and which leaves another portion of the structure at a higher temperature.

[0095] The blocks may be in one or more molded or extruded forms, and may be arranged to have an alternating sequence along both vertical and horizontal axes. The structure includes a plurality of open cavities, or chambers, and blocks, the blocks including air passages having at least one dimension much smaller than the other two dimensions. The passages are open to the chambers and are internally exposed to a radiating surface heated by an electrical resistance. In the chambers, heat is transferred by thermal radiation from relatively warmer surfaces to relatively cooler surfaces.

[0096] [Fig.l] shows a schematic perspective view of a thermal energy storage block 100 according to one embodiment. The block 100 is formed from a thermal storage material, which may be concrete and / or refractory materials.

[0097] The block 100 includes channels, or fluid flow slots 102, disposed in a first direction (horizontally) through a portion of the block. The plurality of fluid flow slots 102 may be formed to be wider than they are tall and may have a continuous cross-section along their length. The fluid flow slots allow passage therethrough of a fluid, such as air, nitrogen, argon, carbon dioxide (CO2), water vapor, a process gas, an inert gas, hydrogen, or other heated fluids.

[0098] Also provided are heat radiation cavities 104 formed in the block, which define a space into which heat energy can radiate onto exposed surfaces of the block from adjacent electric heating elements to transfer heat energy there. The heat radiation cavities 104 each extend from the lower solid base portion 120 of the block to the upper solid platform portion 130 in a second direction perpendicular to the first direction. By extending into the block, the heat radiation cavities provide a large surface area over which heat energy can radiate from adjacent heating elements (not shown) to transfer heat energy to the material of the thermal energy storage block with high efficiency.

[0099] The heat radiation cavities 104 are arranged in opposite faces of the block, in a staggered, or offset, configuration, with their openings arranged on both opposite faces. Accordingly, a face of the block into or out of which a fluid flows is defined by an alternating arrangement of fluid flow slots 102 and heat radiation cavities 104.

[0100] A partial heat radiation cavity 106 is also formed by a recessed side wall 114 of the block 100. The partial heat radiation cavity 106 becomes a complete heat radiation cavity when the block 100 is placed adjacent to another of the blocks 100. In particular, the side wall of an adjacent block 100 forms the missing wall to make the partial radiation cavity a complete radiation cavity.

[0101] A set of fluid flow slots 102 extends from, and in fluid communication with, each of the heat radiation cavities 104, including the partial heat radiation cavity 106. Accordingly, the set of fluid flow slots and the respective heat radiation cavity together define fluid flow paths through the energy storage block. These paths are generally in the first direction (the horizontal direction).

[0102] The block 100 includes one or more integrated rims 110. The rims 110 may be used to support heating elements in a space between rows of thermal storage blocks 100, proximate the thermal radiation cavities, as discussed in more detail below.

[0103] The block 100 also includes openings 112 through the upper massive platform portion 130 and through the lower massive base portion 120 of the block 100. These openings 112 may have the same or different sizes and / or shapes than other fluid flow slots 102 in the thermal energy storage block 100. The openings 112 allow excess heat in an otherwise massive section of the storage block to be dissipated to reduce structural stress that could occur if that massive section were to retain too much heat, relative to the rest of the thermal storage block. The openings may extend through the entire block, thereby defining a fluid flow path through the block.In an alternative embodiment, the upper massive platform portion 130 and the lower massive base portion 120 of the block 100 are closed, without openings or passageways therethrough, for greater structural strength.

[0104] [Fig.l] also shows locking features 108 disposed on the upper surface of the upper massive platform portion 130 of the block 100. As shown in [Fig.2], corresponding locking features 216 are disposed on the inner side of the lower massive base portion of the block 100, and are configured or shaped to be engaged by the locking features 108 disposed on the upper surface of the block 100. Accordingly, the blocks may be stacked, with the locking features 108 on the upper surface of one block engaging a corresponding locking feature 216 on the lower side of a block located thereon. The locking features resist lateral movement and may also maintain alignment when there is vertical movement.

[0105] The locking features 108, 216 may be in the form of protrusions (or tabs) and recesses. As shown in Figures 1 and 2, the locking features are arranged in a regular pattern, such as a square or rectangular arrangement on each surface. The spacing between the locking features is provided to allow for a staggered and overlapping stacking arrangement (as further discussed below).

[0106] [Fig.3a] shows a front view of the thermal energy storage block 100. As explained above, that face of the block, into and from which a fluid flows, has an alternating arrangement of columns of fluid flow slots 102 and thermal radiation cavities 104. As shown, there are also fluid flow slots 102 extending from the far end of the radiation cavity 104, from inside the block 100 to the opposite face of the block 100. Therefore, the face of the block opposite that shown in [Fig.3a] has the same appearance as the face that is shown.

[0107] [Fig.3b] shows a cross-sectional view of the block along section EE as shown in [Fig.3a]. As shown in [Fig.3b], the fluid flow slots 102 extend from, and are in fluid communication with, the respective heat radiation cavity 104. The apertures 112 also extend through the entire depth of the block, thereby defining another fluid flow path through the block.

[0108] [Fig.4] shows a plan view of the block 100. As seen from above, the block 100 has an asymmetrical shape with respect to a longitudinal axis represented by the dashed line 410. The block has two sides with straight edges 430, 432 and two profiled edges 420, 422 having a shape such as, but not limited to, a wavy profile or a zigzag profile. In other words, the edges 420 and 422 may have a portion cut into diagonally opposite regions.

[0109] [Fig.5a] shows a side view of block 100, corresponding to block 100 as shown in [Fig.3a] but rotated 90 degrees about the central vertical axis. The partial heat radiation cavity at one side of the block is shown.

[0110] [Fig.5b] shows a cross-sectional view of the block 100 along the line DD as shown in [Fig.5a]. The cross-section is between the fluid flow slots 102, so the slots 102 are not visible in the cross-sectional view. The cross-sectional view shows the staggered arrangement of the heat radiation cavities 104 on opposite sides of the block 100. The heat radiation cavities 104 extend into the body of the block 100. As shown, the cavities may extend to nearly halfway through the depth of the block. The heat radiation cavities 104 may also be provided with an opening 510 that widens. These openings 510 help to direct fluid into the cavities and ultimately into the fluid flow slots 102.

[0111] [Fig.6a] shows a side view of the block 100, corresponding to the view shown in [Fig.5a]. [Fig.6b] shows a cross-sectional view of the block 100 along the line EE as shown in [Fig.6a]. This cross-section is at a different height than the cross-section shown in [Fig.5b]. In this case, the cross-section intersects a layer of fluid flow slots 102. As shown, the fluid flow slots 102 extend from the rear of each of the heat radiation cavities to the opposite face of the block, such that the heat radiation cavities 104, 106 and the fluid flow slots 102 together define fluid flow paths through the block.

[0112] [Fig.7a] shows a side view of a stacked structure, or assembly 700 of blocks 100. Each block 100 is shown from the side view, as shown in Figures 5a and 6a, with the fluid flow slots (not shown) extending horizontally. From the illustrated side view, there are spaces 710 between each of the blocks 100 in a row. The blocks in the row above are staggered, or laterally offset, relative to the blocks 100 in the row below.

[0113] [Fig.7b] shows a cross-sectional view of the assembly along the line AA as shown in [Fig.7a]. As this cross-section shows, there are no gaps between adjacent blocks in a row of the same layer, since the blocks are arranged in a mosaic pattern.

[0114] [Fig.7c] shows a close-up view of the region marked "B" in [Fig.7b]. As shown, a protrusion 108 on the upper surface of a block 100 in the lower layer engages a recess 216 in the lower portion of a block 100 in the top layer in the stacked arrangement.

[0115] [Fig.7d] shows a plan view of the stacked assembly 700. The blocks 100 are arranged in a mosaic pattern so as to form rows in a first direction, and so that there are spaces 710 between each such row in a given layer, in a second direction perpendicular to the first direction. The blocks 100 in the top layer are laterally offset in both the first direction and a second direction (perpendicular to the first direction), so as to overlap the spaces 710. As a result, the spaces 710 in adjacent layers of the stack are also offset. Each block 100 in the top layer engages four different blocks 100 in the layer below. Therefore, the recesses 216 of a given block 100 in the top layer are engaged by protrusions 108 on four different blocks 100 in the layer below.

[0116] [Fig.7e] shows a perspective view of the stacked assembly 700, in which the offset, the mosaic configuration and the spaces between the blocks, as explained above, are represented.

[0117] As shown in [Fig.7f], the spaces between adjacent rows of blocks are arranged to accommodate electric heating elements 740 for transferring thermal energy to the blocks for storage therein. The electric heating elements 740 are arranged adjacent the heat radiating cavities 104. The heating elements 740 may be arranged to span a row of thermal energy storage blocks 100. The heating elements may be held by a support structure (not shown) that engages the integrated flanges 110 in the blocks. The support structure (not shown) may span the space between rows of blocks to engage the integrated flanges 110 on both sides of the space.

[0118] [Fig. 8] shows an alternative embodiment of a block 800. The block 800 has features corresponding to those of the block 100 as described above. The corresponding features of the block are marked by similar reference numerals. The block 800 has a larger format than the block 100. In particular, the larger block 800 has additional rows of heat radiation cavities 104 and fluid flow slots 102. As seen in the illustrated face, there are three heat radiation cavities 104, a single partial radiation cavity 106, and four sets (or columns) of fluid flow slots 102. Cavities 106 corresponding to the slots 102 are also formed in the opposite face (not shown). A given 800 block has 8 protrusions 108 on its upper surface, and 8 corresponding recesses (not shown) on its lower side.The larger format of the 800 block allows the use of fewer blocks in forming a stacked assembly, having a given thermal storage capacity, than in the case where smaller blocks (such as the 100 block) are used.

[0119] Figures 9a-c show another alternative embodiment of a block 900. The block 900 has features corresponding to those of the block 100 as described above. The corresponding features of the block are marked by similar reference numerals. The block 900 has a deeper format than the block 100. From a front view, block 900 corresponds to block 100 in the number of heat radiation cavities and slot columns. With the deeper structure, the fluid flow slots 102 and heat radiation cavities 104 must also extend further between the opposite faces of the block, which are separated by a greater distance. Block 900 is provided with 6 protrusions 108 on its upper surface and 6 corresponding recesses 216 on its lower side, as shown in [Fig.9c].

[0120] Figures 10a and 10b show perspective views of a support block 1000, or crossmember, for supporting the thermal energy storage blocks described above. The support block 1000 is configured to deliver fluid flow from below the thermal energy storage blocks, and to provide thermal insulation of the thermal energy storage blocks from the ambient environment. In particular, the thermal energy storage blocks may be heated to high temperatures that cannot be tolerated by the structure or the ambient environment.

[0121] As shown in [Fig.10a], the support block 1000 is provided with an upper platform portion 1120, an opposing base portion 1130, and a hollow channel 1002 between the upper platform portion 1120 and the base portion 1130. The hollow channel 1120 defines a fluid flow path through the support block, to allow fluid flow around a stacked structure of thermal storage energy blocks.

[0122] First and second opposing support walls 1040, 1042 extend between the upper platform portion 1120 and the base portion 1130. The hollow channel 1002 is defined by the upper platform portion, the base portion, and the first and second opposing support walls.

[0123] The side walls 1030 of the block are recessed, or indented, so that, in use, one or more further hollow channels are formed when the support block is placed adjacent another of said support blocks, thereby defining one or more further fluid flow paths. In other words, the upper platform portion 1120 and the base portion 1130 extend laterally beyond the support walls 1040, 1042, to create a recessed region that forms a partial channel.

[0124] The support block 100 is also provided with locking features in the form of protrusions 1108 on the upper surface of the upper platform portion of the support block. The shape and purpose of these protrusions 1108 correspond to those of the thermal energy storage block, as described above. The protrusions 1108 may engage recesses 216 in the lower side of a thermal energy storage block, and thus support a thermal energy storage block. thermal energy storage on the upper platform portion of the support block 1000. As shown, 4 protrusions may be arranged in a square or rectangular arrangement.

[0125] As shown in [Fig.10b], the support block 1000 may also be provided with locking features on the lower side of the base portion 1130 of the support block 1000. These locking features may be in the form of recesses 1116 which are configured, shaped and arranged to be engaged by the protrusions 1108.

[0126] [Fig.11a] shows a front elevational view of the support block 1000. As shown, the hollow region 1102 provides a fluid flow path extending through the support block.

[0127] [Fig. 11b] shows a plan view of the support block 1000. As shown, protrusions 1108 are arranged in a grid pattern on an upper surface of the upper platform portion 1120 of the support block 1000.

[0128] [Fig. 1 le] shows a view from the lower side of the support block. As shown, recesses 1116 are arranged in a grid pattern on a lower side of the base portion of the support block 1000.

[0129] [Fig. 12] shows a perspective view of another embodiment of a thermal energy storage block 1200. This embodiment facilitates faster manufacturing, given the simpler design. In particular, thermal radiation cavities are formed by arranging a plurality of blocks 1200 (as discussed below), instead of being formed in an individual block itself.

[0130] The block 1200 is formed in a generally parallelepiped, or cuboid, shape. A plurality of fluid flow slots 1202 extend in a first (horizontal) direction through the block 1200, and thus define fluid flow paths through the block 1200, in a manner similar to the fluid flow slots described above. The block 1200 is also provided with two chamfered edges 1218, which extend in a second (vertical) direction, perpendicular to the first direction. The chamfered edges 1218 are arranged such that, in use, the block 1200 is configured to abut at least one other of the blocks 1200, with the respective chamfered edges engaged to define a heat radiation cavity.

[0131] The block 1200 also includes an integrated rim 1210 configured to support heating elements, in a manner similar to the integrated rims described above.

[0132] The chamfered edges 1218 are both disposed on edges between a front face of the block 1200, in which the fluid flow slots 1202 are formed, and a side face 1220 of the block 1200, which may be a relatively wide face. The integrated flange 1210 is disposed in the opposite front face 1230 of the block 1200, in which the fluid flow slots are formed. The block 1200 is symmetrical about a vertical plane which is located in the first and second directions, the normal of which lies in a third direction perpendicular to the first and second directions and which intersects the two front / end faces via their respective centers.

[0133] [Fig. 13a] shows an assembly of blocks 1200 arranged on support slabs 1700. The support slab is described in more detail below. The blocks 1200 on the support slabs 1700 are arranged in pairs of rows extending in the third direction (perpendicular to the first and second directions, and parallel to a surface of the slabs 1700), with gaps 1340 disposed between the side faces 1220 of the blocks 1200 in a given row. The next row in the pair of rows is arranged directly adjacent to, and facing, the first row, but offset in the third direction so as to align with the gaps 1340 and so that the chamfered edges engage. As a result, the spaces 1340 form heat radiation cavities linked by the front / end face of a given block 1200 and the side walls of two other blocks 1200.These radiation cavities 1340 are in fluid communication with the fluid flow slots 1202 which extend through the block 1200 in the first direction. Therefore, the thermal radiation cavities 1340, together with the fluid flow slots 1202, define fluid flow paths through the assembly. A corresponding arrangement of blocks 1200 is also disposed on the underside of the slabs 1700.

[0134] Pairs of block rows 1200 on the slabs 1700 are arranged with a gap 1360 therebetween, and with their respective flanges 1210 facing each other. As a result, as shown in [Fig. 13b], electric heating elements 1382 may be positioned in the gaps 1360 between pairs of block rows 1200, so as to be adjacent to the heat radiating cavities 1340, to radiate heat energy therein, and thereby store the heat energy in the blocks 1200. The heating elements 1382 are held by a support structure 1380 which engages the integrated flanges 1210 in the blocks.

[0135] [Fig. 14] shows a perspective cross-sectional view of the arrangement shown in [Fig. 12]. The cross-section shows the fluid flow slots 1202, in the form of a channel, extending horizontally through the block 1200, and in fluid communication with the heat radiation cavity 1340.

[0136] [Fig. 15] shows a plan view of the block arrangement 1200 described above. Each of the spaces 1340, 1360 between the rows and blocks is shown, and the engagement of the chamfered edges 1218 is also shown.

[0137] [Fig. 16] shows a side elevational view of the block arrangement 1200 described above. The blocks 1200 are arranged in a staggered, or offset, arrangement both above and below the support slabs 1700.

[0138] [Fig. 17a] shows a perspective view of an upper side of the support slab 1700 for use with the blocks 1200 as described above. The support slab 1700 has a plurality of recessed bays 1702 formed in an upper surface of the slab, each of the recessed bays being shaped and configured to retain a thermal energy storage block therein. The recessed bays are mutually spaced and are arranged in rows to space the thermal energy storage blocks from each other in the manner described above, with appropriate gaps to form the heat radiation cavities, and to form a space for the electric heating elements. Two of the support slabs 1700 may be contiguous in the manner described in Figures 13a-15, to create the pairs of rows of blocks 1200 described above.

[0139] In particular, the recessed bays 1702 are mutually spaced and formed into rows, with the recessed bays 1702 being offset in adjacent rows, such that when blocks 1200 are arranged in respective bays 1702, the blocks 1200 form heat radiation cavities therebetween, as described above. The recessed bays 1702 in adjacent rows are offset such that a recessed bay in a given row aligns with the center of a gap between consecutive recessed bays in the adjacent row. In this way, two of the support slabs 1700 can be combined to create the pairs of rows of blocks 1200 with heat radiation cavities 1340 as described above.

[0140] [Fig. 17b] is a perspective view of a lower side of the support slab 1700 for use with the blocks 1200. Correspondingly to the upper side, the lower side of the support slab 1700 also includes recessed bays 1704. The bays 1704 correspond in shape and arrangement to the bays formed in the upper surface of the support slab 1700, but may be laterally offset to create the staggered configuration shown in [Fig. 16]. The support slab 1700 thus allows for a stacked arrangement of the thermal energy storage blocks 1200 with the support slab between adjacent layers of the stack. Best mode for carrying out the invention

[0141] 1. A thermal energy storage block comprising: one or more thermal radiation cavities; and a first set of fluid flow slots extending from, and in fluid communication with, a first thermal radiation cavity of the one or more thermal radiation cavities, such that the first set of fluid flow slots and the first thermal radiation cavity together define fluid flow paths through the thermal energy storage block.

[0142] 2. The thermal energy storage block of embodiment 1, which block thermal energy storage is formed from a thermal energy storage material, possibly including concrete.

[0143] 3. The thermal energy storage block of any of the modes of previous embodiments, further comprising one or more locking features on an external surface of the thermal energy storage block, wherein the one or more locking features are configured to be inserted into engagement with one or more corresponding locking features on another of said thermal energy storage blocks, thereby enabling a stacked arrangement.

[0144] 4. The thermal energy storage block of embodiment 3, wherein the locking features include protrusions and / or recesses.

[0145] 5. The thermal energy storage block of embodiment 4, wherein one or more of the protrusions are disposed on an upper surface of the thermal energy storage block, and one or more of the recesses are disposed on a lower surface of the thermal energy storage block opposite the upper surface, and wherein the recesses are formed or configured to receive the protrusions.

[0146] 6. The thermal energy storage block of embodiment 5, wherein the fluid flow slots are arranged in a first direction which is parallel to the upper surface and the lower surface of the thermal energy storage block.

[0147] 7. The thermal energy storage block of any of the modes of previous achievements, further comprising: a second set of fluid flow slots extending from, and in fluid communication with, a second thermal radiation cavity of the one or more thermal radiation cavities, such that the second set of fluid flow slots and the second thermal radiation cavity together define further fluid flow paths through the thermal energy storage block.

[0148] 8. The thermal energy storage block of any of the modes of previous achievements, further comprising: a third set of fluid flow slots extending from, and in fluid communication with, a third thermal radiation cavity of the one or more thermal radiation cavities, such that the third set of fluid flow slots and the third thermal radiation cavity together define further fluid flow paths through the thermal energy storage block.

[0149] 9. The thermal energy storage block of any of the modes of previous embodiments, wherein at least one side wall of the thermal energy storage block is configured to define a partial thermal radiation cavity, such that, in use, another thermal radiation cavity is formed when the thermal energy storage block is adjacent another of said thermal energy storage blocks.

[0150] 10. The thermal energy storage block of embodiment 9, wherein the at least one side wall is recessed to define the partial radiation cavity.

[0151] 11. The thermal energy storage block of embodiment 9 or 10, further comprising a fourth set of fluid flow slots extending from, and in fluid communication with, the partial thermal radiation cavity, such that the fourth set of fluid flow slots and the partial thermal radiation cavity together define additional fluid flow paths through the thermal energy storage block.

[0152] 12. The thermal energy storage block of any of the modes of previous embodiment, wherein diagonally opposite portions of the thermal energy storage block are recessed to define partial heat radiation cavities, such that, in use, further heat radiation cavities are formed when the thermal energy storage block is placed adjacent to other thermal energy storage blocks.

[0153] 13. The thermal energy storage block of any of the modes of previous embodiments, wherein the thermal radiation cavities extend through a portion of the thermal energy storage block and the fluid circulation slots extend through the remaining portion of the thermal energy storage block.

[0154] 14. The thermal energy storage block of any of the modes of previous realization, which thermal storage block is put in a mosaic form.

[0155] 15. The thermal energy storage block of embodiment 14, wherein the mosaic shape includes an asymmetrical shape or a symmetrical shape in second-order rotation, possibly including a zigzag shape or a wave profile shape.

[0156] 16. The thermal energy storage block of any of the modes of previous embodiments, wherein at least some of the fluid flow slots have an opening of a different size and / or shape than certain other fluid flow slots.

[0157] 17. The thermal energy storage block of any of the modes of previous embodiments, further comprising: an upper massive platform portion; and a lower massive base portion, wherein the fluid flow slots are arranged in a first direction which is parallel to the upper massive platform portion and the lower massive base portion, and wherein the heat radiation cavity extends between the upper massive platform portion and the lower massive base portion in a second direction perpendicular to the first direction.

[0158] 18. The thermal energy storage block of embodiment 17, comprising furthermore openings formed in the upper massive platform portion and / or in the lower massive base portion to facilitate the passage of air therein.

[0159] 19. The thermal energy storage block of any of the modes of previous embodiments, further comprising one or more integrated flanges for supporting heating elements adjacent to the one or more heat radiating cavities.

[0160] 20. A support block for the thermal energy storage block of the mode of embodiment 3, or any preceding embodiment dependent thereon, the support block comprising: a portion of upper platform; a base portion opposite the upper platform portion; a hollow channel between the upper platform portion and the base portion, the hollow channel defining a fluid flow path through the support block; and locking features disposed on the upper platform and on the lower side of the base portion of the support block and configured to engage the one or more locking features of the thermal energy storage block.

[0161] 21. The support block of embodiment 20, further comprising: first and second opposing support walls extending between the upper platform portion and the base portion, wherein the hollow channel is defined by the upper platform portion, the base portion and the first and second opposing support walls.

[0162] 22. The support block of embodiment 20 or 21, wherein at least one side wall of the support block is recessed, so that, in use, one or more additional hollow channels are formed when the support block is placed adjacent another of said support blocks, thereby defining one or more further fluid flow paths.

[0163] 23. The support block of any one of embodiments 20 to 22, in wherein the locking features include a plurality of protrusions on the upper platform portion and a plurality of recesses formed or configured to receive the protrusions on the lower side of the base portion.

[0164] 24. The support block of embodiment 23 for the energy storage block thermal energy storage block of the embodiment or any preceding embodiment dependent thereon, wherein the protrusions of the upper platform portion are configured to engage the recesses in the lower surface of the thermal energy storage block, such that the support block is configured to support thereon said thermal energy storage block.

[0165] 25. An assembly comprising the thermal energy storage block of one any of embodiments 1 to 19 supported by the support block of any of embodiments 20 to 24.

[0166] 26. An assembly comprising a plurality of energy storage blocks stacked thermal energy storage blocks of embodiment 5 or any preceding embodiment dependent thereon, wherein the thermal energy storage blocks in a given layer of the stack are laterally offset relative to the thermal energy storage blocks in the layer below, such that recesses on the underside of a given block in the given layer are engaged by protrusions on a plurality of blocks in the layer below.

[0167] 27. A thermal energy storage block of overall shape parallelepiped, the block comprising: a plurality of fluid flow slots extending in a first direction through the block, the plurality of fluid flow slots defining fluid flow paths through the block; and at least one edge chamfered in a second direction generally perpendicular to the first direction such that, in use, the block is configured to abut at least one other of said blocks with the respective chamfered edges engaged to define a heat radiation cavity.

[0168] 28. The thermal energy storage block of embodiment 27, which block comprises two edges chamfered in the second direction, such that, in use, the block is configured to abut against at least two other of said blocks with the respective chamfered edges engaged to define a heat radiation cavity between the blocks, the heat radiation cavity being in fluid communication with the fluid flow slots to define a fluid flow path therethrough.

[0169] 29. The thermal energy storage block of embodiment 27 or 28, further comprising one or more integrated flanges configured to support one or more heating elements.

[0170] 30. A support slab for the thermal energy storage block of one any of embodiments 27 to 29, the support slab having a plurality of recessed bays formed in an upper surface thereof, the recessed bays each being formed and configured to retain said thermal energy storage block therein, wherein the recessed bays are spaced apart from each other and formed in rows, and wherein the recessed bays in adjacent rows are offset, such that when said blocks are disposed in respective bays, the blocks form thermal radiation cavities therebetween.

[0171] 31. Support slab of embodiment 30, wherein the recessed bays in adjacent rows are offset so that a recessed bay in a given row aligns with the center of a space between consecutive recessed bays in the adjacent row.

[0172] 32. The support slab of embodiment 30 or 31, further comprising a a plurality of recessed bays formed in a lower surface, opposite the upper surface, said bays corresponding to the bays formed in the upper surface of the support slab, thereby enabling, in use, a stacked arrangement of thermal energy storage blocks with the support slab disposed between adjacent layers of the stack.

[0173] 33. An assembly comprising a plurality of the energy storage blocks thermal of any one of embodiments 27 to 29, each disposed in a respective recessed bay on a support slab of any one of embodiments 30 to 32.

Claims

Claims

1. A thermal energy storage block comprising: one or more thermal radiation cavities; and a first set of fluid flow slots extending from, and in fluid communication with, a first thermal radiation cavity of the one or more thermal radiation cavities, such that the first set of fluid flow slots and the first thermal radiation cavity together define fluid flow paths through the thermal energy storage block.

2. A thermal energy storage block according to claim 1, which thermal energy storage block is formed from a thermal energy storage material, optionally comprising concrete.

3. A thermal energy storage block according to any preceding claim, further comprising one or more locking features on an external surface of the thermal energy storage block, wherein the one or more locking features are configured to be inserted into engagement with one or more corresponding locking features on another of said thermal energy storage blocks, thereby enabling a stacked arrangement.

4. The thermal energy storage block of claim 3, wherein the locking features comprise protrusions and / or recesses, wherein one or more of the protrusions are disposed on an upper surface of the thermal energy storage block, and one or more of the recesses are disposed on a lower surface of the thermal energy storage block opposite the upper surface, and wherein the recesses are shaped or configured to receive the protrusions.

5. A thermal energy storage unit according to any preceding claim, further comprising: a second set of fluid flow slots extending from, and in fluid communication with, a second heat radiation cavity of the at least one heat radiation cavity, such that the second set of fluid flow slots and the second heat radiation cavity define set of other fluid flow paths through the thermal energy storage block.

6. A thermal energy storage block according to any preceding claim, wherein at least one side wall of the thermal energy storage block is configured to define a partial heat radiation cavity, such that, in use, a further heat radiation cavity is formed when the thermal energy storage block is adjacent another of said thermal energy storage blocks, wherein the at least one side wall is recessed to define the partial radiation cavity.

7. The thermal energy storage block of claim 6, further comprising a fourth set of fluid flow slots extending from, and in fluid communication with, the partial thermal radiation cavity, such that the fourth set of fluid flow slots and the partial thermal radiation cavity together define additional fluid flow paths through the thermal energy storage block.

8. A thermal energy storage block according to any preceding claim, wherein the heat radiation cavities extend through a portion of the thermal energy storage block and the fluid circulation slots extend through the remaining portion of the thermal energy storage block.

9. A thermal energy storage block according to any preceding claim, wherein the thermal storage block is provided in a mosaic shape, wherein the mosaic shape comprises an asymmetric shape or a two-fold rotationally symmetric shape, optionally comprising a zigzag shape or a wave profile shape.

10. A thermal energy storage block according to any preceding claim, further comprising: an upper massive platform portion; and a lower massive base portion, wherein the fluid flow slots are arranged in a first direction which is parallel to the upper massive platform portion and the lower massive base portion, and wherein the heat radiation cavity extends between the upper massive platform portion and the lower massive base portion. of upper massive platform and the lower massive base portion in a second direction perpendicular to the first direction.

11. A thermal energy storage unit according to claim 10, further comprising openings formed in the upper solid platform portion and / or in the lower solid base portion to facilitate the passage of air therethrough.

12. A thermal energy storage block according to any preceding claim, further comprising one or more integral flanges for supporting heating elements adjacent to the one or more thermal radiation cavities.

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