Thermal energy storage system with improved earthquake stability

Abstract

Thermal energy storage (TES) systems convert variable renewable energy (VRE) into continuous heat exceeding 900°C. Intermittent electrical energy heats a solid medium. Heat from the solid medium is supplied continuously as needed. Heat supply through a flowing gas establishes a temperature stratification that maintains a high outlet temperature through discharge. The supplied heat can be used in processes including power generation and cogeneration. The thermal storage medium can consist of heat-resistant materials such as brick or concrete, composed of radiant cavities and fluid channels to provide rapid radiative charging and long-term convective discharge from VRE. The configuration of the thermal storage medium allows for substantially horizontal temperature stratification and thermal supply arrangement, which provides seismic stability and facilitates significant scalability of the TES system by increasing the length of the system without adding excessive height, contributing to both the stability and efficiency of the thermal supply structure.

Description

Technical Field

[0003] , , , ,

[0004] , , , , , , ,

[0001] Cross - reference to Related Applications [1] This application claims priority to the following patent applications. [2] U.S. Provisional Patent Application No. 63 / 459,540, filed on April 14, 2023, [3] U.S. Provisional Patent Application No. 63 / 578,139, filed on August 22, 2023, and [4] U.S. Provisional Patent Application No. 63 / 626,501, filed on January 29, 2024, [5] U.S. Provisional Patent Application No. 63 / 627,523, filed on January 31, 2024. [6] The foregoing patent applications are hereby incorporated by reference in their entirety for all purposes.

[0002] [7] Technical Field [8] The present disclosure relates to thermal energy storage and utilization systems. More particularly, the present disclosure relates to an energy storage system that stores electrical energy in the form of thermal energy, and such thermal energy can be used to supply high-temperature air, nitrogen, argon, carbon dioxide (CO2), steam, process gas, inert gas, hydrogen, or other heated fluids in various applications including the supply of heat for power generation. More specifically, the present disclosure relates to using a thermal energy storage system to improve the efficiency related to material processing or other industrial applications anywhere in the world and to reduce carbon emissions.

Background Art

[0003] [9] Related Art

[10] I. Thermal Energy Systems

[0004]

[11] A. Variable Renewable Electricity

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

[0005]

[13] Variable renewable energy (VRE) sources, such as solar and wind power, have developed rapidly as costs have decreased as the world moves toward reducing carbon emissions to mitigate climate change. However, the main challenge associated with the use of VRE is, as its name suggests, its variability. Due to the variable and intermittent nature of wind and solar power, these types of energy sources are not strong candidates for supplying continuous energy demands such as power grids and industrial processes. Thus, there is an unmet need for storing VRE so that energy can be supplied efficiently and flexibly at different points in time.

[0006]

[14] Furthermore, the International Energy Agency reports that industrial energy use accounts for the largest portion of global energy use, and that three-quarters of industrial energy is used in the form of heat rather than electricity. Thus there is an unmet need for lower-cost energy storage systems and technologies that can expand VRE and reduce the burning of fossil fuels, and that can provide industrial process energy using VRE.

[0007]

[15] B. Storage of energy as heat

[16] Thermal energy in industrial, commercial and residential applications may be collected over a period of time, stored in storage devices, and released for intended use over another period of time. Examples include sensible heat in tanks of liquids, including water, oil and molten salt; sensible heat in solid media, including rock, sand, concrete and refractory materials; latent heat in phase transitions between 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 a number of repetitive cycles; and energy storage in media that can combine these effects, such as in which phase-change materials are embedded in or integrated with materials that store energy as sensible heat. Thermal energy can be stored in large quantities underground, in the form of temperature or phase transitions of subsurface materials, in containing media such as liquids or granular solids, or in freestanding solid materials.

[0008]

[17] Electrical energy storage devices, such as batteries, typically transfer energy mediated by a flowing electric current. Some thermal energy storage devices also transfer energy to and from the storage area using a single heat transfer method, such as convection heat transfer through a flowing liquid or gas heat transfer medium. Such devices use “heat-resistant” materials that can withstand high temperatures as their energy storage medium. These materials may be arranged in a configuration that allows large amounts of air and combustion gases to pass through the material.

[0009]

[18] Some thermal energy systems can absorb one form of energy, such as incoming solar radiation or incoming electricity, at their system boundaries and supply a different form of output energy, such as heat carried by a liquid or gas. However, thermal energy storage systems must also be able to provide storage economically. In the case of sensible heat storage, the range of temperatures over which the bulk storage material ("storage medium") can be heated and cooled is a key determinant of the amount of energy that can be stored per unit of material. Thermal storage (thermal storage) materials have their usable temperatures limited by factors such as freezing, thawing, softening, boiling, or thermal decomposition or degradation, including chemical and mechanical effects.

[0010]

[19] Furthermore, different applications of thermal energy (different heating processes or industrial processes) require energy at different temperatures. For example, electrical energy storage devices can store and retrieve electrical energy at any convenient voltage and convert that voltage efficiently up or down using active devices. On the other hand, converting low-temperature heat to high-temperature heat is inherently costly and inefficient. Therefore, the challenge in thermal energy storage devices is to supply thermal energy at a temperature that has sufficient heat content to meet a given application, and in a cost-effective manner.

[0011]

[20] Some thermal energy storage systems store heat in a liquid that flows from a “cold tank” through a heat exchanger to a “hot tank” during charging, and then from the hot tank to the cold tank during discharge, providing a relatively isothermal state at the system outlet during discharge. There is a need for systems and methods to maintain a sufficient outlet temperature while using lower-cost solid media.

[0012]

[21] Thermal energy storage systems generally have costs that are primarily related to their total energy storage capacity (the amount of energy contained within the system, MWh) and their energy transfer rate (the instantaneous power in MW of the energy flowing into or out of the energy storage unit at any given moment). Within an energy storage unit, energy is transferred from an inlet to a storage medium and then from the storage medium to an outlet at another point in time. The rate of heat transfer to and from the storage medium is limited by factors including the thermal conductivity and capacity of the medium, the surface area over which heat is being transferred, and the temperature difference across that surface area. High charging rates are made possible by the use of a storage medium having a high temperature difference between the heat source and the storage medium, a high surface area, and high heat capacity and / or high thermal conductivity.

[0013]

[22] Each of these factors can significantly increase the cost of energy storage devices. For example, increasing the heat exchange surface generally requires 1) increasing the volume of the heat transfer fluid and 2) increasing the surface area of ​​the heat exchanger, both of which are often costly. Increasing the temperature difference requires the heat source to operate at relatively high temperatures, which can result in loss of efficiency (e.g., radiative or convective cooling to the environment, or a decrease in the coefficient of performance of the heat pump) and increased costs (e.g., the selection and use of materials that are more durable at higher temperatures). Mediums with higher thermal conductivity and heat capacity may also require the selection of more expensive, higher-performance materials or aggregates.

[0014]

[23] Another challenge for systems storing energy from VRE sources is the charging rate. A VRE source may, on a given day, provide only a small fraction of its energy during short periods of the day, depending on its conditions. For an energy storage system connected to a VRE source and designed to provide a continuous output, all of the supplied energy must be absorbed during the period when the incoming VRE is available. As a result, for example, in a solar energy system, if the discharge period (overnight) is significantly longer than the charging period (daytime), the peak charging rate can be several times (e.g., 3 to 5 times) the discharge rate. In this respect, the challenges of VRE storage differ from those of thermal regenerators, for example, which typically absorb and release heat at similar rates. In VRE storage systems, the design of units that can charge quickly and efficiently is important, and this can be a more determining factor in the total system cost than the discharge rate.

[0015]

[24] C. Problems and disadvantages of thermal energy storage

[25] The methods described above have various problems and shortcomings. Early systems do not take into account several important phenomena in the design, construction and operation of thermal energy storage systems and therefore do not facilitate the construction and efficient operation of such systems. More specifically, current design cannot address “thermal runaway” and element failures resulting from the non-uniformity of thermal energy storage and release across arrays of solid materials, including the design of storage, release and unit control to achieve and restore temperature equilibrium across large arrays of thermal storage materials.

[0016]

[26] Thermal energy storage systems incorporating radiative charging and convective discharge are, in principle, susceptible to "thermal runaway." This phenomenon can arise from imbalances, even slight imbalances, in localized heating by heating elements and cooling by heat transfer fluid flow. Variations in heating and cooling rates, unless controlled and mitigated, can lead to thermal runaway, causing heater failure and / or degradation of heat-resistant materials. Overheating can cause heating elements to fail prematurely, shortening the system's lifespan. For example, in a laminate, blocks closest to the heating wire will be heated more than blocks further away from the heating wire. This can result in increased wire failure rates and a shortened heater lifespan.

[0017]

[27] One effect that further exacerbates thermal runaway is the thermal expansion of air flowing through the air conduit. Hotter air expands more, resulting in a higher outlet velocity relative to a given inlet flow rate, and therefore a higher pressure drop through the conduit, which can lead to a further decrease in flow rate and reduced cooling during discharge. Thus, in a continuous heating and cooling cycle, local cooling gradually decreases, which can result in even greater local overheating.

[0018]

[28] The effective operation of heat supply from thermal energy storage relies on continuous discharge, which is a particular challenge in systems that rely on a VRE source to charge the system. There is a need for a solution that can efficiently capture and store that VRE energy and provide the stored energy reliably and uninterruptedly as needed for a variety of applications, including various industrial applications.

[0019]

[29] Conventional systems do not adequately address the problems associated with VRE energy sources, such as variability arising from challenging weather patterns like storms and long-term supply fluctuations resulting from seasonal variations in VRE generation. In this regard, there is an unmet need in the field of technology to provide efficient control of charging and discharging energy storage systems in smart storage management. Current designs do not adequately provide storage management that takes into account a variety of factors, including medium- to short-term weather forecasts, VRE generation forecasts, and time-varying energy demand, which may be determined holistically or partially by factors such as industrial process demand, grid energy demand, real-time electricity prices, wholesale electricity market capacity prices, utility resource adequacy values, and the carbon intensity of alternative energy sources. A system is needed that can provide stored energy to various demands that are prioritized, taking these factors into account and maximizing practicality and economic efficiency.

[0020]

[30] There are various unmet needs for energy in general, more specifically for thermal energy. Generally, there is a need to switch from fossil fuels to clean and sustainable energy. There is also a need to store VREs and supply energy at different points in time to meet society's energy needs. There is a need for lower-cost energy storage systems and technologies that will enable VREs to supply energy to industrial processes, thereby expanding the use of VREs and thus reducing the combustion of fossil fuels. It is also desirable to maintain sufficient outlet temperatures while using low-cost solid media.

[0021]

[31] Furthermore, despite fluctuations in VRE supply, there is a need to design VRE units that can be charged quickly and at low cost, provide dispatchable continuous energy as required in a variety of industrial applications, and facilitate efficient control of charging and discharging of energy storage systems.

[0022] II. Storage of Intermittent Energy

[32] Since the Industrial Revolution, fossil fuels have powered the world economy. However, humanity has discovered that not only are these energy resources limited in supply, but burning fossil fuels to extract energy generates greenhouse gases and other pollutants that threaten the global ecosystem. Specifically, such systems are inherently inefficient at harnessing the energy trapped in chemical bonds because they emit vast amounts of hot combustion gases into the atmosphere through chimneys, directly causing global warming and indirectly contributing to global warming through the effect of greenhouse gases increasing the Earth's solar absorption rate, and further contributing to the degradation of the Earth through the effect of pollutants, for example, bathing various ecosystems of the Earth with acid rain.

[0023]

[33] To address the need for renewable energy sources that do not generate these harmful greenhouse gases, energy sources have been developed to tackle this problem, such as solar energy, wind energy, and tidal energy. One drawback of renewable energy sources is their intermittent nature. The sun does not always shine, the wind does not always blow, and the tide does not always flow. This has prevented these technologies from replacing fossil fuel energy sources because industry requires electricity on demand 24 hours a day, 365 days a year.

[0024]

[34] Therefore, what is needed is a method for storing the intermittent energy provided by renewable energy sources in a closed loop without releasing heat and pollutants into the atmosphere to meet the constant electricity demand of industry. This has led to the development of green energy storage solutions and systems and methods for storing and extracting heat from structured solid blocks in thermal energy storage units as described herein.

[0025]

[35] One of the hurdles between the conception and initial development of thermal storage solutions and their actual implementation is that such solutions must work in conjunction with existing industrial equipment to leverage existing assets and infrastructure. Therefore, what is needed is a system for modularizing such thermal energy storage units that can be combined in various ways to provide customized solutions that meet the individual needs for improving such fossil fuel-burning power generation systems. Furthermore, there is a strong need to enable the evaluation of thermal energy storage units as green energy alternatives to existing fuel-burning boiler systems without redesigning and reconstructing existing industrial infrastructure. In this context, there is a strong need for a system that can easily switch between fossil fuel energy sources and variable renewable electricity sources and evaluate the latter as an alternative to existing fossil fuel-burning energy sources. This will facilitate the achievement of the global goals set out in the Paris Agreement, in particular the targets of setting a net-zero emissions target by 2050 and reducing greenhouse gas emissions by 45% by 2030. In particular, systems and methods for connecting one or more thermal energy storage units to a fuel-burning boiler system are needed, along with control systems that coordinate the operation of systems including multiple thermal energy storage units. By connecting two completely different energy sources in this way, it becomes possible to reversibly evaluate this new sustainable technology's potential to improve or replace fossil fuel-based systems with green energy supplies while maintaining the majority of equipment that is already paid for and operational.

[0026] III. Seismic Stability of Thermal Storage Energy Systems

[36] Thermal energy storage (TES) systems can be deployed to solve energy storage problems in a variety of locations around the world, including seismically active areas. Since the thermal storage medium can be in the form of heavy blocks of heat-resistant material, the availability of TES systems around the world can be increased by designing TES systems that can fix these blocks in place and withstand seismic events.

Summary of the Invention

Means for Solving the Problems

[0027] Overview

[37] Exemplary implementations facilitate the development of thermal energy storage technology, enable the practical construction and operation of a high-temperature thermal energy storage (TES) system that can be charged by VRE, store energy in a storage medium, and supply high-temperature heat. This "Summary of the Invention" section pertains to the disclosure as described in U.S. Patent Application No. 17 / 668,333 (U.S. Patent No. 11,603,776).

[0028]

[38] Aspects of an exemplary implementation include an input (e.g., electricity from a variable renewable electricity (VRE) source), a container having sides, a roof, and a lower platform, a plurality of vertically oriented thermal storage units (TSUs) inside the container, where each TSU includes a stack of a plurality of blocks and a heater attached thereto, and each heater is connected to the input electricity via a switching circuit, the TSUs, a heat insulation layer interposed between at least one of the plurality of TSUs, the roof, and the sides, a duct formed between the heat insulation layer and a boundary formed by the sides, the roof of the container, and the lower platform, a blower for blowing a relatively low-temperature fluid such as air or another gas (e.g., CO2) along a flow path, an output (e.g., high-temperature air at a predetermined temperature for industrial use), and a controller for controlling and coordinating the management of the energy received from the input and the high-temperature air generated at the output based on a prediction associated with ambient conditions (e.g., season or weather) or conditions (e.g., output temperature, energy curve, etc.). The external and internal shapes of the container can be rectangular, cylindrical (in which case, the "sides" refer to the cylindrical wall), or other shapes suitable for individual applications.

[0029]

[39] In this specification, the terms air, fluid and gas are used synonymously to refer to any suitable type of fluid heat transfer medium, including various types of gases (alone or in combination, air, CO2, oxygen and other gases), and it should be understood that when one is referred to, the others can be used just as well. Thus, for example, “air” can be any suitable fluid or gas, or combination of fluids or gases.

[0030]

[40] The thermal energy storage (TES) system of this design can be advantageously integrated with or coupled with steam generators, including heat recovery steam generators (HRSGs) and once-through steam generators (OTSGs). In this specification, the terms “steam generator,” “HRSG,” and “OTSG” are used synonymously to refer to a heat exchanger that transfers heat from a first fluid to a second fluid, the first fluid may be air circulating from the TSU, and the second fluid may be (heated and / or boiled) water, oil, salt, air, CO2, or another fluid. In such an implementation, the heated first fluid is discharged from the TES unit and provided as input to a steam generator, which heats the second fluid, such as by extracting heat from the discharged fluid to produce steam, and this heated second fluid can be used for any of a variety of purposes, such as driving a turbine to generate shaft work or electricity. The second fluid, after passing through the turbine, still contains considerable thermal energy, which can be used for other processes. Therefore, the TES system can drive the cogeneration process. The first fluid, upon exiting the steam generator, can be returned to the TES as input, thus capturing waste heat and effectively preheating the input fluid. Waste heat from another process can also preheat the input fluid to the TES.

[0031]

[41] In another embodiment, the dynamic thermal insulation system includes a container having sides, a roof and a lower platform; a plurality of vertically oriented heat storage units (TSUs) spaced apart from each other; an insulating layer interposed between the plurality of TSUs, the roof, and at least one of the sides and the floor; a duct formed between the insulating layer and a boundary formed by the sides, the roof and the lower platform of the container; and a blower that blows unheated air upward along an airflow path from the platform to the highest part of the upper portion, so that an airflow path is formed from the highest part of the roof to the platform, which is heated by the plurality of TSUs and output from a TES device. The unheated air along the airflow path is preheated by forming an insulating layer and absorbing heat from the insulating material.

[0032]

[42] This summary is provided to introduce in a simplified form some of the concepts that will be further described below in the detailed description. This summary is not intended to identify any important or essential features of the subject matter of the claims, nor is it intended to be used to limit the scope of the subject matter of the claims.

[0033] Brief explanation of the drawing

[43] The accompanying drawings are included for further understanding of this disclosure, are incorporated herein, and constitute part of this specification. The drawings illustrate exemplary implementations of this disclosure and, together with the description, are useful in illustrating the principles of this disclosure.

[0034]

[44] In the drawings, similar components and / or features may have the same reference numeral. Furthermore, different components of the same type may be distinguished by adding a second reference numeral after the reference numeral to distinguish them from similar components. Where only the first reference numeral is used herein, the description is applicable to any of the similar components having the same first reference numeral, regardless of the second reference numeral. [Brief explanation of the drawing]

[0035] [Figure 1]

[45] A schematic diagram of a thermal energy storage system architecture in an exemplary implementation is shown. [Figure 2]

[46] A schematic diagram of the system in an exemplary implementation configuration is shown. [Figure 3]

[47] A schematic diagram of an exemplary implementation of a regenerative combustion type once-through steam generator (OTSG) is shown. [Figure 4]

[48] ​​An exemplary diagram of a system used as an integrated cogeneration system in an exemplary implementation configuration is shown. [Figure 5]

[49] An example of a dynamic adiabatic system in an exemplary implementation configuration is shown. [Figure 6]

[50] The present invention provides isometric views of a heat storage unit in which multiple vent closures are open, according to several implementation configurations. [Figure 7A]

[51] A side view of a thermal energy storage assembly subjected to lateral acceleration due to an earthquake, in at least one exemplary implementation configuration, is shown. [Figure 7B]

[51] A perspective view of a thermal energy storage assembly subjected to lateral acceleration due to an earthquake, in at least one exemplary implementation, is shown. [Figure 8A]

[52] A side view of a thermal energy storage assembly subjected to lateral acceleration due to an earthquake, in at least one exemplary implementation configuration, is shown. [Figure 8B]

[52] A perspective view of a thermal energy storage assembly subjected to lateral acceleration due to an earthquake, in at least one exemplary implementation. [Figure 9]

[53] A perspective view of a thermal energy system with an earthquake stability mechanism, according to at least one exemplary implementation. [Figure 10]

[54] A perspective view of a thermal energy system with an earthquake stability mechanism, according to at least one exemplary implementation. [Figure 11]

[55] A diagram of a support block used with a thermal energy storage assembly in at least one exemplary implementation is shown. [Figure 12]

[55] A diagram is shown of a support block used with a thermal energy storage assembly in at least one exemplary implementation. [Figure 13]

[56] A perspective view of two layers of a thermal energy storage block in at least one exemplary implementation is shown. [Figure 14]

[57] Enlarged view of a portion of the heat storage block and shear key mechanism in at least one exemplary implementation. [Figure 15]

[57] Enlarged view of a portion of the heat storage block and shear key mechanism in at least one exemplary implementation. [Figure 16]

[58] A perspective view of a thermal energy storage block in at least one exemplary implementation. [Figure 17]

[59] A plurality of thermal energy storage blocks arranged in an interlocking configuration are shown in at least one exemplary implementation. [Figure 18]

[60] A perspective view of a plurality of thermal energy storage blocks stacked in a terraced configuration, according to at least one exemplary implementation. [Figure 19]

[61] A perspective view of a thermal energy storage system having a plurality of thermal energy storage assemblies connected to a common heat exchange assembly, in at least one exemplary implementation. [Figure 20]

[62] A support structure used with an assembly of thermal energy storage blocks is shown in at least one exemplary implementation. [Figure 21]

[63] An enlarged view of a portion of the support structure in Figure 20, in at least one exemplary implementation. [Figure 22]

[64] An enlarged cross-sectional view of another part of the support structure of Figure 20, according to at least one exemplary implementation. [Figure 23]

[65] A cross-sectional view of one end of a thermal energy storage system in at least one exemplary implementation is shown. [Figure 24]

[66] A perspective view of another thermal energy storage system having multiple thermal energy storage assemblies connected to a common heat exchange assembly, in at least one exemplary implementation. [Figure 25]

[67] A plurality of thermal energy storage blocks arranged in a stepped configuration on a support structure, according to at least one exemplary implementation. [Figure 26]

[68] Multiple thermal energy storage systems of different storage capacities and configurations are shown in at least one exemplary implementation. [Figure 27]

[69] Disassembled perspective views of various components to a housing used with a thermal energy storage system, in at least one exemplary implementation. [Figure 28A]

[70] A side section view of a thermal energy storage system with vertical flow, representing at least one exemplary implementation. [Figure 28B]

[70] A side section view of a thermal energy storage system with horizontal flow, according to at least one exemplary implementation, is shown. [Figure 29]

[71] A graph showing the thermal output over time for various thermal energy storage systems in at least one exemplary implementation. [Figure 30]

[72] Side views of multiple thermal energy storage blocks in at least one exemplary implementation are shown. [Figure 31A]

[73] A diagram is shown of an air or gas distribution system used in conjunction with a thermal energy storage system in at least one exemplary implementation. [Figure 31B]

[73] A diagram is shown of an air or gas distribution system used in conjunction with a thermal energy storage system in at least one exemplary implementation. [Figure 31C]

[73] A diagram is shown of an air or gas distribution system used in conjunction with a thermal energy storage system in at least one exemplary implementation. [Figure 31D]

[73] A diagram is shown of an air or gas distribution system used in conjunction with a thermal energy storage system in at least one exemplary implementation. [Figure 31E]

[73] A diagram is shown of an air or gas distribution system used in conjunction with a thermal energy storage system in at least one exemplary implementation. [Figure 32]

[74] An orifice plate with a molded orifice is shown for use with an air or gas distribution system in at least one exemplary configuration. [Figure 33]

[75] A side cross-sectional view of a thermal energy storage system comprising an air or gas distribution system in at least one exemplary implementation. [Figure 34]

[76] A cross-sectional view from one end of a thermal energy storage system comprising an air or gas distribution system in at least one exemplary implementation is shown. [Figure 35A]

[77] A diagram of a gate used in an air or gas distribution system is shown, in at least one exemplary implementation. [Figure 35B]

[77] A diagram of a gate used in an air or gas distribution system is shown, in at least one exemplary implementation. [Figure 36A-C]

[78] A diagram of a gate and orifice opening used in an air or gas distribution system in at least one exemplary implementation is shown. [Figure 37A]

[79] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 37B]

[79] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 38]

[80] A perspective view of one end of an air or gas distribution system in at least one exemplary implementation is shown. [Figure 39A]

[81] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 39B]

[81] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 40A]

[82] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 40B]

[82] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 41A]

[83] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 41B]

[83] A diagram is shown of components used in an air or gas distribution system in at least one exemplary implementation. [Figure 42]

[84] An end view of an air or gas distribution system in at least one exemplary configuration is shown. [Figure 43]

[85] A diagram of an orifice plate system in at least one exemplary implementation is shown. [Figure 44]

[85] A diagram of an orifice plate system in at least one exemplary implementation is shown. [Figure 45]

[85] A diagram of an orifice plate system in at least one exemplary implementation is shown. [Figure 46A]

[86] Diagrams of rotating orifice plate systems in at least several exemplary implementations are shown. [Figure 46B]

[86] Diagrams of rotating orifice plate systems in at least several exemplary implementations are shown. [Figure 47A]

[86] Diagrams of rotating orifice plate systems in at least several exemplary implementations are shown. [Figure 47B]

[86] Diagrams of rotating orifice plate systems in at least several exemplary implementations are shown. [Figure 48A]

[87] A perspective view of an external enclosure used with a thermal energy storage system, in at least one exemplary configuration. [Figure 48B]

[87] A perspective view of an external enclosure used with a thermal energy storage system, in at least one exemplary configuration. [Figure 49]

[88] Showing the flow of air or gas in at least one exemplary implementation of a thermal energy storage system in at least a portion of it. [Figure 50]

[89] Perspective views of various components of a thermal energy storage system in at least one exemplary implementation are shown. [Figure 51]

[90] An enlarged perspective view of a modular support structure used in a thermal energy storage system in at least one exemplary implementation. [Figure 52A]

[91] A diagram is shown of a modular support structure used in a thermal energy storage system in at least one exemplary implementation. [Figure 52B]

[91] A diagram is shown of a modular support structure used in a thermal energy storage system in at least one exemplary implementation. [Figure 53]

[92] A modular support structure used in a thermal energy storage system in at least one exemplary implementation is shown. [Figure 54A]

[93] A diagram of a modular support structure used in a thermal energy storage system in at least one exemplary implementation is shown. [Figure 54B]

[93] A diagram of a modular support structure used in a thermal energy storage system in at least one exemplary implementation is shown. [Figure 55]

[94] A perspective view of a support structure with a post-tensioning mechanism in at least one exemplary implementation is shown. [Figure 56]

[95] An end view of a modular support structure used in a thermal energy storage system in at least one exemplary implementation is shown. [Figure 57]

[96] A cross-sectional perspective view of several parts of a thermal energy storage system in at least one exemplary implementation. [Figure 58]

[97] A side cross-sectional view of a thermal energy storage system in at least one exemplary implementation is shown. [Figure 59]

[98] Various diagrams of one end of a thermal energy storage system and electrical components in at least one exemplary implementation are shown. [Figure 60]

[99] A thermal energy storage system and various electrical components are shown in at least one exemplary implementation. [Figure 61]

[0100] A schematic diagram of a thermal energy storage system and various electrical components according to at least one exemplary implementation. [Figure 62]

[0101] A cross-sectional view of a heat storage block positioned on a support structure having various thermal insulation or cooling components, according to at least one exemplary implementation. [Figure 63]

[0102] A cross-sectional view of one end of a thermal energy storage assembly according to at least one exemplary implementation is shown. [Figure 64]

[0103] This is a schematic diagram of an alternating arrangement configuration of heat storage blocks on the contact surface of a support structure, according to at least one exemplary implementation. [Figure 65]

[0104] A cross-sectional view of a portion of a support structure having a preferred cooling path, according to at least one exemplary implementation configuration, is shown. [Figure 66A]

[0105] A diagram of a support structure in at least one exemplary implementation form is shown. [Figure 66B]

[0105] A diagram of a support structure in at least one exemplary implementation form is shown. [Figure 67A]

[0106] Enlarged views of several parts of the support structure in at least one exemplary implementation form are shown. [Figure 67B]

[0106] Enlarged views of several parts of the support structure in at least one exemplary implementation form are shown. [Figure 68]

[0107] A cross-sectional view of a support structure having multiple air or gas channels, according to at least one exemplary implementation, is shown. [Figure 69A]

[0108] A schematic diagram of a heat dissipation port in at least one exemplary implementation configuration is shown. [Figure 69B]

[0108] A perspective view of a heat dissipation port in at least one exemplary implementation configuration is shown. [Figure 70]

[0109] A system in which the heat dissipation port is open to another sealed enclosure is shown in at least one exemplary implementation. [Figure 71]

[0110] A side view of a thermal energy storage assembly in at least several exemplary implementation configurations is shown. [Figure 72]

[0110] A side view of a thermal energy storage assembly in at least several exemplary implementation configurations is shown. [Figure 73]

[0111] Perspective views of several parts of a thermal energy assembly in at least one exemplary implementation form are shown. [Figure 74]

[0112] One configuration of a heating element supported by a support structure, according to at least one exemplary implementation. [Figure 75A]

[0113] A schematic end face of a fault-tolerant heater element is shown in at least one exemplary implementation. [Figure 75B]

[0113] A schematic side view of a fault-tolerant heater element in at least one exemplary implementation is shown. [Figure 76]

[0114] This is a schematic top view of a fault-tolerant heater element in at least one exemplary implementation. [Figure 77]

[0115] A schematic perspective view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 78]

[0116] An example of an implementation configuration is shown, with a perspective view of the lower side of the thermal energy storage block. [Figure 79]

[0117] A front view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 80]

[0118] A side cross-sectional view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 81]

[0119] A plan view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 82A]

[0120] A side view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 82B]

[0121] A cross-sectional plan view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 83A]

[0122] A side view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 83B]

[0123] Another cross-sectional plan view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 84A]

[0124] A side view of a stacked assembly of thermal energy storage blocks in an exemplary mounting configuration is shown. [Figure 84B]

[0125] A cross-sectional view of a stacked assembly of thermal energy storage blocks in an exemplary mounting configuration is shown. [Figure 84C]

[0126] An enlarged view of the meshing mechanism of the thermal energy storage block in an exemplary implementation configuration is shown. [Figure 84D]

[0127] A plan view of a stacked assembly of thermal energy storage blocks in an exemplary mounting configuration is shown. [Figure 85]

[0128] A perspective view of a stacked assembly of thermal energy storage blocks in an exemplary mounting configuration is shown. [Figure 86]

[0129] A perspective view of a stacked assembly of thermal energy storage blocks including a heating element, according to an exemplary mounting configuration, is shown. [Figure 87]

[0130] A schematic perspective view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 88A]

[0131] A schematic perspective view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 88B]

[0132] A schematic perspective view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 88C]

[0133] A schematic perspective view of the lower part of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 89A]

[0134] A schematic perspective view of a support block for a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 89B]

[0135] A schematic perspective view of the lower side of a support block for a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 90A]

[0136] A front view of a support block for a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 90B]

[0137] A plan view of a support block for a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 90C]

[0138] A lower view of a support block for a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 91]

[0139] A schematic perspective view of a thermal energy storage block in an exemplary implementation configuration is shown. [Figure 92]

[0140] An illustrative perspective view of an assembly of thermal energy storage blocks placed on a support slab is shown. [Figure 93]

[0141] A perspective view of an assembly of a thermal energy storage block having a heating element, arranged on a support slab, is shown in an exemplary mounting configuration. [Figure 94]

[0142] A cross-sectional perspective view of an assembly of thermal energy storage blocks placed on a support slab, according to an exemplary implementation configuration, is shown. [Figure 95]

[0143] A plan view of an assembly of thermal energy storage blocks placed on a support slab, according to an exemplary implementation configuration, is shown. [Figure 96]

[0144] A side view of an assembly of thermal energy storage blocks placed on a support slab, according to an exemplary implementation configuration. [Figure 97]

[0145] A schematic perspective view of the upper part of the support slab for the thermal energy storage block in an exemplary implementation configuration is shown. [Figure 98]

[0146] A schematic perspective view of the lower part of the support slab for the thermal energy storage block in an exemplary implementation configuration is shown. [Modes for carrying out the invention]

[0036] Detailed explanation

[0147] The exemplary embodiments disclosed herein relate to systems, methods, materials, compositions, articles, and improvements for thermal energy storage systems for power generation in various industrial applications.

[0037] I. Thermal Energy Storage Systems

[0148] Section I of this summary relates to disclosures as described in U.S. Patent No. 11,603,776, and this application is a continuation of that patent.

[0038]

[0149] U.S. Patent No. 11,603,776 addresses the aforementioned issues in the field of thermal energy storage and utilization systems. A thermal energy storage system is disclosed which stores electrical energy in the form of thermal energy in a charging mode and supplies the stored energy in a discharge mode. Discharge can occur simultaneously with charging, i.e., the system can be heated by electrical energy at the same time as providing a flow of convectively heated air. The energy discharged can be in the form of hot air, generally hot fluid, steam, heated CO2, heated supercritical CO2, and / or power generation, and can be supplied to a variety of applications, including industrial applications. The disclosed implementations include efficiently constructed, long-life thermal energy storage systems having materials, fabrication, physical form, and other properties that mitigate damage and degradation due to repeated temperature cycles.

[0039]

[0150] Optionally, the heating of the storage unit elements can be optimized to store the maximum amount of heat during a charging cycle. Alternatively, the heating of the elements can be optimized to maximize the lifespan of the heating element by means including minimizing the time at a particular heater temperature and / or by adjusting the peak charging rate and / or peak heating element temperature. Further alternatives may balance these competing interests. Specific actions for achieving these optimizations will be discussed further later.

[0040]

[0151] The exemplary implementation employs efficient yet economical insulation. Specifically, dynamic insulation design can be used alone or in combination with static primary insulation. The disclosed dynamic insulation technique controls airflow within the system to limit the dissipation of thermal energy to the external environment, resulting in higher energy storage efficiency.

[0041] Overview of the system disclosed in U.S. Patent No. 11,603,776

[0152] Figure 1 is a block diagram of System 1, including a thermal energy storage system 10, in one implementation configuration. In the illustrated configuration, the thermal energy storage system 10 is connected between the input energy source 2 and the downstream energy consumption process 22. For ease of reference, the input and output components of System 1 may be described as "upstream" and "downstream" of System 10.

[0042]

[0153] In the illustrated implementation, the thermal energy storage system 10 is connected to an input energy source 2, which may include one or more sources of electrical energy. Source 2 may be renewable, such as photovoltaic (PV) batteries or solar, wind, or geothermal energy. Source 2 may also be another energy source, such as nuclear, natural gas, coal, or biomass. Source 2 may include a combination of renewable and other energy sources. In this implementation, source 2 is supplied to the thermal energy storage system 10 via infrastructure 4, which may include one or more conductors, commutators, etc. In some implementations, infrastructure 4 may include circuits configured to transport electricity over long distances, or alternatively, in implementations where the input energy source 2 is located very close to the thermal energy storage system 10, infrastructure 4 may be significantly simplified. Finally, infrastructure 4 supplies energy in the form of electricity to the input 5 of the thermal energy storage system 10.

[0043]

[0154] Electrical energy supplied by infrastructure 4 is input to a heat storage structure 12 in system 10 via switchgear, protective devices and active switches controlled by control system 15. The heat storage structure 12 includes a heat storage section 14, which further includes one or more assemblies (e.g., 14A, 14B) of solid storage media (e.g., 7B, 13A) configured to store thermal energy. These assemblies are referred to by various names throughout this disclosure, such as “laminated” or “array.” These terms are intended to be inclusive and not to imply any particular orientation in space or anything else. Generally, an array may include any material suitable for storing thermal energy and which can be oriented in any given orientation (e.g., vertical, horizontal, etc.). Similarly, the solid storage media within the assemblies may be referred to by various names, such as heat storage blocks or blocks. In an implementation using multiple arrays, the arrays can be insulated from each other and controlled separately, meaning that the arrays can be charged or discharged independently of each other. This configuration provides maximum flexibility, allowing multiple arrays to be charged simultaneously, at different times or rates, and enabling one array to be discharged while another remains charged.

[0044]

[0155] The heat storage unit 14 is configured to receive electrical energy as input. The received electrical energy can be supplied to the heat storage unit 14 via a resistive heating element that is heated by the electrical energy and emits heat primarily as electromagnetic radiation in the infrared and visible spectra. During the charging mode of the heat storage unit 14, the electrical energy is emitted as heat from the resistive heating element and is transferred primarily by radiation emitted by the heating element and radiation emitted by the high-temperature portion of the solid storage medium, absorbed and stored in the solid storage medium within the heat storage device 14. When the array within the heat storage unit 14 is in discharge mode, the heat is discharged from the heat storage structure 12 as output 20. As will be described later, the output 20 can take various forms, including fluids such as hot air. (Where the use of “air” and “gas” is referred to in this disclosure, it can be understood to refer more generally to “fluid”). The hot air may be supplied directly to a downstream energy consumption process 22 (e.g., an industrial application) or passed through a steam generator (not shown) to generate steam for the process 22.

[0045]

[0156] Furthermore, the thermal energy storage system 10 includes a control system 15. In various implementations, the control system 15 is configured to control the thermal storage device 14 by setting operating parameters (e.g., discharge rate), controlling fluid flow rate, or controlling the operation of an electromechanical or semiconductor electrical switching device. Figure 1 shows an interface 16 between the control system 15 and the thermal storage structure 12 (and in particular the thermal storage unit 14). In various implementations, the control system 15 may be implemented as a combination of hardware and software.

[0046]

[0157] The control system 15 can also interface with various entities outside the thermal energy storage system 10. For example, the control system 15 can communicate with the input energy source 2 via the input communication interface 17B. For example, interface 17B may allow the control system 15 to receive information related to the energy generation conditions at the input energy source 2. In an implementation where the input energy source 2 is a photovoltaic array, this information may include, for example, current weather conditions at the location of the source 2, and other information available to any upstream control systems, sensors, etc. Interface 17B may also be used to transmit information to components or equipment associated with the source 2.

[0047]

[0158] Similarly, the control system 15 can communicate with the infrastructure 4 via the infrastructure communication interface 17A. In a manner similar to that described above, the interface 17A can be used to provide the control system 15 with infrastructure information such as current or projected VRE availability, power grid demand, infrastructure conditions, maintenance, and emergency information. Conversely, the communication interface 17A may also be used by the control system 15 to transmit information to components or equipment within the infrastructure 4. For example, the information may include control signals transmitted from the control system 15, which control valves or other structures within the heat storage structure 12 to move between open and closed positions, or control electrical or electronic switches connected to heaters within the heat storage unit 14. The control system 15 uses the information from the communication interface 17A when determining control actions, which may coordinate the closing or starting of switches in a manner that optimizes the use of currently available power and maintains the voltage and current flow within the infrastructure 4 within selected limits.

[0048]

[0159] The control system 15 can also communicate downstream using interfaces 18A and / or 18B. Interface 18A can be used to communicate information to any output transmission structure (e.g., a steam transmission line), while interface 18B can be used to communicate with the downstream process 22. For example, the information provided via interfaces 18A and 18B may include temperature, industrial application demand, output, or current or future expected conditions of the industrial application. Based on the various information, the control system 15 can control the input, heat storage, and output of the heat storage structure. Similar to interfaces 17A and 17B, communication via interfaces 18A and 18B may be bidirectional, for example, the system 10 can inform the downstream process 22 of the available capacity. Furthermore, the control system 15 can also communicate with any other relevant data sources (indicated by reference numeral 21 in Figure 1) via an additional communication interface 19. The additional data source 21 is broadly intended to encompass any other data sources not maintained by either the upstream or downstream location. For example, data source 21 may include third-party forecasting information, data stored in a cloud data system, etc.

[0049]

[0160] The thermal energy storage system 10 is configured to efficiently store thermal energy generated from an input energy source 2 and supply output energy to downstream processes 22 in various forms. In various implementations, the input energy source 2 may be from renewable energy sources, and the downstream processes 22 may be industrial applications requiring input such as steam or hot air. Through various techniques, including an array of thermal storage blocks that efficiently stores energy using radiant heat transfer and a lead-lag discharge paradigm that provides desirable thermal properties such as reduced temperature non-uniformity within the thermal storage section 14, the system 10 can advantageously provide a continuous (or nearly continuous) flow of output energy based on intermittently available sources. The use of such systems may reduce the reliability of industrial applications compared to fossil fuels.

[0050]

[0161] Figure 2 provides a schematic diagram of one implementation of the thermal energy storage system 200, further illustrating the components and concepts described above with respect to Figure 1. As illustrated, one or more energy sources 201 provide input electricity. For example, as described above, renewable sources such as wind energy from a wind turbine 201a, solar energy from a solar cell 201b, or other energy sources may provide electricity whose availability or price is variable because the conditions for generating electricity change. For example, in the case of a wind turbine 201a, the amount of energy generated changes over time due to wind speed, duration and fluctuations, as well as other meteorological conditions. Similarly, the amount of energy generated by a solar cell 201b also changes over time depending on factors such as the time of day, day length depending on the season, cloud cover level depending on meteorological conditions, temperature, and other ambient conditions. Furthermore, input electricity can be received from the existing power grid 201c, which may also change based on factors such as pricing, customer demand, maintenance, and emergency requirements.

[0051]

[0162] The electricity generated by the power source 201 is supplied to the heat storage structure within the thermal energy storage system. In Figure 2, the passage of electricity into the heat storage structure is represented by the wall 203. The input electrical energy is converted into heat within the heat storage unit 205 via a resistive heating element 207 controlled by a switch (not shown). The heating element 207 provides heat to the solid storage medium 209. The heat storage components (sometimes called “blocks”) within the heat storage unit 205 are arranged to form an integrated radiant chamber. Figure 2 shows that multiple heat storage arrays 209 may exist within the system 200. These arrays can be thermally isolated from each other and can be controlled separately. Figure 2 is merely intended to provide a conceptual representation of how the heat storage unit 205 can be implemented, and one such implementation may include, for example, only two arrays, or six or more arrays.

[0052]

[0163] In the illustrated configuration, a blower 213 blows air or other fluid into the heat storage unit 205 so that the air is ultimately received in the lower portion of each of the arrays 209. The air flows upward through channels and chambers formed by the blocks within each of the arrays 209, and the flow rate is controlled by louvers. Heat is radiated to the arrays 209 of blocks during the charging mode by the release of thermal energy from the resistive heating element 207. The relatively hot block surfaces re-radiate the absorbed energy (sometimes referred to as radioactive "echoes"), contributing to the heating of the cooler surfaces. During the discharge mode, the heat stored in the arrays 209 is output as shown in 215.

[0053]

[0164] When heat is output in the form of a fluid, such as hot air, the fluid can be provided for one or more downstream applications. For example, as shown in 217, hot air can be used directly in an industrial process configured to receive hot air. Furthermore, hot air can be supplied as a flow 219 to a heat exchanger 218 of a steam generator 222, thereby heating a pressurized fluid such as air, water, CO2, or other gases. In the illustrated example, as the hot air flow 219 passes through line 221, which provides water from pump 223 as input, the water is heated and steam is produced as output 225, which can be supplied to an industrial application as shown in 227.

[0054]

[0165] The heat storage structures shown in Figures 1 and 2 may also include output equipment configured to generate steam for downstream use. Figure 3 shows a block diagram of an implementation of the heat storage structure 300, including, for example, a regenerative combustion once-through steam generator (OTSG). The OTSG is a type of heat recovery stream generator (HRSG), which is a heat exchanger that receives hot air from the storage unit and returns cooler air to heat an external process fluid. The illustrated OTSG is configured to use the thermal energy stored in the structure 300 to generate steam at the output 311.

[0055]

[0166] As described, the heat storage structure 300 includes external structures 301 such as walls, a roof, and a heat storage section 303 in a first section of the structure. The OTSG is located in a second section of the structure, separated from the first section by a thermal barrier 325. During the charging mode, thermal energy is stored in the heat storage section 303. During the discharge mode, the thermal energy stored in the heat storage section 303 receives a fluid flow (e.g., air) from the blower 305. These fluid flows can be generated from fluid entering the structure 300 through the inlet valve 319 and may include a first fluid flow 312A (which can be directed towards the first layer in the heat storage section 303) and a second fluid flow 312B (which can be directed towards the second layer in the heat storage section 303).

[0056]

[0167] Air or other fluid induced by the blower 305 is heated as it flows from the lower to the upper part through the heat storage unit 303, and is eventually output in the upper part of the heat storage unit 303. The heated air, which may at some point mix with a bypass fluid flow 312C that has not passed through the heat storage unit 302, passes through a conduit 309 through which water or another fluid, pressurized by a water pump 307, flows. When the hot air heats the water in the conduit, steam is generated in 311. The cooled air that has crossed the conduit (and transferred heat to the water flowing through the conduit) is then returned to the block heat storage unit 303 by the blower 305. As will be described later, the control system can be configured to control steam quality, or steam attributes including steam fraction in the gas phase and flow rate.

[0057]

[0168] As shown in Figure 3, an OTSG does not include a recirculating drum boiler. The characteristics of the steam produced by an OTSG are generally more difficult to control than those of steam produced by a more conventional HRSG with a drum or reservoir. In such an HRSG, the steam drum acts as a phase separator for the steam produced in one or more heated tubes that recirculate water, with the water collecting at the bottom of the reservoir and the steam rising to the top. Saturated steam (with 100% steam quality) can be collected from the top of the drum, superheated by passing through an additional heated tube structure, further ensuring high steam quality. Drum-type HRSGs are widely used in power plants and other applications where the water circulating the steam generator is highly purified and kept clean within a closed system. However, in applications where the water has a significant mineral content, mineral deposits tend to form in the drum and tubes, clogging the system and making the implementation of a recirculating drum design difficult. In many implementations, steam quality is not 100% unless a very special steam separator is installed inside the drum. The steam contains less than 1%, and frequently less than 0.1%, of water mist. As mentioned above, superheating further ensures high steam quality. The function of a superheater is to evaporate any mist and heat the steam above its evaporation temperature, i.e., the saturation steam temperature, which is the dew point at that pressure. The dew point is the temperature and pressure at which, as the steam cools even slightly, some of the steam (water vapor) condenses into liquid water.

[0058]

[0169] In applications using water with a high mineral content, an OTSG may be a better option. One such application is oil extraction, where feedwater for the steam generator can be recovered from a water / oil mixture produced by a well. Even after filtration and softening, this water may have a condensed solid concentration of approximately 10,000 ppm or higher. The absence of recirculation within the OTSG allows for operation in a mode that reduces the formation of mineral deposits. However, in some implementations, the OTSG needs to be operated carefully to avoid mineral deposits in the OTSG water conduit. For example, the presence of some water droplets in the steam as it moves through the OTSG conduit may be necessary to prevent mineral deposits by retaining minerals in the solution within the droplets. This consideration suggests that the steam quality (steam fraction) of the steam in the conduit must be kept below a specified level. On the other hand, high steam quality at the output of the OTSG may be important for the process employing the steam. Therefore, it is advantageous for the steam generator, powered by a VRE via a TES, to maintain a strict tolerance for outlet steam quality. There are delicate interactions between variables such as input water temperature, input water flow, and heat input, and these must be managed to achieve the specified steam quality of the output steam while avoiding damage to the OTSG.

[0059]

[0170] The implementations of the thermal energy storage system disclosed herein provide a controlled and specified heat source to the OTSG. The controlled temperature and flow rate available from the thermal energy storage system enable effective feedforward and feedback control of the steam quality at the OTSG output. In one implementation, feedforward control includes determining the heat supply rate required by the thermal energy storage system to achieve target values, using target steam supply rate and steam quality values ​​together with the measured water temperature at the input to the OTSG's water conduit. In this implementation, the control system can provide control signals to instruct the thermal storage structure to supply the flowing gas across the OTSG at the determined rate. In one implementation, the thermal energy storage system integrated with the OTSG includes instruments for measuring the input water temperature to the OTSG.

[0060]

[0171] In one implementation, feedback control involves measuring the steam quality value of the steam generated at the outlet of the OTSG and the controller using that value to adjust the system's operation to return the steam quality to a desired value. Obtaining the outlet steam quality value may include separating the steam into its liquid and gas phases and independently monitoring the heat of each phase to determine the gas phase fraction. Alternatively, obtaining the outlet steam quality value may include measuring the pressure and velocity of the outlet steam flow, as well as the pressure and velocity of the inlet water flow, and using the relationship between the values ​​to calculate an approximate value of the steam quality. Based on the steam quality value, the flow rate of the outlet fluid supplied to the OTSG by the heat storage unit can be adjusted to achieve or maintain a target steam quality. In one implementation, the flow rate of the outlet fluid is adjusted by providing a feedback signal to a controllable element of the heat storage system. The controllable element may be a blower or other fluid transfer device, louvers or valves, or other elements used to move the fluid through the storage medium.

[0061]

[0172] Real-time measurements of outlet steam quality can be used as feedback for a control system to determine the desired heat supply rate to the OTSG. To achieve this, an implementation of a thermal energy storage system integrated with the OTSG may include a separator with instruments for measuring inlet water velocity and outlet steam flow velocity, and optionally, instruments for providing separate measurements of liquid and steam heat values. In some implementations, the piping within the OTSG is arranged such that the piping closest to the water inlet is positioned at the lowest temperature portion of the airflow, and the piping closest to the steam outlet is positioned at the highest temperature portion of the airflow. In some implementations of the innovations of the present invention, the OTSG instead positions the highest steam quality pipe (closest to the steam outlet) at a point in the middle of the piping arrangement, allowing for higher inlet fluid temperatures from the TSU to the OTSG while maintaining appropriate steam quality, while mitigating scale formation in the pipe and overheating of the pipe. The specified flow parameters of the heated fluid produced by a thermal energy storage system such as those disclosed herein can, in some implementations, enable precise modeling of heat transfer as a function of position along the conduit. Such modeling allows for the specific design of conduit geometry to achieve a specified steam quality profile along the conduit.

[0062]

[0173] As shown in Figure 4, the output of the thermal energy storage system can be used for the integrated cogeneration system 400. As previously described, the energy source 401 provides electrical energy that is stored as heat in the thermal storage unit 403 of the TSU. During discharge, heated air is output at 405. As shown in Figure 4, a line containing fluid, in this case water, is pressurized into the drum 406 of the HRSG 409 via the preheating section of piping 422. In this implementation, the HRSG 409 is a recirculating drum-type steam generator, including a drum or boiler 406 and a recirculating evaporator section 408. The output steam passes through line 407 into the superheater coil and is then supplied to the turbine at 415, where the turbine generates electricity at 417. As output, the remaining steam 421 can be released for use as a heat source for the process or condensed at 419 and optionally passed through the degassing unit 413 to be supplied to the pump 411 to carry out subsequent steam generation. In many implementations, when superheated steam is used at least partially for mechanical power, the pressure drops through the turbine. This causes the temperature to drop further than the pressure, the temperature to pass the dew point, and some of the steam condenses in the turbine. Water is harmful to the turbine. Therefore, in cogeneration or power generation projects, it may be desirable to heat the steam to raise its temperature so that the temperature drops and still exceeds the dew point in order to extract mechanical power without condensing water. For heating, the steam is saturated, as condensation at high temperatures provides the most heat at the highest temperature, similar to distillation.

[0063]

[0174] Some industrial applications may be particularly well-suited to cogeneration. For example, in some applications, the first system uses high-temperature heat for purposes such as converting heat into mechanical motion, as in the case of a turbine, and the second system uses lower-temperature heat released in a cascade manner by the first system for a second purpose. The steam can drive a low-pressure fall steam turbine to rotate a pump, and the exhaust steam can still have 90% of its energy for another use of the lower-quality steam, replacing an electric motor. Optionally, some implementations may use a reverse temperature cascade. One example is a steam generator that produces high-pressure steam to drive a steam turbine that extracts energy from the steam, and low-pressure steam in a process such as an ethanol refinery to drive distillation and supply power to operate pumps. Yet another example is a thermal energy storage system in which high-temperature gas is output to a turbine, and the heat of the turbine outlet gas is used to preheat the inlet water to a boiler for processing the heat in another steam generator (e.g., used in oilfield industrial applications). In one application, cogeneration involves using high-temperature gas, for example, 840°C, to power or in conjunction with hydrogen electrolysis, and the lower-temperature output gas from the hydrogen electrolyzer, which may be around 640°C, is supplied from the TSU to a steam generator or turbine for reuse, either alone or in combination with the higher-temperature heat. In another application, cogeneration involves supplying heated gas at a first temperature, for example, 640°C, to enable the operation of a fuel cell, and the waste heat from the fuel cell, which may exceed 800°C, is supplied from the TSU to a steam generator or turbine for reuse, either alone or in combination with other heat supplied from the TSU.

[0064]

[0175] The cogeneration system may include a heat exchanger that receives the output discharged from the heat storage unit and generates steam. Alternatively, the system may heat another fluid, such as supercritical carbon dioxide, by circulating hot air from the system through a series of pipes that carry a fluid such as water or CO2 (transferring heat from the hot air to the pipes and fluid), and then recirculating the cooled air back as input to the heat storage structure. This heat exchanger is an HRSG, and in one implementation, it is incorporated into a section of the housing, separate from the heat storage unit.

[0065]

[0176] The HRSG may be physically housed within a heat storage structure, or it may be packaged in a separate structure having ducts for transporting air to and from the HRSG. The HRSG may include conduits at least partially located within a second section of the housing. In one implementation, the conduits may be made of a thermally conductive material and may be arranged so that a fluid flows through a series of tubes in a "through-flow" configuration, entering as a low-temperature fluid and exiting as a high-temperature, possibly partially evaporated, two-phase flow. As described above, through-flow is beneficial, for example, when treating feedwater with substantially dissolved mineral contaminants to prevent accumulation and sedimentation within the conduits.

[0066]

[0177] In an OTSG implementation, the first end of the conduit can be fluidically connected to a water source. The system can provide fluid inflow from the water source to the first end of the conduit and allow the outflow of received fluid or steam from the second end of the conduit. The system may include one or more pumps configured to facilitate the inflow and outflow of fluid through the conduit. The system may include a set of valves configured to facilitate the controlled outflow of steam from the second end of the conduit to one or more second locations for industrial applications or power generation. As shown in Figure 6, the HRSG may also be configured as a circulating drum boiler with an economizer and an optional superheater for supplying saturated or superheated steam.

[0067]

[0178] The output of a steam generator can be supplied for one or more industrial applications. For example, steam can be supplied to a turbine generator that outputs electricity used as retail local power. A control system can receive information associated with local power demand and determine the amount of steam to be supplied to the turbine, thereby meeting the local power demand.

[0068]

[0179] In addition to power generation, the output of the heat storage structure can be used for industrial applications, as described below. Some, but not limited to, these applications include electrolytic cells, fuel cells, gas generation units such as hydrogen, carbon recovery, the manufacture of materials such as cement, and calcination. Further details on these industrial applications will be provided later.

[0069] Dynamic adiabatic insulation

[0180] Generally, it is beneficial for heat storage structures to minimize their total energy loss and thus their insulation costs through effective insulation. Some insulation materials are more resistant to high temperatures than others. High-temperature resistant materials tend to be more expensive.

[0070]

[0181] Figure 5 provides a schematic cross-sectional view 500 of a dynamic insulation implementation. The outer container includes a roof 501, walls 503, 507 and a foundation 509. Inside the outer container, an insulation layer 511 is provided between the outer container and rows of blocks in the laminate 513, the rows of blocks are represented as 513a, 513b, 513c, 513d and 513e. The heated fluid discharged from the upper portion of the rows of blocks 513a, 513b, 513c, 513d and 513e exits through an output 515 connected to a duct 517. The duct 517 provides the heated fluid as input to a steam generator 519. As the heated fluid passes through the steam generator 519, some of its heat is transferred to the water in the steam generator, and the fluid flow becomes cooler than when it exits the steam generator. Furthermore, the heated fluid can be used directly in an industrial process 520 configured to receive the heated fluid, as shown in 518. The cooler recirculated fluid exits the bottom portion 521 of the steam generator 519. The blower 523 receives the cooler fluid and delivers it downward through a passage 525 defined between the wall 503 and an insulating body 527 positioned adjacent to the laminate 513, through an upper air passage 529 defined between the insulating body 511 and the roof 501, through side passages 531 defined on one or more sides of the laminate 513 and insulating body 511, and then downward to a passage 533 directly below the laminate 513.

[0071]

[0182] The air in passages 525, 529, 531, and 533 acts as an insulating layer between (a) the insulators 511 and 527 surrounding the laminate 513 and (b) the roof 501, walls 503, 507, and foundation 509. Thus, heat from the laminate 513 is prevented from overheating the roof 501, walls 503, 507, and foundation 509. At the same time, the air flowing through these passages 525, 529, 531, and 533 is carried by convective heat that can penetrate the insulators 511 and / or 517 and enter the airflow passages 535 of the laminate 513, thus preheating the air, which is then heated by passing through the airflow passages 535.

[0072]

[0183] The rows of blocks 513a, 513b, 513c, 513d, and 513e, as well as the air passage 535, are schematically shown in Figure 5. The physical structure of the laminate and the air passage through the laminate in the implementation described herein is more complex, which leads to advantages.

[0073]

[0184] In some implementations, to reduce or minimize total energy loss, the insulation layer 511 is a high-temperature primary insulator surrounding rows 513a, 513b, 513c, 513d, and 513e within the housing. A lower-cost outer layer of insulation may be provided. The primary insulator can be made of an insulating material selected from any combination of heat-resistant blocks, alumina fibers, ceramic fibers, and glass fibers, or any other material that may be apparent to those skilled in the art. Considering the temperature difference between the storage medium and the environment, the amount of insulation required to achieve low loss may be large. To reduce energy loss and lower insulation costs, conduits are arranged to guide the cooler fluid returning from the HRSG along the outside of the primary insulation layer before flowing into the storage core for reheating.

[0074]

[0185] The cooler plenum, including passages 525, 529, 531, and 533, is insulated from the external environment, but the total temperature difference between the cooler plenum and the external environment is reduced, thereby reducing heat loss. This technique, known as "dynamic adiabatic," uses the cooler return fluid, as described above, to recapture heat passing through the primary adiabatic layer and preheat cooler air before it flows into the storage unit's lamination. This technique further helps maintain the design temperature within the foundation and supports of the heat storage structure. The requirements for foundation cooling in existing designs (e.g., for molten salts) require expensive dedicated blowers and generators, but these requirements are avoided by the implementation according to this teaching.

[0075]

[0186] The ground beneath construction materials and storage units may not be able to withstand high temperatures, and this system can maintain temperatures within design limits through active cooling (assisted by a self-flowing heat exchange fluid in the event of a power outage).

[0076]

[0187] A portion of the fluid returning from the HRSG is guided through conduits, such as element 521 located within the support and base elements, to cool them and return the absorbed heat to the input of the storage unit stack as a preheated fluid. Dynamic insulation may also be provided by positioning blocks 513a, 513b, 513c, 513d, and 513e within the housing such that blocks 513a, 513b, 513c, 513d, and 513e do not come into contact with the outer surfaces 501, 503, and 507 of the housing, and are therefore thermally insulated from the housing by a primary insulator formed by a layer of cryogenic fluid. Blocks 513a, 513b, 513c, 513d, and 513e may be positioned at a height raised from the bottom of the housing using a platform made of insulating material.

[0077]

[0188] During unit operation, a controlled flow of relatively cool fluid is supplied by the fluid injection unit 523 to the region between the housing and the primary insulator (which may be located inside or outside the internal housing for one or more heat storage assemblies) (including passages 525, 529, 531, and 533), resulting in dynamic insulation between the housing and the block, thereby limiting the dissipation of thermal energy generated by the heating element and / or stored by the block into the external environment or into the housing, and preheating the fluid. As a result, the controlled flow of cool fluid by the system's fluid injection unit can facilitate the controlled transfer of thermal energy from the block to the conduit, also facilitating dynamic insulation, thereby making the system efficient and economical.

[0078]

[0189] In another exemplary implementation, fluid buoyancy allows for the autonomous flow of cryogenic fluid around the block between the housing and the primary insulator 511, so that even if the fluid injection unit 523 becomes inoperable due to a power or mechanical failure, the cryogenic fluid can passively provide dynamic insulation, thereby maintaining the system temperature within predefined safety limits and achieving intrinsic safety. By opening vents, ports, or louvers (not shown), a passive buoyancy-driven flow can be established to maintain such flow, including cooling for the support and base cooling, during such power outages or unit failures, without requiring any active equipment.

[0079]

[0190] In the fluid flow described above, the fluid may flow to the upper part of the unit, down the walls, and into the inlet of the lamination, depending on the overall surface area to volume ratio which depends on the overall unit size, and the dynamic adiabatic flow path may be altered. For example, in the case of a small unit with a large surface area relative to its volume, the amount of fluid flowing through the lamination relative to the area can utilize a flow pattern that includes a series of meandering channels so that the fluid flows outwards, down the walls, up the walls, down the walls again, and then into the inlet. Other flow guidance patterns may also be used.

[0080]

[0191] Furthermore, a pressure difference can be maintained between the return fluid in the insulation layer and the fluid in the laminate so that the dynamic insulation layer has a substantially higher pressure than the pressure in the laminate itself. Therefore, if there is a leak between the laminate and the insulation layer, the return fluid with the higher pressure can be pushed into the leak or crack rather than the fluid in the laminate leaking into the dynamic insulation layer. Thus, if a leak occurs in the laminate, the very hot fluid in the laminate may not leak out of the unit, but instead, the return fluid may be pushed into the laminate until the pressure between the dynamic insulation layers within the laminate becomes equal. Pressure sensors providing relative and absolute pressure information can be placed on both sides of the blower. In such a configuration, a pressure drop in the system can be detected and used to pinpoint the location of the leak.

[0081]

[0192] Early systems for storing high-temperature sensible heat in rock and molten salt required a continuous active means to cool the base, and in some implementations, a continuous active means to heat system elements to prevent damage to the storage system; therefore, a continuous active power supply and backup power supply system were required. Systems such as those described herein do not require an external energy supply to maintain the safety of the unit. Instead, as described later, this disclosure provides a thermal storage structure that provides a thermally induced flow to passively cool critical elements when the equipment fails or power or water supply is lost. This also reduces the need for fans or other cooling elements inside the thermal storage structure.

[0082] Prediction-based system control

[0193] As mentioned above, control systems can use predictive information, such as weather forecasts, to reduce wear and deterioration of system components. Another objective of prediction-based control is to ensure sufficient thermal energy production from the thermal energy storage system to the load or application system. Measures that can be taken in consideration of predictive information include, for example, adjusting the operating parameters of the thermal energy storage system itself, adjusting the amount of input energy entering the thermal energy storage system, and actions or adjustments related to the load system receiving the output of the thermal energy storage system.

[0083]

[0194] Weather forecast information can be obtained from one or more sources. One source is a weather station located at a site where electrical energy is generated, such as a solar array or photovoltaic array, or a wind turbine. The weather station may be integrated with the power generation facility and may be used operationally for control decisions of that facility, such as for detecting ice formation on wind turbines. Another source is weather information from a source that covers a wider area, such as radar or other weather stations, and this information can be fed into a database accessible by the control system of the thermal energy storage system. Weather information covering a wider geographic area may be advantageous in providing more sophisticated notification of changes in conditions compared to point-source information from weather stations located at the power source. Yet another possible source of weather information is virtual or simulated weather forecast information. Generally, machine learning methods can be used to train a system while considering such data and modifying the system's behavior.

[0084]

[0195] For example, historical information associated with the power curve of an energy source can be used as a predictive tool, taking actual conditions into account, to provide predictions of power availability and adjust the control of the thermal energy storage system with respect to both the amount of energy available to charge the unit and the amount of heat output available for discharge. For instance, power curve information can be compared with actual data to indicate that when the power output of a photovoltaic array is reduced, it may indicate clouds passing through one or more parts of the array, or cloudy weather across the entire area related to the array.

[0085]

[0196] Predictive information is used to improve heat storage and generation in thermal energy storage systems, taking into account changing conditions. For example, predictions can help determine the amount of heat that needs to be stored and the rate at which heat must be released to ensure consistent steam quality and quantity, and to ensure that the steam generator does not need to be shut down, for example, when supplying heat to a steam generator to provide the desired output for an industrial application. The controller can adjust current and future heat output in response to the current or predicted decline in the availability of charging electricity, so as to ensure that the charge state of the storage unit does not deteriorate over a future period to the point where heat output must be stopped. The unit can operate continuously by adjusting the continuous operation of the steam generator to a lower rate in response to the predicted decrease in available input energy. Avoiding shutdowns and subsequent restarts is a desirable feature, as shutting down and restarting a steam generator is a costly, energy-wasting, time-consuming process that can expose workers and industrial facilities to safety risks.

[0086]

[0197] The forecast may, in some cases, indicate a lower power input than expected, or some other change in the power input pattern to the thermal energy storage system. Therefore, based on the input forecast information, the control system may determine that the amount of energy required by the thermal energy storage system to generate the heat desired to meet the demands of the steam generator or other industrial applications is less than the amount of energy expected to be available. In one implementation, making this determination involves considering any adjustments to the operation of the thermal energy storage system that could increase the amount of heat the thermal energy storage system can generate. For example, one adjustment that could increase the amount of heat generated by the system is to operate the heating elements within the thermal storage assembly at a higher power than usual during periods when input supply is available, in order to obtain a higher temperature of the thermal storage assembly and a larger amount of stored thermal energy. As will be further discussed later, such “overcharging” or “supercharging” of the assembly can, in some implementations, allow sufficient output heat to be generated throughout periods of reduced input energy supply. Overcharging can increase stress on the system's heat storage medium and heater elements, thus increasing the need for maintenance and the risk of equipment failure.

[0087]

[0198] As an alternative to adjusting the operation of a thermal energy storage system, or in implementations where such adjustments are not expected to compensate for a predicted shortage of input energy, the control system can initiate operation on either the source side or the load side of the thermal energy storage system. For example, on the input side, the predicted difference between the predicted input power and the required input power can be used to provide support for decisions or judgments regarding procuring input electrical energy from other sources during the coming period to provide the predicted difference. For example, if a forecast system determines, for instance, that the amount of electrical energy to be supplied from the photovoltaic array will be 70% of the predicted amount required over a given period due to a cloudy weather forecast, the control system can enable connection to an alternative input source of electrical energy, such as a wind turbine, natural gas, or other source, so that the thermal energy storage system receives 100% of the predicted amount of energy. In implementations of a thermal energy storage system with a power grid connection available as an alternative input power source, the control system can enable connection to the power grid in response to a predicted shortage of input power.

[0088]

[0199] In certain implementations, predictive data can be used to determine desired output rates a certain number of hours or days in advance, and the operator can be provided with signals and information regarding expected operational adjustments to achieve those output rates, and a mechanism to implement the output rates determined by the system, or alternatively, to modify or override those output rates. This may be as simple as a "click to agree" feedback option provided to the operator, a dead man's switch that automatically implements the determined output rates unless overridden, and / or more granular options for the system's control parameters.

[0089]

[0200] II. Heat Transport in TSUs: Blocks and Heating Elements

[0201] A. Problems resolved by one or more disclosed implementations

[0202] Conventional methods for forming energy storage cells may have various problems and drawbacks. For example, conventional methods may not provide uniform heating of the thermal energy storage cell. Instead, they may use structures that cause uneven heating, such as hot spots and cold spots. Uneven heating can reduce the efficiency of the energy storage system, lead to premature equipment failure, and cause safety problems. Furthermore, conventional methods can lead to wear and cracking of the thermal energy storage cell. For example, stresses such as mechanical and thermal stresses can cause material destabilization, such as cracking of the block, along with performance degradation.

[0090]

[0203] B. Exemplary solutions disclosed herein

[0204] In some implementations, heat storage blocks (e.g., blocks) have various features that promote a more uniform distribution. As one example, a block can be formed and positioned to define a fluid flow path having a chamber that opens to a heating element to receive radiant energy. Thus, a given fluid flow path (e.g., oriented vertically from the top to the bottom of a stack) can include two types of openings: radiant chambers that open to a flow path for a heating element, and fluid flow openings that do not open to a flow path (e.g., fluid flow slots). The radiant chambers can receive infrared radiation from the heater element, which, in conjunction with conductive heating by the heater element, can provide more uniform heating of the heat storage block assembly compared to conventional implementations. Fluid flow openings can indirectly receive a small amount of radiant energy through the chamber, but do not open directly to the heating element. Stacks of blocks can be used alone or in combination with other stacks of blocks to form a heat storage unit, and one or more heat storage units can be used together in a thermal energy storage system. As explained above, because the fluid blower circulates the fluid through the structure during charging and discharging, a substantially vertical temperature stratification can be formed, meaning that within a substantially vertically oriented plane or virtual "slice" through the storage medium, the temperature difference between regions of the fluid is relatively small or minimal. Furthermore, the fluid transfer system can guide relatively cooler fluids along, for example, the insulating walls and roof of the structure for thermal insulation purposes. Finally, the ventilation system can enable controlled cooling for maintenance or in the event of power loss, water loss, blower failure, etc., which can provide a significant safety advantage compared to conventional techniques.

[0091]

[0205] The design according to this disclosure combines several key innovations that address these challenges together, enabling the construction and operation of a cost-effective, safe, and reliable high-temperature thermal energy storage system. The carefully structured solid medium system according to this teaching has structured airflow passages to achieve effective temperature stratified discharge, repeatedly arranged mixing chambers along the direction of airflow to mitigate the thermal effects of any localized air channel blockage or non-uniformity, and a radiant chamber structure that effectively shields vertically propagating thermal radiation and uniformly and rapidly heats the block material with high heater output loads, low and uniform exposed surface temperatures, and long-distance heat transfer within the storage medium array via multi-stage thermal radiation.

[0092]

[0206] The innovative structures described herein may include an array of blocks forming a chamber. The blocks have structured air passages, allowing air to flow upward in a continuous open chamber and smaller air passages in the vertical direction. In some implementations, the array of blocks with internal air passages is arranged such that the outer surface of each block within the TSU core forms the wall of the chamber, and within the chamber, each block is exposed to radiation from an electric heater, as well as radiation from the surfaces of other blocks.

[0093]

[0207] The chamber structure is created by arranging block material alternately in a checkerboard pattern, where each block is surrounded on all sides by an open chamber, and each open chamber has adjacent blocks as its walls. In addition, horizontal parallel passages are provided through multiple chambers. Electric heating elements are installed in these passages, extending horizontally through an array. Each heating element can be exposed to the internal space of the multiple chambers along its length. In such a checkerboard structure, all sides of each block are exposed to the open chambers. Therefore, during charging, radiant energy from the multiple heating elements heats all outer surfaces of each block, contributing to rapid and uniform heating of the block and reducing reliance on conductive heat transfer within the block by limiting the internal dimensions of the block.

[0094]

[0208] The radiant chamber structure offers a significant advance in the design and production of effective thermal energy storage systems charged by electrical energy. The large surface area radiated to the heater means that the average temperature of the large surface determines the radiative balance, and therefore the heater's surface temperature. This inherent uniformity allows for a high wattage per unit area of ​​the heater without the possibility of localized overheating. Furthermore, the exposed block surface is larger per unit mass than in conventional systems, which means a correspondingly lower input wattage per unit area, resulting in lower thermal stress due to temperature differences within the block. Importantly, the re-radiation of energy, i.e., radiation from a higher-temperature block surface absorbed by a lower-temperature block surface, significantly reduces surface temperature fluctuations, and consequently reduces thermal stress on the block material exposed to radiant heat. Therefore, the radiant chamber design effectively allows for relatively uniform heat distribution over a large horizontally oriented surface area, enabling a high wattage per unit area of ​​the heater at a relatively low wattage per unit area of ​​the block.

[0095]

[0209] While this configuration is described in terms of "horizontal" and "vertical," it should be noted that these are not absolute degree or angle limitations. Advantages include maintaining temperature stratification and providing fluid flow through the lamination in a direction that results in convective heat transfer, exiting the lamination at the relatively hotter portion of the temperature stratification. An additional advantage that can be incorporated is positioning the lamination so that buoyant hot air rises through the lamination and exits at the hotter end of the temperature stratification. In this case, a lamination where the hotter end of the temperature stratification is at a higher height than the cooler end of the temperature stratification is effective, and vertical temperature stratification maximizes its effectiveness.

[0096]

[0210] A key advantage of this design is the significant improvement in the uniformity of the heating element temperature in the design according to this disclosure. Any fluctuations in the block's thermal conductivity, or any cracks formed within the block that cause changes in thermal conductivity, are largely mitigated by radiative heat transfer away from the area of ​​reduced conductivity. That is, areas that reach a higher temperature than neighboring areas due to reduced efficiency of internal conduction are rapidly cooled by radiation to a temperature relatively close to the surrounding surface temperature, as the radiative balance with neighboring surfaces is disrupted. As a result, both thermal stress within the solid medium and local peak heater temperatures are significantly reduced compared to previous designs.

[0097]

[0211] The system may include one or more air blowing units, which include any combination of fans and blowers and are configured in predefined positions within the housing to facilitate a controlled airflow between the combination of the first section, the second section, and the external environment. The first section may be isolated from the second section by a thermal barrier. The air blowing units may facilitate an airflow at a predetermined flow rate through at least one of the channels of the block from the bottom end of the cell in the first section to the top end of the cell, and then into the second section, thereby heating the air passing through the heating elements of the block and / or cell to a second predetermined temperature at a predefined flow rate, so that such air can absorb and transfer thermal energy released by the heating elements and / or stored by the block in the second section. The air may flow from the second section through a steam generator or other heat exchanger including one or more conduits, which carry a fluid and, upon receiving thermal energy from the air having a predefined second temperature, can heat the fluid flowing through the conduits to a higher temperature or convert the fluid into steam.

[0098]

[0212] Furthermore, the system can facilitate the outflow of generated steam from the second end of the conduit to a predefined location for one or more industrial applications. The predefined second temperature of the air can be based on the material used in the conduit and the required temperature and pressure of the steam. In another implementation, the air exiting the second section may be supplied to an industrial process from an external source. Furthermore, the exemplary implementations described herein disclose a resistive heating element. The resistive heating element may include a resistive wire. The resistive wire may have a cross-section that is substantially circular, elongated, flat, or other in shape so as to receive energy received from an electrical energy input as heat.

[0099]

[0213] Passive cooling

[0214] Figure 6 provides isometric views of a heat storage unit in several implementation configurations with multiple vent closures open. Thus, Figure 6 can represent maintenance or fail-safe operation modes. As shown, the heat storage unit also includes an internal housing 623. A fluid passage is defined between the outer surface of the internal housing 623 and the inner surface of the external housing, through which fluid can be conducted, either actively for dynamic cooling or passively for fail-safe operation.

[0100]

[0215] The internal enclosure 623 includes two vents 615 and 617, which in some implementations include corresponding vent closures (part of the vent door 613 in this example). In some implementations, the vents 615 and 617 define passages between the inside of the internal enclosure 623 and the outside of the internal enclosure. When the external vent closure 603 is open, these two vents are also exposed to the outside of the external enclosure.

[0101]

[0216] As illustrated, the vent 615 can discharge heated fluid from the heat storage block, which is guided by the duct 619. The vent 617 can allow external fluid to enter the fluid passage and eventually the bottom of the heat storage block assembly via the louver 611 (in this situation, the vent closure 609 may remain closed). In some implementations, the buoyancy of the fluid heated by the block causes the fluid to exit the vent 615, and the chimney effect draws the external fluid into the external housing via the vent 617. This external fluid is then guided through the louver 611 due to the chimney effect, which can facilitate the cooling of the unit. Generally, the first vent closure can be opened to expel heated fluid, and the second vent closure can be opened to allow external fluid to enter for passive ventilation.

[0102]

[0217] During passive cooling, the louvers 611 can also directly receive external fluid, for example, when the vent cover 609 is open. In this situation, both vents 615 and 617 can output fluid from the inner and outer housings.

[0103]

[0218] In the illustrated configuration, the vent door 613 also closes the input to the steam generator when vents 615 and 617 are open. This prevents damage to components of the steam generator (such as water supply pipes) when water is shut off, when the blower is not operating, or in other fault conditions. Vent 617 can communicate with one or more blowers, which can allow fluid to move passively through them even when the blowers are not operating. Generally speaking, one or more fail-safe vent closures can close one or more passages to shut off fluid heated by the heat storage block and reduce or avoid damage to the equipment.

[0104]

[0219] When closed, the ventilation door 613 can define a portion of the fluid passage used for dynamic insulation. For example, a fluid transfer system can move fluid upward along one wall of the internal enclosure, across the outer surface of the ventilation door 613, across the roof of the internal enclosure, and downward along one or more other sides of the internal enclosure (e.g., via the louvers 611) into the heat storage block. In some implementations, the louvers 611 can enable control of the fluid flow into the heat storage block assembly, including independent control of a separately insulated assembly.

[0105]

[0220] In the closed position, the vent door 613 can also define an input path through which heated fluid enters the duct 619 from the heat storage block, passes under the vent door 613, and enters the steam generator to generate steam.

[0106]

[0221] In some implementations, one or more of the vent doors 613, vent closures 603, and vent closures 609 are configured to open in response to a non-operating state of one or more system elements (e.g., non-operation of a fluid transfer system, power outage, water outage, etc.). In some implementations, one or more vent closures or doors are held in the closed position using power during normal operation and open automatically when power is lost or in response to a signal instructing them to open.

[0107]

[0222] In some implementations, for example, to rapidly cool the unit for maintenance, one or more vent closures are opened while the fluid blower is operating.

[0108]

[0223] Thermoelectric power generation

[0224] 1. Problems to be solved

[0225] Gasification is the thermal conversion of organic matter through partial oxidation into gaseous products, primarily H2 and carbon monoxide (CO), which may also include methane, water, CO2, and other products. Biomass (e.g., wood pellets), carbon-rich waste (e.g., paper, cardboard), and even plastic waste can be gasified to produce hydrogen-rich synthesis gas in high yield using high-temperature steam, with optimal yields obtained at temperatures above 1000°C. The rate of combustible gas formation increases with increasing reaction temperature, leading to a more complete conversion of the fuel. The hydrogen yield increases, for example, with increasing reaction temperature.

[0109]

[0226] Transforming waste carbon sources into a stream of raw materials for useful alternative energy sources or fossil fuels is a potentially highly impactful way to reduce carbon emissions and make effective use of carbon sources that would otherwise be underutilized.

[0110]

[0227] 2. Thermoelectric power generation

[0228] Indirect gasification uses a two-column fluidized bed (DFB) system, which consists of two interconnected fluidized bed reactors (one combustor and one gasifier), with a considerable amount of fluidized bed material circulating between them. This circulating fluidized bed material acts as a heat carrier from the combustor to the gasifier, thus meeting the net energy demand in the gasifier, which arises from the fact that fluidization occurs solely by steam, i.e., without air / oxygen, in contrast to conventional methods in gasification technology also known as direct gasification. The absence of nitrogen and combustion in the gasification chamber means the production of a feed gas with a much higher calorific value than direct gasification. Carbides that are not converted in the gasification chamber follow the circulating fluidized bed material into the combustor, where they are fluidized by air, burn there, and release heat, which is then absorbed by the circulating fluidized bed material and transported into the gasifier to balance the system's heat balance.

[0111]

[0229] Referring to Figure 4, in some exemplary implementations, the thermal energy storage structure 403 can be directly integrated with a steam power plant to provide an integrated cogeneration system 400 for the continuous supply of hot air, steam, and / or electricity for various industrial applications. The thermal energy storage structure 403 can be operationally coupled to an electrical energy source 401 to receive electrical energy and convert it into thermal energy for storage. In some implementations, at least one of the electrical energy sources 401 may include an input energy source with intermittent availability. However, the electrical energy sources 401 may also include an input energy source with on-demand availability, and a combination of intermittent and on-demand sources is also possible and intended. The system 403 can be operationally coupled to a heat recovery steam generator (HRSG) 409, which is configured to receive heated air from the system 403 to convert water flowing through the conduits 407 of the HRSG 409 into steam for a steam turbine 415. In an alternative implementation, the HRSG 409 is a once-through steam generator in which the water used to generate steam is not recirculated. However, as shown in Figure 4, implementations in which the water used to generate steam is partially or completely recirculated are also possible and intended.

[0112]

[0230] The control unit can control the flow of heated air (and more generally, fluid) to the HRSG 409 based on load demand, the cost per kWh of the available energy source, and the thermal energy stored in the system. The steam turbine 415 can be operationally coupled to a steam generator 409 which can be configured to generate a continuous supply of electrical energy. Furthermore, the steam turbine 415 can also supply industrial processes by releasing a continuous flow of relatively low-pressure steam 421 as output. Thus, an implementation is possible and intended in which steam is received by the turbine at a first pressure, output from the turbine at a second, lower pressure, and the reduced-pressure steam is supplied to industrial processes. Examples of such industrial processes that can utilize reduced-pressure output steam include (but are not limited to) the production of liquid transport fuels including petroleum fuels, biofuel production, diesel fuel production, ethanol production, and grain drying.

[0113]

[0231] The production of ethanol as fuel from starch and cellulose involves aqueous processes including hydrolysis, fermentation, and distillation. Ethanol plants have substantial electrical energy demands for process pumps and other equipment, as well as significant heat demands to facilitate the hydrolysis, cooking, distillation, dehydration, and drying of biomass and alcohol streams. It is well known that fuel production processes are operated using conventional electric and fuel-burning boilers, or steam and electric fuel-burning cogeneration. Such energy inputs are a significant source of CO2 emissions, sometimes accounting for more than 25% of the total CO2 associated with agriculture, fuel production, and the transportation of the finished fuel as a whole. Therefore, the use of renewable energy to power such production processes is valuable. Some ethanol plants are located in areas where excellent solar resources are available. Other plants are located in areas where excellent wind and solar resources are available.

[0114]

[0232] The use of electrothermal energy storage can provide grid operators with local benefits in such locations, including switchable electrical loads to stabilize the power grid, and intermittently available grid electricity (e.g., during periods of low prices) can provide a low-cost, continuous energy source supplied from electrothermal storage units.

[0115]

[0233] By using renewable energy (wind or solar power) as the energy source to charge the electric heat storage unit, significant overall reductions can be achieved. CO2 emissions associated with fuel production could come from the cogeneration of heat and electricity by a steam turbine powered by steam generated by the electric heat storage unit, accounting for up to 100% of the driving electricity and steam required to operate the plant. These emission reductions are beneficial to the climate and also commercially valuable under a program that brings financial value to renewable, low-carbon fuels.

[0116]

[0234] Electrically heated energy storage units with air as the heat transfer fluid can offer other significant advantages to ethanol production facilities, particularly in supplying heated and dry air to process elements, including the drying of spent grain. One useful combination of heated air output and steam output from a single unit is achieved by directing the outlet flow from the HRSG to a grain dryer. In this way, a given amount of energy storage material (e.g., a block) can be circulated through a wider temperature range, and excess energy can be stored in a given mass of storage material. There may be periods when the temperature of the energy storage material is lower than the temperature required to generate steam, but the discharge of heated air for drying or other operations continues.

[0117]

[0235] In some implementations, the heat storage structure 403 can be directly integrated into industrial processing systems to supply heat directly to the process without generating steam or electricity. For example, the heat storage structure 403 can be incorporated into industrial systems for lime production, concrete production, petrochemical processing, or any other process that requires a supply of high-temperature air or heat to drive chemical processes. By integrating the heat storage structure 403 charged by VRE, the fossil fuel requirements of such industrial processes can be significantly reduced or, in some cases, eliminated.

[0118]

[0236] The control unit can change both the total power generation and steam production as needed to determine the amount of steam to flow through the condenser 419 for the steam output 421. As a result, the integrated cogeneration system 400 can simultaneously generate steam and electricity for one or more industrial applications.

[0119]

[0237] If an OTSG as shown in Figure 3 is used instead of the recirculating HRSG shown in Figure 5, the overall integrated cogeneration system 400 can be used as a heat storage once-through steam generator (TSOTG), which can be used in oil fields and industry to supply wet saturated steam or superheated dry steam at a predetermined flow rate and steam quality under automatic control. The high temperature supplied by the block and heating elements of system 403 can power the integrated heat recovery steam generator (HRSG) 409. The closed air recirculation loop minimizes heat loss and can maintain an overall steam generation efficiency of over 98%.

[0120]

[0238] The HRSG 409 may include a positive displacement (PD) pump 411 under variable frequency drive (VFD) control for supplying water to the HRSG 409. The TSOTG 400 can provide automatic control of steam flow rate and steam quality (including feedforward and feedback quality control). In an exemplary implementation, a built-in local operator interface (LOI) panel operatively coupled to the system 400 and control unit can provide monitoring and control of the unit. Furthermore, the heat storage structure 403 can be connected to a monitoring, control and data acquisition system (SCADA) associated with the steam power plant (or other load system). In one implementation, a second power supply is electrically connected to the steam generator pump, blower, instrument and control unit.

[0121]

[0239] In some embodiments, the system 400 may be designed to operate using feedwater with substantially dissolved solids, and therefore a recirculating boiler configuration is not practical. Instead, a once-through steam generation process can be used to supply moist steam without the accumulation of mineral contaminants in the boiler. The meandering arrangement of conduits 407 in an alternative once-through configuration of the HRSG 409 can be exposed to the hot air generated by the heat storage structure 403, in which case the feedwater can be continuously preheated and evaporated. Water can be forced through the conduits of the HRSG 409 by a boiler feedwater pump and enter the HRSG 409 at the "low-temperature" end. The water can change phases along the circuit and exit as moist steam at the "high-temperature" end. In one implementation, steam quality is calculated based on the temperature of the air provided by the heat storage structure 403, as well as the feedwater temperature and flow rate, and measured based on the velocity acceleration at the HRSG outlet. Implementations are also possible and intended to implement a separator for separating steam from water vapor and determining steam quality based on their relative ratio.

[0122]

[0240] In the OTSG implementation configuration, the airflow (or other fluid flow) can be arranged so that the hottest air is closest to the steam outlet at the second end of the conduit. By mounting the OTSG conduits laterally to the airflow path and arranging them sequentially, low material costs can be achieved while providing highly efficient heat transfer and steam generation. As a result, steam generation efficiency can reach over 98%, excluding heat loss from the energy storage unit. Preventing scale formation in the piping is an important design consideration in the selection of steam quality and piping design. As water flows through a meandering conduit, its temperature first rises according to the saturation temperature corresponding to the pressure, and then, as the flow continues through the heated conduit, it begins to evaporate (boil).

[0123]

[0241] When boiling occurs, the volume expansion accelerates the flow velocity, and the concentration of dissolved solids increases proportionally to the residual fraction of the liquid phase. Maintaining concentrations below the precipitation concentration limit is an important consideration for preventing scale formation. In bulk flows, mean mineral precipitation, localized nucleation boils, and film boils can cause localized increases in mineral concentration at the conduit walls. To mitigate the potential for scale formation resulting from these localized increases in mineral concentration, conduits carrying heated water can be rearranged so that the highest-temperature heated air flows through conduits carrying lower-vapor-quality water, and lower-temperature heated air flows through conduits carrying the highest-vapor-quality flow.

[0124]

[0242] Returning to Figure 6, various implementation configurations are envisioned in which a fluid transfer device moves fluid across a heat storage medium to heat the fluid, and then moves it to an HRSG such as an HRSG 409 for use in steam generation. In one implementation configuration, the fluid is air. Thus, the air circulation through the HRSG 409 can be forced by a variable-speed blower, which acts as the fluid transfer device in such an implementation configuration. The air temperature can be adjusted by recirculation / mixing to provide an inlet air temperature that does not change depending on the charge state of the block or other mechanism used to implement the heat storage unit. The HRSG 409 can be fluidically coupled to a steam turbine generator 415, which, upon receiving steam from the HRSG 409, uses a generator 417 to generate electrical energy. Furthermore, in various implementation configurations, the steam gas turbine 415 releases low-pressure steam, which is condensed into a liquid by a condenser 419, then deaerated using a deaerator 413, and again supplied to the HRSG 409.

[0125]

[0243] III. Configuration of Thermal Energy Storage

[0244] Thermal energy storage (TES) systems can be deployed to solve energy storage problems in a variety of locations around the world, including areas with high seismic activity. Since the thermal storage medium sometimes takes the form of heavy blocks of heat-resistant material, designing TES systems that can secure these blocks and withstand seismic events can increase the availability of TES systems worldwide.

[0126]

[0245] Figure 7A shows a thermal energy storage medium 710 formed from a plurality of thermal energy storage blocks 720. The implementation configuration in Figure 7A demonstrates that these thermal energy storage blocks 720 can be stacked in multiple layers to increase the thermal energy storage density for a particular footprint area of ​​the thermal energy storage medium 710. As the energy storage density per unit height and footprint area of ​​the stack of storage blocks 720 increases, the risk of damage to the stack due to seismic events also increases. Figure 7A shows one example in which the entire stack of thermal energy storage blocks 720 shifts and / or at least some individual thermal storage blocks 722 are displaced from their interlocking configuration due to seismic acceleration in at least a first direction 730. Figure 7B shows a perspective view of the thermal energy storage medium 710 of Figure 7A, with a plurality of thermal energy storage blocks 722 displaced due to seismic acceleration in at least a first direction 730.

[0127]

[0246] It should be understood that Figure 7A is highly exaggerated to more easily visualize the maximum displacement for an earthquake load with a horizontal acceleration (Eh) acting in the horizontal direction 730. In the example shown in Figure 7A, the maximum displacement in this implementation occurs at the boundary between the 6th and 7th layers of the block, and in this particular implementation, has a peak value of 0.027 m, or 1.05 inches. The maximum displacement changes from almost zero at the bottom layer of block 720 to the maximum value at the top of block 722 at level 6, and then decreases to about 0.010 m (0.39 inches) at cap 724, where the stack of heat storage block 722 is constrained by the cross brace system (shown more clearly in Figure 9). The displacement shape of the block stack at maximum displacement is most clearly visible in the end view of Figure 7A when there is acceleration in direction 730.

[0128]

[0247] Figure 8A shows another example of seismic acceleration for a thermal energy storage medium 810 formed from multiple thermal energy storage blocks 820, similar to that shown in Figure 7A. It should be understood that Figure 8A is also a highly exaggerated image, allowing for a more easily visualized representation of the maximum displacement for a seismic load with a horizontal acceleration (Eh) acting in the horizontal direction 830. The thermal energy storage medium 810 can provide fluid flow from beneath the thermal energy storage medium 810, or it can be supported on a layer of support blocks 840 to provide insulation for soil or other foundations from the thermal energy storage blocks 820.

[0129]

[0248] Figure 8B shows a perspective view of the thermal energy storage medium 810 shown in Figure 8A, with a horizontal acceleration (Eh) acting in direction 830. In the examples shown in Figures 8A and 8B, the maximum displacement (0.024 meters, 0.94 inches) is approximately the same as in the case of the lateral acceleration load shown in Figures 7A and 7B, but in this example, the maximum displacement occurs at the end of the laminate at the boundary between the 7th and 8th layers of block 822. In the case of this load, the displaced shape of the block laminate is most clearly visible in the side view of Figure 9A.

[0130]

[0249] Figure 9 shows that various mechanisms can be incorporated into the design of the thermal energy storage medium 910 to improve the structural stability of the laminate of thermal energy storage blocks 920 when subjected to seismic acceleration. In one implementation, the uppermost portion of the thermal energy storage medium can be captured within a cap layer 924 that holds the upper layer blocks together and acts as a shear diaphragm to provide horizontal support points at the corners 930, where a second stabilization mechanism, such as a column and cross brace system, which may include, but is not limited to, tension braces 940, is implemented to help stabilize the thermal energy storage medium. In some implementations, the capture of the uppermost portion of the thermal energy storage medium may take the form of an outer peripheral support bracket that engages with the peripheral portion of the thermal energy storage medium.

[0131]

[0250] Figure 10 shows that the cross brace system can use tension braces 1040 on two or more sides of the thermal energy storage medium 910. In some implementations, more or fewer braces 1040 may be used. In some implementations, tension wires, other non-rigid supports that can be tensioned, or a combination of rigid and non-rigid supports may be used.

[0132]

[0251] For at least some implementations, the stability of the laminate depends in part on a system of struts 1050 at the corners of the laminate, with intersecting braces, non-intersecting braces, or equivalent structures between the struts on all four sides of the heat storage medium. Some implementations may use more struts 1050. Some implementations may use fewer struts 1050. Some implementations may use struts 1050 of different heights, or some implementations may use struts 1050 of the same height. Some struts may have a linear shape, while other implementations may use arched, curved, or other non-linear shapes relative to the struts 1050. Optionally, some implementations may use non-strut structures, such as I-beams, rectangular or trapezoidal beams, or other shaped structures for structurally connecting a portion of the “cap” layer 1024 to the ground or other fixed surface, but are not limited to these.

[0133]

[0252] As shown in Figures 9 and 10, the tops of one or more stacks can be joined together by a semi-rigid shear diaphragm "cap" 924 or 1024 that effectively captures the top layer of the block and transmits horizontal loads to the bracing system at this level. The cap 924 or 1024 may be formed from multiple modular sections, or in some implementations, the cap may be a single continuous unit. The modular sections may be the same size, or they may be configured to be different sizes or shapes. Some implementations may use multiple tiles or blocks that interlock to form the upper cap 924 or 1024. In some implementations, the entire top surface may not be covered, and instead, a bracket structure or scaffolding may be used that provides a circumferential support 1070 or partial support 1072 but does not cover the entire top surface.

[0134]

[0253] Although Figures 7 to 10 show only one stack of block 720, some configurations may have two or more individual stacks standing side by side within a single enclosure. In some configurations, the two stacks are connected at the top by a cap layer that acts as a shear diaphragm.

[0135]

[0254] Figure 11 shows a side view of the support block 1110 beneath the thermal energy storage medium 910. In this implementation, the stack of thermal energy storage blocks 920 rests on multiple longitudinal "pillow" beams 1120 that provide vertical support at the lowest level of the block 926. The pillow beam block 960 can rest on the vibration isolation system slab and is anchored to the slab with anchor bolts. In some implementations, the base nodes of the pillow beams are constrained, and the uplift and shear reactions at this contact surface can then be used to design the anchor bolts of the pillow beams and check the support pressure. In one implementation, the support block 1060 may be anchored to the vibration isolation system slab using anchor bolts (or similar) to support uplift loads due to earthquakes.

[0136]

[0255] Figure 12 shows a perspective view of the layers of support blocks 1110 supporting the thermal energy storage medium. While this implementation can use multiple support blocks, some implementations may use larger modular sections, such as long beams or other sub-sized members, to define a larger support layer.

[0137]

[0256] Figure 13 shows one implementation configuration in which the block stack is an assembly of only six individual block geometries 1310, 1312, 1314, 1316, 1318, and 1320. As seen in Figure 13, some block geometries 1314 have fewer cavities and structures. Some block geometries 1316 and 1320 have movable cavities and mechanisms. In this implementation configuration, these multiple block geometries are arranged in two unique block layer configurations, which are stacked together alternately on top of each other to result in a total block stack height of eight individual layers for this particular implementation configuration. As shown in Figures 14 and 15, the two unique layer configurations and individual block geometries are used to provide further structural integrity.

[0138]

[0257] In addition to friction, horizontal sliding between blocks within the laminate is limited by rectangular interlocking “shear keys” at the horizontal contact surfaces between each layer of blocks and at the horizontal contact surfaces on the top of the bolster. Figure 14 shows how these shear keys are positioned within corresponding slots on the horizontal contact surfaces of the blocks. Figure 14 shows a shear key 1410 of the upper block and a shear key 1420 at the top of the block. Figure 14 also shows that some blocks include gaps 1430 as part of the block geometry, allowing for the insertion of heating elements or other components into the laminate of blocks. Figure 15 shows a shear key at the contact surface with the top of the bolster, where the gap is larger laterally. Figure 15 shows a slot 1510 in the bolster and a shear key 1520 from the upper block. Also, as seen in the preceding Figures 7-11, the block arrangement in each layer may have an alternating arrangement that helps to hold the laminate together under horizontal acceleration loads.

[0139] Heat energy storage block for horizontal flow

[0258] Figure 16 shows one implementation configuration of a thermal energy storage block 1610 configured for use in a system with horizontal air or fluid flow. This perspective view shows that the top and / or bottom surfaces of the block 1610 may have projections 1620 and / or recesses 1622 to facilitate alignment and interlocking with adjacent blocks (not shown) above or below. The thermal energy storage block 1610 may include a plurality of horizontal channels 1630 and 1632, which may be of different sizes and / or shapes. The block 1610 may include at least one radiating chamber 1640 for receiving thermal energy radiated to the thermal energy storage block 1610, the chamber being in a column horizontally offset from the channels 1630 and 1632. In one implementation configuration, one or more of the horizontal channels 1633 of the block 1610 are in fluid communication with the radiating chamber 1640. In one implementation, the channel 1633 has a similar shape and size to the arrangement shown for channels 1630 and 1632. In some implementations, block 1610 can include two or more radiating chambers 1640, each having multiple horizontal channels in fluid communication with each of the radiating chambers 1640. In Figure 16, within block 1610, the second radiating chamber of the radiating chambers 1640 is positioned horizontally aligned with channel 1635, but it opens on the opposite surface 1612.

[0140]

[0259] Figure 16 also shows that when storage block 1610 is placed adjacent to an adjacent block thermal energy block (not shown), storage block 1610 may have a wall 1650 that forms part of the surface of the radiating chamber. The adjacent thermal energy storage blocks may have complementary mechanisms that, when combined with the mechanism of block 1610, define a radiating chamber similar to that of radiating chamber 1640, except that one part is defined by one block and the other part by the adjacent block. Horizontal channels 1634 and 1636 open into this partial radiating chamber, which is partially defined by the wall 1650. The wall 1660 can also form a radiating chamber when connected to another storage block (not shown), which in this case also forms a radiating chamber similar to that of radiating chamber 1640. Naturally, some implementations may have radiating chambers formed by adjacent storage blocks of different sizes or shapes than radiating chamber 1640, but many implementations may have radiating chambers that are all of similar size and shape.

[0141]

[0260] Viewed from above, one implementation configuration of block 1610 has an outer perimeter shape asymmetric with respect to the longitudinal axis, as indicated by the dotted line 1680. Block 1610 has an outer perimeter having two sides with linear edges and two sides with molded edges, such as, but not limited to, the corrugated contours shown for edges 1690 and 1692. The asymmetric shape facilitates the positioning of the blocks so that they are correctly oriented within the lamination. The asymmetry also provides surfaces for interlocking one block 1610 with an adjacent block 1610. The asymmetry further allows air passages 1634 and 1636 to be incorporated into block 1610. Block 1610 also includes at least one shelf-like surface 1694, which can be used to mount a heater element support thereon. Optionally, block 1610 may have multiple shelf-like surfaces 1694, typically on different edges of block 1610. This allows a shelf-like surface 1694 on one block to face a shelf-like surface 1694 on an opposing block, defining a gap between them, and provides a mounting surface for a heater element or other hardware (including, for example, a temperature-deposition or other temperature sensor) that can be inserted into the gap between the opposing blocks. Optionally, the shelf-like surface 1694 is a separate component from the block 1610. Such a separate component may be added to the block after manufacturing or during on-site assembly. The separate component may be bonded to the block 1610, mechanically attached, or otherwise integrated.

[0142]

[0261] In some implementations, the heat storage block is made of a heat-resistant material (e.g., a castable material) with high thermal conductivity and absorption capacity. The block can be made of a predefined composition of any or a combination of aggregates such as alumina, magnetite, or olivine, and a binder. The selection of materials in the binder, sizing, and proportion of aggregates can be chosen to optimize strength, thermal conductivity, temperature range, specific heat, and / or cost. For example, materials with higher thermal conductivity reduce the temperature difference for a given heat flux, allowing the use of fewer, larger bricks. The binder material may be selected to solidify during casting, or to be sintered before use or to change composition when heated during use.

[0143]

[0262] Blocks can be manufactured using molds. More specifically, the material can be provided in powder form, mixed with water and / or other liquids, to achieve a viscosity based on the amount of liquid added relative to the volume of powder. The mixture is poured into a mold and solidified within the mold over a period of time. The mold is removed, and the solidified brick is formed. Alternatively, blocks may be manufactured using a block press system, a block extrusion system, or 3D printing. Regardless of the manufacturing method, blocks can be formed to reduce or eliminate unintended voids within the solid block area. Various mechanisms of the block (such as channels, radiation chambers, protrusions, recesses, or other mechanisms) are formed from heat-resistant materials and / or other thermal energy storage materials by pressing, extrusion, casting, or a combination of these or other suitable manufacturing techniques.

[0144]

[0263] Figure 17 shows one implementation configuration of multiple interlocking stacked blocks 1710 and 1712. In this non-limiting example, the upper layer block 1710 spans the gap 1720 between the lower level blocks 1712. In this exemplary implementation configuration, one level block 1710 can be seen in contact with four lower level blocks 1712. Furthermore, an exemplary horizontal flow path 1714 through this assembly of heat storage blocks 1710 crosses the radiating chamber 1640, a pair of fluid channels 1633 or 1635 (not shown, but behind the wall 1650 or 1660), and an acceptance channel (including any heating elements or other hardware within that acceptance channel) provided by the gap 1720, and repeats in that pattern until the air or gas flow exits the heat energy storage assembly.

[0145]

[0264] By interlocking blocks 1710 and 1712 in this way, a space such as a heater element receiving channel is created in the gap 1720 between the rows of lower-level blocks 1712. In a non-limiting example, the heater element fitted into the gap 1720 may be a heater wire or conduit, formed as a coil, sinusoidal, other corrugated shape, or other geometric shape suitable to fit into this receiving channel provided by the gap 1720. This allows the blocks to interlock while also providing space for other hardware that can be installed in the storage medium. In one non-limiting example, the gap 1720 is defined as part of a block stacking process, where multiple blocks 1710 are simultaneously engaged by a pickup tool that lifts the blocks in a configuration that pre-separates the rows when the multiple blocks are lifted into place. In this way, at least two rows of blocks 1710 are positioned simultaneously, and as a result, they are positioned simultaneously within the stack such that the rows of blocks are already pre-separated by a predetermined distance. This reduces the number of steps involved in assembly, thus making lamination more efficient and maintaining the gaps 1720 between rows of blocks in a precise and predefined manner. Optionally, in some implementations, the pickup device may be able to selectively release blocks that are not to be lifted and placed in place, thereby allowing for variations in the number of blocks lifted into the lamination when there are configurations where fewer blocks are desirable in some sections, such as when stacking layers in upper layers that may have fewer blocks in that layer. In one non-limiting example, this ability to selectively release blocks can be implemented by a vacuum lift system that can selectively disengage itself from one or more blocks while maintaining vacuum connections to one or more other blocks.

[0146]

[0265] Figure 18 shows that the blocks 1810 can be stacked to have cross-sectional contours selected from a variety of geometric shapes. In the implementation shown in Figure 18, the cross-sectional contour has a ziggurat (tiered) shape. Other implementations may have a pyramidal, mesa, top-flat pyramidal, trapezoidal, rectangular, square, or other geometric shape for the cross-sectional contour. Having a ziggurat shape improves the stability of the stack of energy storage blocks, allowing them to withstand lateral or other accelerations associated with seismic activity better. Figure 18 shows a tiered configuration where each layer has a smaller width or other lateral dimension than the layer below. This tiered configuration can be implemented along the longitudinal axis of the stack and / or along the short axis of the stack. Both ends of the stack may have a tiered configuration, or optionally, only one end may have a tiered configuration.

[0147]

[0266] Figure 19 shows a configuration in which multiple stacks 1910 and 1920 of a thermal energy storage block share a common output to a heat recovery steam generator (HRSG) 1930 or other common hardware for receiving output from two or more thermal energy storage media or assemblies. This non-limiting example shows that a plenum 1932 for receiving thermal output from assembly 1910 and a plenum 1934 for receiving thermal output from assembly 1920 may be provided. Circulating air or gas can enter each assembly through an intake plenum 1940 for assembly 1910 and an intake plenum 1942 for assembly 1920. This also shows that the plenums may have the same or different shapes with respect to the fluid inlet side of the thermal energy storage media. In any of the implementations described herein, it should be understood that the circulation may be to air, carbon dioxide, nitrogen, argon, other noble gases, other gases, or one or more combinations thereof.

[0148]

[0267] As a non-limiting example, having a common steam generator, heat exchanger, or heat extractor reduces the amount of hardware used to enable multiple thermal energy storage assemblies compared to having a separate steam generator for each individual thermal energy storage assembly. Advantageously, this can also increase the amount of storage capacity available to the system by enabling lead-lag discharge from the entire system. Thus, this configuration offers lower hardware costs while increasing the usable capacity of the composite system.

[0149]

[0268] Some implementations may include an external enclosure 1950 (shown by dashed lines) that encloses the thermal energy storage medium within. These enclosures can be fabricated from sections of molded material that can interlock with each other. This type of enclosure can be configured to withstand an internal pressurized environment, i.e., pressures exceeding atmospheric pressure. Some implementations may include two or more thermal energy storage assemblies within a single enclosure 1950.

[0150]

[0269] Figure 20 shows one implementation of a base structure 2010 that can be used to support thermal energy storage media such as thermal energy storage blocks 1710, 1810, or assemblies 1910 and / or 1920. The entire base structure 2010 can be placed on a foundation of gravel, river gravel, crushed stone, or other suitable base material (not shown). In this implementation, tiles 2020 can be provided where the thermal energy storage media will be located on top of the base structure 2010. Other features of the base structure 2010 will be described in more detail later.

[0151]

[0270] Figure 21 is an enlarged view of a portion near one end of the base structure 2010. This configuration shows tiles 2020, thermal insulation material 2120, and fluid or air channels 2130 within the thermal insulation material 2120. Additional thermal insulation material 2140 may be included beneath the thermal insulation material 2120. An air channel 2150 formed internally as part of the underside of the base structure 2010 may also be provided. A foundation 2160 made of pebbles, other crushed material, concrete, or similar material may be placed beneath the support material. As the thermal insulation material, in one configuration, Foamglas® by Owens Corning of Toledo, Ohio is used. Optionally, some embodiments may use calcium silicate as the thermal insulation material. Optionally, some configurations may use a combination of one or both materials for insulation. In one configuration, the flow of air or gas through the channel 2130 is an active flow. Optionally, the flow of air or gas through those channels 2130 may be a passive flow. In one implementation, the flow of air or gas through the channel 2150 is an active flow. Optionally, the flow of air or gas through those channels 2150 may be a passive flow.

[0152]

[0271] Figure 22 shows a perspective cross-sectional view of the support material used in the base structure 2010. As can be seen from the figure, the support material 2210 can be shaped to have a channel 2150 within it. Furthermore, one implementation can use concrete 2220 or a similar material which can contain reinforcing bars 2230 or other structural reinforcements internally to fill the space above the structure for the base layer. Multiple sections of the base structure 2010 may be joined together with concrete 2220 using post-tensioning techniques as described in Figure 55.

[0153]

[0272] Figure 23 is a cross-sectional view of one implementation configuration of the thermal energy storage system 2300. Figure 23 shows an external enclosure 2310 surrounding the thermal energy storage medium 2320. The external enclosure 2310 may be a floating structure, a movable structure, etc. In one implementation configuration, the storage medium 2320 is formed from a plurality of thermal storage blocks 1610 or 1710. An insulating layer 2322 may be present on the storage medium 2320. To provide stability to the configuration, straps 2324 or tie-downs can be attached to or otherwise connected to the insulating layer 2322. Optionally, some embodiments may use bars or other structures across the top of the laminate or on the top of the insulating layer at the top of the laminate, and then attach the straps to the bars or structures. This provides strap attachment points that are further removed from the heat associated with the thermal storage blocks of the laminate. High-temperature insulating material, such as heat-resistant tiles 2330, may be placed beneath the thermal energy storage medium 2320. Another layer of insulation material 2332, such as low-temperature insulation and / or medium-temperature insulation, including but not limited to calcium silicate insulation, Foamglas® insulation, and / or other suitable materials, may be positioned beneath the insulation material 2330. Reinforced concrete and / or steel may be used for the base layer 2340, which may be similar to that shown in Figure 22, having air channels 2150. The temperature of the base layer 2340 at the low-temperature end may be in the range of about 70-80°C. A foundation 2350 of river rock, rounded river gravel, gravel, or similar material may form the bottom layer. The foundation 2350 may also include channels 2360 for the flow of air or fluid.

[0154]

[0273] Figure 24 shows an overall system diagram illustrating that separate housings 2400 and 2402 can be used for electronic circuits and other components to support each of the thermal energy storage assemblies. Figure 24 shows one configuration with a housing 2406 on top of the storage assembly, and one end of the assembly with the housing removed for maintenance, etc. It should also be understood that in some implementations, different thermal storage block assemblies 2410 and 2420 can be used to supply a common heat exchanger, such as a common steam generator 2430.

[0155]

[0274] Figure 25 shows a thermal storage medium 2500 that uses multiple thermal energy storage blocks 2510 on a base 2520. In this implementation, the stack of thermal energy storage blocks 2510 is composed of pyramidal (ziggurat) stacks, which improve stability from seismic motion. In one example, the ziggurat shape is stepped, with each level having smaller dimensions than the level below it. In this particular example, some of the blocks 2530 are support blocks provided to complete the ziggurat shape at the entrance end, and the blocks 2530 are not heated by the heating element. In at least some implementations, the stability of the ziggurat stack substantially reduces the need for dedicated base isolation. Optionally, some implementations can still include base isolation in the stack of thermal energy storage blocks. Base isolation has the function of reducing the connection between earth motions at the center of gravity of the stack of thermal energy storage blocks 2510. Specifically, the base isolation device reduces friction in the stack, and the reduction can exceed 50%. Therefore, while this would result in a significant reduction in the Earth's energy consumption, including this additional hardware in the storage medium would increase additional costs and lead times.

[0156]

[0275] During seismic events, the Earth's movement is irregular in both velocity and direction. This means that the Earth's movement from any direction can cause bounces that tend to impact blocks within the storage stack, such as shaking off corner blocks, blocks along the top surface, etc. By using an inwardly sloping pyramidal or ziggurat shape, the center of gravity is lowered at the center of the storage medium's mass. If the stack is rectangular, the corners are further away from the center of gravity, and due to its rectangular shape, the forces on certain blocks at the corners or similar locations are increased. Because all four sides are sloped, the system is more resistant to all irregularities caused by the Earth's movement. Optionally, in implementations where a few sides have a pyramidal sloping configuration, the sloped sides will be more resistant to irregularities caused by the Earth's movement. Firstly, the ziggurat shape lowers the center of gravity, thereby shortening the moment from the Earth to the center of gravity, and thus making the stack of storage blocks more stable. In earthquake zones, high-center-of-gravity masses that are not fixed together as a single homogeneous member, such as those that may split on their own, require base isolation, which may physically consist of two slabs, configured to allow the upper slab to slide relative to the lower slab.

[0157]

[0276] Compared to rectangular structures, ziggurat-shaped laminates can withstand higher G-factors. Ziggurat-shaped laminates have greater self-stability and, as a result, can withstand seismic motion better than rectangular-shaped laminates.

[0158]

[0277] In one implementation, the heat storage medium 2500 can be located on gravel or other substrates. Optionally, some implementations may use river rock gravel to facilitate the movement of any support structure located on the river rock gravel. Optionally, yet other implementations may include, but are not limited to, further components such as rubber or polymer blocks or fragments used in conjunction with the gravel. The material composition used for the foundation can help isolate the metal raft or support structure on the foundation from earthquake-induced ground movement, thus improving seismic stability.

[0159]

[0278] Optionally, some implementations can improve the seismic stability of the laminate by increasing the coefficient of friction between blocks using retaining straps or other fasteners to the surrounding structure, ground, or base surface, and one or more fixed points can be provided throughout the laminate. Some implementations of the laminate may also be reinforced by stronger blocks at one or more locations in the laminate, such as the corners of the laminate, but are not limited to these. A pyramidal shape, featuring inclined sides at one or more ends, can provide support and stability for the thermal energy storage blocks in operation while maintaining a compact structure. Optionally, the interlocking design of the thermal storage blocks can improve the assembly and disassembly of the laminate. Simplifying the disassembly of only certain sections of the laminate array can enable flexible maintenance and repair work. In one example, the temperature range of the laminate material may be in the range of approximately 25°C to 1000°C.

[0160]

[0279] Figure 26 shows various different-sized enclosures 2600, 2602, 2604, and 2606 that house one or more thermal storage assemblies 2608 internally, each having a “high temperature” end 2610 for heat output and another end where the electrical hardware 2620 is located. The implementation form of FIG. 26 shows a zigzag laminate configuration for the thermal storage medium, but it should be understood that other geometric configurations are not excluded in this specification. Enclosure 2606 houses internally two storage assemblies having a common “high temperature” end 2610, such as, but not limited to, a common steam generator, duct, plenum, etc. The electrical hardware 2620 may be located at the same end or different ends of the thermal storage medium. Enclosures 2600, 2602, and 2604 can be expanded to use two thermal storage assemblies similar to those in enclosure 2606, where the plurality of thermal storage assemblies are configured by connecting end to end so as to share the high temperature end 2610 for collecting the output from the thermal storage assemblies. This end-to-end connection configuration allows doubling the storage capacity within the thermal storage system while using only a single set of hardware for heat output. Implementation forms having two or more array laminates can be used for lead / lag discharge, which enables deeper discharge and larger storage capacity with the same device. The two laminates can be discharged with unequal fluid flow in each laminate. The laminate with a higher flow rate will have a faster temperature drop and may drop to a temperature close to the air temperature available for generating steam while the other laminate is still at a high temperature. At this time, the air from the lagging laminate can be mixed with the air from the cooler laminate to form a larger mass flow at a lower temperature and continue to generate steam. This is most prominent with a large air flow for turndown. This design enables a higher storage efficiency than a single larger laminate of the thermal storage block.

[0161]

[0280] In at least some implementations, it should be understood that the housings 2600-2606 that contain the stack of thermal storage blocks can be formed from modular movable sections to facilitate assembly and disassembly for maintenance and repair operations. Such examples are shown more clearly in FIGS. 48A and 48B. There may be movable or fixed passages on the housing to allow access to various parts of the housing. Some implementations may include heat discharge ports 2650 to provide heat discharge capacity to the housings 2600-2606. The heat discharge ports 2650 can be positioned to correspond to at least one of the thermal storage assemblies within the housings 2600-2606.

[0162]

[0281] FIG. 27 shows various components of the external structure of the housing. FIG. 27 shows that the roof component 2700 can be compactly stored and transported within a container 2702 having an openable top for ease of transportation. When transported to the site, the roof component 2700 can be assembled into an arch-shaped or other shaped section 2710 to form a modular section of the external structure. In one example, the roof section 2700 can be made of a heat insulating material such as rock wool (mineral wool insulation) having, but not limited to, metal. In another example, the external structure 2720 can be made of a heat insulating material such as Foamglas (registered trademark) having ribs 2722 and a support structure. Foamglas (registered trademark) is available from Owens Corning of Toledo, Ohio. The external structure 2720 can be made of modular panels 2724 of heat insulating material and support structure to assemble a larger roof section. Various components of a thermal energy storage system configured for modularization and containerization. The components of such a configuration can be incorporated into pre-manufactured partial sections that are transported for on-site assembly or construction.

[0163]

[0282] Figures 28A and 28B show the thermal profiles within a heat storage medium based on a vertical fluid flow 2800 in Figure 28A and a horizontal fluid flow 2802 in Figure 28B. In Figure 28B, cooler air or gas 2804 surrounding the heat energy storage assembly is drawn into or flows into the assembly at the inlet end 2820. When the air or fluid is heated, it typically results in a decrease in density and rises. In a vertical flow as shown in Figure 28A, this helps maintain a temperature stratified profile due to the buoyancy that keeps the hotter air or fluid rising. For example, at low flow rates, a hotspot region has air or fluid that is expanding and more buoyant, and therefore flows faster in that region. In a vertical flow, all of this tends to help maintain a temperature stratified profile.

[0164]

[0283] In horizontal fluid flows as shown in Figure 28B, buoyancy acts to counteract the maintenance of a stable horizontal temperature stratification profile, particularly at low or zero flow rates. In Figure 28B, the hot air column at the hot end 2810 of the thermal energy storage (TES) system is less dense than the air column of the same height at the cold end 2820. This buoyancy at the hot end 2810 causes the hot airflow to flow backward along the top of the stack and the cold air to flow forward at the bottom of the stack, resulting in a backflow as indicated by arrow 2830. Again, this is applicable particularly in low or zero flow rate scenarios. This leads to a situation where, when the TES is restarted, the heater elements (oriented vertically within the stack) overheat at the top of the stack before the colder air or fluid at the bottom of the stack reaches the desired temperature. This is because the air / fluid and blocks at the top of the stack are already hotter than those at the bottom. This becomes a problem in scenarios where a "bottle-up" function (the ability to retain heat within the TES even during a shutdown lasting 12 hours or more) is desirable, or in turndown situations where the flow rate is very low or the flow is approaching shutdown. During bottle-up, some implementations may seal the inlet end to prevent backflow, which dramatically slows down the rate of backflow. In one example of undesirable backflow, the temperature at the top of the laminate may be around 1000°C while the bottom of the laminate is around 200°C.

[0165]

[0284] As seen in Figure 29, this backflow not only causes problems when restarting the TES system but also leads to an early drop in usable thermal output, resulting in an early shutdown of the TES system. At the outlet, the mixing of cold and hot air can result in a mixture that is not hot enough at the outlet to be usable for anything. Figure 29 shows a temperature versus time graph of thermal output from the TES. The minimum usable output temperature is shown as the dotted line 2910. Due to the backflow, more cold air or fluid mixes with the thermal output shown by the solid line 2920. At point A, the colder mixture drops below the minimum usable temperature threshold 2910 faster than the thermal output 2930 from the TES system maintaining a temperature stratified profile. By maintaining a temperature stratified profile and reducing backflow, less cold air or fluid is mixed into the output, and as a result, the thermal output 2930 does not drop below the minimum usable temperature threshold 2910 until point B, which is later in time than point A, thus increasing the time that usable thermal output is available from the TES unit.

[0166]

[0285] Figure 30 is a side view showing a horizontal flow system, each eliminating the top outlet and bottom inlet that extend throughout the entire heat storage medium. The horizontal system redirects the flow path, with low-temperature air or fluid returning at one side 3010 and high-temperature air or fluid exiting at the other side 3020. This advantageously directs a very short high-temperature duct (not shown) at 3020 toward a steam generator at one end of the thermal energy storage unit. In one example, the duct is made of a material capable of withstanding output temperatures of approximately 900°C to 1500°C, but because it is located at one end of the TES unit, the length of the duct is shorter than the length of the entire TES. The support block also effectively reduces its length from the length extending throughout the entire TES to the length of one section of the angled laminate of the unheated block 3030 at the low-temperature end 3010.

[0167]

[0286] Figure 30 also shows that the storage blocks in operation across region 3042 are not simply stacked vertically. A section of the block is placed above region 3032 to support the overhang of the block 3040 in operation. The block 3030 is typically non-thermal and primarily structural, but other configurations are not ruled out. The block 3030 may be of different lengths so that its end faces have flat surfaces instead of alternating surfaces.

[0168]

[0287] Figure 30 shows a heat storage medium having a ziggurat (tiered) shape in one example. The tiered configuration may have inclined sides at both ends or at either end. Figure 30 shows an example with an inclined side at the outlet end 3020 and a vertical side 3010 at the other end. The vertical end 3010 may have some mechanism or structure to hold the stack of heat storage blocks in place for seismic or other stability reasons. This is more easily achieved at the inlet side 3010, which operates at a lower temperature due to the inflow of incoming air or fluid. This temperature reduction allows for the use of mechanisms such as pull-downs or straps that would melt or degrade as they would at the hot end of the side 3020. As can be seen from the side view of Figure 30, there is interlocking between the blocks 3040, but the blocks 3040 are not directly on top of each other. This allows for a hot surface at the end 3020 that inclins "backward" as indicated by the dotted line 3050, which may be advantageous. The high-temperature side 3020, which may have temperatures exceeding 1000°C, presents a challenging environment for placing metal or straps at its ends. Therefore, tilting the working block 3040 backward relative to the vertical is advantageous because it provides structural stability in the high-temperature zone without necessarily relying on external supports or tie-downs.

[0169]

[0288] In the case of a heat storage medium, one or more implementation configurations are made in which the heating path length is the same. For example, a reverse slope can be configured on the low-temperature end 3010, which results in a longer physical path length at the bottom. However, the heating path length can be maintained at the same length by using one or more unheated blocks 3040.

[0170]

[0289] In this inclined configuration, the thermal stratification is configured to have a similarly inclined configuration relative to the vertical. By maintaining the same path length and the same pressure drop, the thermal stratification can be controlled to have the desired angled or non-angled profile throughout the storage medium and at the thermal outlet. Having symmetrical interlocking at both ends, stacking blocks in this pattern not only homogenizes the inertia of the laminate but also allows for horizontal sealing of the layer by vertically closing the gaps between the lower paths.

[0171]

[0290] The convection portion 3058 of the thermal output from the outlet end 3020 can be recovered into a plenum 3060 or other ductwork for recovering hot air, hot gas, hot fluid, or other thermal output from the thermal energy storage system. In some embodiments, there may be a structure for recovering the radiating portion of the thermal output. Such a structure may include, but is not limited to, a radiation-absorbing pipe, conduit, or other structure 3070 for transporting water, steam, gas, or other medium to receive thermal energy radiated from the hot outlet surface of the thermal energy storage system facing the structure 3070. Optionally, a shutter, louver, or other structure may be present between the hot surface and the structure 3070 to regulate the amount of radiation received by the radiation-receiving structure 3070.

[0172]

[0291] Flow balance to maintain temperature stratification profile

[0292] Referring again to Figures 28A and 28B, one way to maintain the temperature stratification profile in a TES system is to adjust the flow so that there is a higher pressure in one or more upper sections of the heat storage medium while there is a lower pressure in one or more lower sections of the heat storage medium. This can be achieved by one or more different techniques, such as valves, louvers, orifice plates, or other regulators, to control the flow entering one or more sections of the heat storage medium. In some implementations, heating can be adjusted in a selective manner, heating the cooler sections of the heat storage medium more than the hotter sections of the heat storage medium, using heating elements that can be controlled in one or more sections. In some implementations, one or more techniques can be combined to maintain the temperature stratification profile in the heat storage medium. In some implementations, if there is heat in the storage unit, but the temperature stratification and the heater lines in the control circuit are not parallel, and the temperature stratification in the heat storage medium is lost due to a longer shutdown of steam generation, one or more techniques can be combined to re-establish the temperature stratification profile.

[0173]

[0293] In implementations that address pressure gradient problems by adjusting pressure, the TES can be configured to individually adjust pressure at all levels, such as a system that can essentially adjust the inlet to a certain target pressure that can counteract the buoyancy effect that causes backflow. As mentioned above, this target pressure can be achieved using various devices such as orifice plates, louvers, or valves that can be opened and closed continuously.

[0174]

[0294] If the temperature is known, the pressure gradient is also known vertically at the outlet. In one implementation, the system attempts to maintain the same pressure difference from inlet to outlet across all layers. One implementation achieves this by active control, which involves measuring and monitoring pressure drops at multiple locations in the heat storage medium. This system can apply larger pressure drops than those mentioned above (by closing valves, orifices, or louvers). This implementation uses multiple active sensors and multiple independent control valves. Optionally, some implementations may have controllable fluid transfer devices, such as blowers, to adjust the pressure drop through each layer or a group of layers.

[0175]

[0295] In an alternative implementation, the system can connect valves and sensing to use fewer sensors and fewer operating valves. In one non-limiting example, louvers can be provided at any height or layer in the heat storage medium. A pressure sensor may be located at the bottom of the heat storage medium and another at the top. This implementation uses two actuators (one at the bottom and one at the top), and all louvers can be connected to the top controller, the bottom controller, and the two actuators via an electrical or mechanical mechanism. By using this connected sensing and valve control, the system can achieve a desired pressure gradient throughout the heat storage medium.

[0176]

[0296] Further implementations can be configured to reduce mechanical complexity and tolerance issues by using mechanical mechanisms such as valves and louvers that operate in a near-closed state.

[0177]

[0297] In high-turndown scenarios with very low air or fluid flow rates, the louver or valve may remain nearly closed because not much air or fluid flows across it, potentially producing the desired pressure drop. Operating a mechanical device in a nearly closed state exposes the system to risks associated with thermal expansion differences, tolerance issues, or similar factors that could result in the louver or valve unexpectedly closing completely instead of nearly closing. This introduces some complexity and risk when managing such active systems.

[0178]

[0298] Orifice plate air distribution mechanism

[0299] Figure 31A shows one implementation of an air distribution mechanism (ADM) 3110 to address the reverse airflow problem associated with horizontal configurations in bottle-up (no flow) or turn-down (very low flow rate) of the thermal system. As seen in Figure 31A, the 3110 can be positioned at one end of the TES and regulates the flow rate through the heat storage medium. This implementation can address some of the complexity and tolerance issues by using an orifice plate 1620 with multiple orifices 1630 of different sizes inside.

[0179]

[0300] In the example shown in Figure 31B, the orifice plate 3120 can be raised or lowered, as indicated by arrow 3122, to expose one or more orifices 3130 that adjust the pressure drop on the inlet side of the TES system. As shown in Figure 31C, raising or lowering exposes a desired orifice size to adjust the air or fluid flow rate on the inlet side. In one implementation, a single orifice plate 3120 moves relative to the heat storage medium to adjust the air or fluid flow rate. Relative motion between plate 3120 and the plate having the opening 3130 allows for the relative movement of either plate to cover or expose the opening 3130. In some implementations, multiple orifice plates can be used. The size of the orifices can be varied layer by layer based on the desired pressure drop in that layer of the heat storage medium.

[0180]

[0301] In one implementation, feedback for controlling the flow rate of air or fluid may take the form of data from temperature sensors along the hot surface at the end 3020. In one example, the goal is to align this with temperature stratification so that all temperature sensors decrease at the same rate toward discharge. The orifice plate 3120 may use a long piece of metal (possibly a single piece 10 meters long) that may expand due to heat. The system operates in an environment where temperature changes cause the orifice plate 3120 to expand or contract. With a long piece of metal, if the upper part of the orifice plate 3120 is much hotter than the lower part, the upper part will expand, pushing the rest of the plate relatively "downward" and altering the alignment between the orifice and the layer section in the heat storage medium. In an implementation of the orifice plate 1620 with individual positions and individual orifices with some buffer or dead zone between the orifices, the flow does not change due to differences in thermal expansion even if the positioning is slightly misaligned. This results in a robust system even when dealing with changes associated with thermal expansion. In other configurations of the multiple orifice plates 3120, inserts can be provided to change the size of the orifice 3120 to fine-tune the flow, or the orifice 3120 can be ground larger as the system is fine-tuned at each deployment site. The heat storage block has tolerances, which may result in a need to fine-tune the orifice 3120 based on the actual heat storage block used at the deployment site.

[0181]

[0302] As shown in Figure 31D, this implementation of the ADM3110 uses two orifice plates 3120, which supply air to manifolds 3140 that direct the airflow to various levels of heat storage blocks that receive air or gas flow from the ADM3110.

[0182]

[0303] Figure 31E shows an implementation form having a manifold 3140, and each level of the thermal storage block has its own level 3150 within the manifold 3140 for receiving air from the orifice plate 3120. In some implementations, each level 3150 is fluidly isolated from another level 3150 to enable fine-tuning of the air flow through each level of the thermal storage block to the desired pressure drop at that level of the heat storage block. In this way, the ADM3110 can control the air flow across the levels of the thermal storage box without making the orifice plate 3120 the same width as the width of the storage block at that level. Thereby, the size of the orifice plate 3120 becomes easier to manage with respect to the material and size of the actuator used to move the orifice plate 3120 to various open or closed configurations.

[0183]

[0304] Figure 32 shows an orifice plate 3200 with a shaped orifice 3210 for adjusting the flow rate of air or fluid. In this example, the valve style is still a gate that rises or falls to change the cross-section or cross-sectional area of a single opening. The difference from the plate 3120 is that the plate 1620 operates by exposing completely separate orifices, whereas different cross-sections of the same orifice 3210 are exposed by the rising or falling of the gate. The different cross-sections of the orifice 3210 adjust the openings exposed to adjust the pressure drop. The different cross-sectional shapes of the orifice 3210 can change the shape of the opening at any single point, and by raising or lowering the plate 3200, the flow cross-section can be continuously changed to achieve the desired target pressure. This variable cross-section implementation form can be implemented in a mechanically controlled configuration, such as using front and back plates made of the same material so that the thermal expansion is the same. Optionally, the system can overcome tolerance problems by using feedback from the high-temperature end of the side 3020 to adjust and compensate for the rising or falling of the gate.

[0184]

[0305] In some cases, good temperature stratification is desirable due to the interaction between heater wires. In this non-limiting implementation, the system can control the vertical "plane" of the heater wires. In one implementation, the heater wires are switched or controlled in groups rather than individually to reduce switch and sensor costs. By controlling the various vertical planes of these heaters, the system can safely control the heaters as long as the temperature stratification remains parallel to the plane of these heaters as it passes through. If the temperature stratification begins to drift and is no longer parallel to the angle of the heater wires, the top of the heater wires will be in the hot region and the bottom of the heater wires will be in the cold region. This results in a situation where the heater wire assembly cannot be turned on because, if the assembly is turned on, the top heater wire will overheat because the top region is at a higher initial temperature. This results in a system that needs to be thermally reset before more power can be put into the heat storage. This explains why, in this non-limiting example, it is desirable that the temperature stratification does not break down and remains parallel to each other as it moves through the system.

[0185]

[0306] Regarding the wire positioning within the heat storage medium, in one implementation configuration, the first radiating cavity among the radiating cavities begins after the first row of heat storage blocks. The first heating wire is positioned with a complete block in front of it. Since the heat storage blocks are designed to be heated from both sides, if there are wires on only one side, the other side of the heat storage block will remain cool, particularly due to the air blown onto the side of the block away from the heating wires.

[0186]

[0307] Structured thermal energy storage medium

[0308] The connection point as end 3020 may be a common plenum or duct extending across all layers, meaning that these layers communicate even if the flow of hot air or fluid does not communicate vertically through the lamination itself. The system uses a structured medium, such as a heat storage block, to prevent air or fluid from moving vertically between "layers". The system with a structured medium forms a substantially horizontal plane, preventing air or fluid from moving up and down between planes within the heat storage medium. The layers communicate at the end plenum, and air exits from here at the bottom of the hot end and returns towards the cold end, causing backflow.

[0187]

[0309] Other air or fluid distribution systems

[0310] Figure 33 shows an air or fluid distribution system (ADS) 3310 having an angled front surface 3420 of the ADS. This angled configuration (approximately 7° to 15° in one implementation configuration) at the low-temperature inlet end of the heat storage medium can help seal the inlet of the ADS system, especially when bottle-up occurs when there is no flow. The column pressure is maximum at the lowest level of the block and minimum at the lowest level. In region 3324, there may be an overlapping region between the ADS 3310 and the support block 3322. Each layer in the ADS 3310 can be fluidically separated from one another, as indicated by the dashed line 3330. In this way, the air or fluid flow for each level, indicated by the dashed line 3332, can be individually adjusted to an appropriate output for that level and / or a desired output from the system. The ADS system makes it possible to adjust the flow output from channels of different physical lengths. A bracket 3340 indicates the heated section of the heat storage block. As can be seen in Figure 33, the heated portion of the heat storage block can be shifted at each level so that the length of the heated section 3440 is maintained at approximately the same length at each level in the heat storage medium.

[0188]

[0311] Figure 34 is a cross-sectional view of one end of the heat storage medium 3410. In one implementation configuration, the ADS gate is sized to be within the boundary of the insulating layer 3420 so as not to obstruct the flow of air or gas in the space 3430 between the insulating layer 3420 and the housing 3440.

[0189]

[0312] Figures 35A and 35B are various perspective views of one implementation configuration of gate 3510 used in ADS. The gate may include one or more structures, including cross braces 3520 for mechanical stability and strength across the gate surface. In one example, gate 3510 may be made of a high-alloy metal, carbon steel, or similar, with an insulating material such as calcium silicate on at least one side of the metal surface. Some implementation configurations may include periphery framing or reinforcement to prevent the gate from warping during high-pressure conditions. Some examples may include air vents in the gate material that can be distributed in a predetermined or other pattern.

[0190]

[0313] Figure 36A shows another implementation of gate 3610 used in ADS. In this example, the flow rate of air or gas across the entire cross-section of the heat storage medium is controlled by a single gate 3610. In the “upward” position as shown in Figure 36A, gate 3610 does not extend beyond the contour or periphery defined by the insulating material 3620 surrounding the heat storage block, as indicated by the dotted line. Figure 36A shows that the gate in the open position and the orifices 3630 can be arranged alternately vertically and / or horizontally to align with the opening in the heat storage medium. If a portion of the gate aligns with a closed portion of the heat energy storage block, no orifice is placed on that portion of the gate.

[0191]

[0314] Figure 36B shows an enlarged view of the orifice 3630 and its configuration in the ADS. As discussed, the relative motion between the gate 3610 and the orifice 3630 allows the orifice 3630 to be covered and / or exposed as desired to produce a suitable pressure drop relative to its level in the heat storage block. As seen in Figures 36A and 36B, the gate has a rectangular opening 3632 that exposes all or part of the orifice 3630 when the gate 3610 rises to the appropriate height. The flow through the orifice 3630 can be measured by using one or more orifices 3630 of a suitable size relative to its level in the heat storage block so that a desired profile of isotherms in temperature stratification is maintained throughout the thermal energy storage medium. In one non-limiting example, this is desirable so that the heating element at the top of the heat storage medium does not overheat. Overheating can prevent the entire heating element from operating because the heat storage medium is hotter at the top and colder at the bottom, resulting in an unbalanced temperature stratification profile. As a result, the upper heating elements are already close to their overheating temperature and therefore cannot operate.

[0192]

[0315] Figure 36C shows that the gate 3610 can move up and down relative to the heat storage medium to open and close the orifice 3630. In one implementation, the gate 3610 is designed to be closed in the event of power loss or control signal loss.

[0193]

[0316] Figure 37A is a perspective view of one module 3710 of an ADS, comprising a cavity 3720, an insulating material 3730 (shown by a dotted line), and a support structure 3740 attached to a heat storage medium. In this configuration, there may be one module 3710 for each level of heat storage blocks in the heat storage medium. The system may include a metal frame structure 3740 with a cavity 3720 for an orifice array. A heat-resistant lining 3730 with a carbon steel outer surface may be present within the cavity of the frame structure 3740. The upper part 3742 of the frame may be a metal alloy sheet with or without the heat-resistant lining. The frame structure 3740 may have interlocking portions 3744 shaped to engage with blocks in the heat storage medium. Optionally, insulating material 3750 may be present in the portion of the frame structure that interlocks with the heat storage blocks. In one configuration, there is one of these frame structures for each level of heat storage blocks. Optionally, some implementations may have more of these structures for each level of the heat storage block. Optionally, some implementations may have one structure that regulates the flow to two or more levels of heat storage blocks. Optionally, some implementations may have two or more structures for managing the flow to at least several parts of a single level of heat storage block.

[0194]

[0317] Figure 37B is a perspective view of an orifice array 3760 to be received within the cavity 3720 of the ADS module 3710 shown in Figure 37A. In this example, multiple different orifice shapes are shown on the orifice array. It should be understood that the orifice array 3760 may use one type of orifice shape / size for each orifice array, or one or more combinations of orifice shapes / sizes. In one implementation form, this is an orifice array 3760 which may be a laminated or single-piece ceramic fiberboard 3762, a calcium silicate insulation material with orifices, or another suitable insulation material with orifices. Figure 37B shows six examples of orifice arrangements. The first arrangement has multiple vertically aligned slots 3770. The second arrangement has multiple horizontally aligned slots 3772. The third arrangement has multiple diagonally aligned slots 3774, from smallest to largest, then smallest. The fourth configuration has multiple slots 3776 arranged in a uniformly distributed pattern. The fifth configuration has multiple slots 3778 arranged diagonally. The sixth configuration has multiple slots 3780 arranged diagonally.

[0195]

[0318] Figure 38 shows one example of how the ADS assembly 3810 can be attached to the heat storage medium 3812. Support structures such as bolt-on frame structures or strap-down structures 3820 may be available to stabilize the ADS and transform it into a self-supporting structure. In this implementation, each of the frame structures 3830, such as, but not limited to, the one in Figure 37A, is stacked to form the ADS. As seen in Figure 38, each of the frame structures can be of different sizes, such as different widths, to match the width of the heat storage block, which is positioned to receive air or fluid flow from that portion of the ADS. This modular system allows for the selection of ADS portions 3830 based on the size of the heat storage medium to be deployed in any particular location, without being constrained by pre-built, fixed-size ADS assemblies.

[0196]

[0319] Figure 39A shows one implementation of the actuator and control unit used in the gate 3910 of the ADS. In this implementation, one or more linear actuators 3920, including but not limited to ball screw linear actuators, are used to provide relative motion between the gate and the heat storage medium. Structural beams 3930 can be positioned across the top or other parts of the gate to connect the gate to one or more actuators. In some embodiments, a single actuator 3920 can be used to raise or lower the ADS gate 3910. Optionally, multiple linear actuators 3920 can be used to raise or lower the ADS gate 3910, as shown in Figure 39A.

[0197]

[0320] Figure 39B shows another implementation of the actuator and control unit used in the gate 3910 of the ADS. A 90-degree actuator 3940 is used to rotate shaft 3942, which converts rotational motion into linear motion via a linkage mechanism. In one implementation, multiple linkage mechanisms can be used to improve reliability and reduce the risk of single-point failure. Other types of actuators can be used instead of or in combination with the actuators described herein to produce the desired relative motion of the gate.

[0198]

[0321] Figure 40A shows one implementation of an ADS gate 4010 that slides from a first position to a second position to expose the orifice within the ADS. By covering and exposing the orifice, the flow through the thermal energy storage medium is metered. In this implementation, the ADS has a vertical outer surface instead of an inclined outer surface. The length of the cavity 4020 in the ADS is also constant instead of varying in length. The support block 4022 and the thermal storage block 4024 are also shown. While this implementation uses vertical motion to open and close the orifice, it should be understood that motion in other directions, such as horizontal or other angles to vertical, is not excluded in at least some implementations. For ease of explanation, fluid isolation between different levels in the thermal storage assembly (as shown in Figure 33) is not shown in Figure 40A.

[0199]

[0322] Figure 40B shows an enlarged cross-sectional view of a portion of the ADS 4030. This configuration includes a horizontally hinged door 4040, similar to a "dog door," which functions as a thermal radiator to shield the outer portion of the ADS gate from direct thermal radiation from the heat storage medium. The hinged door 4040 can be formed of structurally reinforced thermal insulation material, which moves to the open position when there is air or fluid flow from the gate. The hinged door 4040 returns to the closed position when the air or fluid flow rate drops below a threshold level. This configuration has a hinge 4042 at its top, but it should be understood that configurations with hinges on the sides, bottom, or other locations within the cavity may also be preferable. To regulate the heat storage medium's exposure to thermal radiation, a shutter valve, an iris valve, or other type of valve may be used.

[0200]

[0323] Figure 41A shows a side section view in which the gate has been removed and a hinged door 4110 is used to measure the flow rate of air or gas and / or to act as a thermal radiation shield. Figure 41A shows that the hinged doors 4110, or "dog doors," can be positioned one per level and configured in an array. This configuration has a hinge 4120 at the top, but it should be understood that configurations with hinges on the sides, bottom, or other locations within the cavity may also be preferable. To regulate the exposure of the heat storage medium to thermal radiation, a shutter valve, an iris valve, or other type of valve may be used. In this configuration, there is one hinged door 4110 per level of the heat storage block.

[0201]

[0324] Figure 41B shows an enlarged perspective view in which the hinge 4120 can be connected to an actuator that allows the door to be opened and closed at various angles. The inner surface of the hinged door can be covered with insulating material to withstand thermal radiation from the heat storage medium. The sides of the frame structure in the ADS can also include insulating material 4130 on the inside of the frame structure to minimize heat transfer to the external environment.

[0202]

[0325] Figure 42 shows an end view of a gate assembly having the door 4110 of Figures 41A and 41B, viewed from one end of the thermal energy storage system. The system may have multiple actuators 4210 for each of the hinged gates at each level of the thermal energy storage system for redundancy. In one implementation, all actuators 4210 are connected to the same control system, allowing them to operate in harmony. It is also shown that the actuators 4210 can be positioned outside the adiabatic boundary of the thermal energy storage medium. This can help maintain the actuators 4210 within an operating temperature range. Optionally, at least some parts of the actuators may be included within the boundary region for components that can withstand higher temperatures.

[0203] Orifice plate design

[0326] Figure 43 shows a further implementation of the air distribution system 4300, similar to those shown in Figures 31-42. In this example, there are two parts 4310 and 4320 that are movable relative to each other to vary the amount of gas or fluid flow into each layer of the heat storage medium. Part 4310 has a larger opening 4330, while part 4320 has several smaller openings 4340 of different sizes and / or shapes. The gas or fluid flow through the air distribution system 4300 is controlled by the number of openings 4330, which are "exposed" by the openings 4340, allowing the flow to pass through.

[0204]

[0327] Figure 45 is an enlarged view of one cross-section of the air distribution system 4300, where each of the larger openings 4330 is in a more closed configuration, and only one row of the smaller openings 4340 allows flow through the air distribution system. In this configuration, most of the openings 4330 are in a closed configuration, except that gas or fluid passes through each set of openings 4340.

[0205]

[0328] Figure 45 shows a view of the air distribution system 4300 from the opposite side, more clearly illustrating a configuration in which most of the openings 4340 are not exposed to the openings 4330. In this case as well, in this configuration, only a single row of openings 4330 is exposed for each opening 4340. It should be understood that other implementations can vary the number of openings 4340 exposed in each 4330, and they do not all need to allow the same amount of flow, as shown in Figure 46.

[0206]

[0329] Figure 46A shows yet another implementation where rotational motion of the orifice plate is used. This can be used instead of, or in combination with, one or more linear motion orifice plates. The rotational orifice plate assembly 4610 is implemented as one or more plates 4620, which rotate relative to another adjacent plate by the relative rotational motion of either plate 4620 or the plate having the opening 4630, as indicated by arrow 4640, to cover or expose the opening 4630. The two adjacent plates are in slidable contact with each other. It should be understood that the front plate, the rear plate, or both plates can rotate to provide the desired relative rotational motion to open and close the orifice. In one implementation, there may be one or more rotational orifice plate assemblies 4610 per level of thermal energy storage block in a thermal energy storage system. Figure 46B shows an implementation where there are two rotational orifice plate assemblies 4610 per level of thermal energy storage block. Multiple rotary orifice plate assemblies can be connected together using a mechanical linkage mechanism, such as gears or other components, reducing the number of actuators or motors required to open and close multiple rotary orifice plate assemblies. In one implementation, these linkage mechanisms connect orifice plate assemblies in a single horizontal plane. Optionally, in some implementations, the linkage mechanisms connect orifice plate assemblies in a single vertical plane. Optionally, the rotary orifice plates may be configured to close, such as by the use of a spring or other restoring force, so that a system-wide power outage returns the ADS to the closed position. While this embodiment shows two sets of openings in the rotary orifice plate assembly, it should be understood that some implementations may use only one set of openings. Optionally, some implementations may use two or more sets of openings, with a corresponding number of cover parts for opening and closing such sets of openings.

[0207]

[0330] It should be understood that the size and / or shape of the openings 4630 are illustrative and non-limiting. In some implementations, multiple openings 4630 of different sizes and / or shapes may be used. Optionally, some embodiments may have openings 4630 of different sizes or shapes based on which level of heat storage block is fluidly coupled to the orifice plate assembly 4610. Optionally, the openings 4630 may be spaced differently on the plate 4620 so that different pressure drops are implemented based on fine-tuning of the desired fluid or gas flow rate at that level of the storage block in the heat storage medium.

[0208]

[0331] Figures 47A and 47B illustrate the use of other implementations of rotational motion of the orifice plate. This can be used in place of or in combination with one or more linear motion orifice plates. The rotational orifice plate assembly 4710 is implemented as one or more plates 4720, which rotate relative to another plate by the rotational motion of either plate 4720 or the plate having the opening 4730, as indicated by arrows 4740, to cover or expose the opening 4630. In one implementation, there may be one or more rotational orifice plate assemblies 4710 for each level of thermal energy storage block in the thermal energy storage system. In one implementation, the rotational orifice plate assembly 4710 is supplied to a manifold similar to manifold 3140, and the manifold can be sized to interface with all inlets to the storage assembly. Manifold 3140 and the manifolds described herein can be configured such that each level of the storage medium remains similarly fluidically isolated from the inlet to the other levels within the manifold.

[0209]

[0332] Figure 47B shows an implementation configuration in which there are two rotating orifice plate assemblies 4750 at each level of the thermal energy storage block. Each of the orifice plate assemblies 4750 has three sections of opening 4730. These additional sections of opening 4730 allow this configuration to distribute the opening more uniformly across the orifice plate assemblies.

[0210] External enclosure

[0333] Figure 48A shows that the external enclosure 4810 can be fabricated with modular sections 4820 that can be separated into individual movable sections to provide access to the heat storage medium and enable flexible maintenance and repair work. In one implementation configuration, the enclosure sections are mounted movably on rails, allowing for unbolting and rolling movement to provide access to all locations within the enclosure. The housings at both ends of the stack are sized so that the modular sections of the external enclosure can slide over the housings without hindering the movement of the modular sections. There may be rails 4830 of extra length extending to or beyond the housings to allow the modular sections 4820 to roll over and / or beyond the housings.

[0211]

[0334] Figure 48B shows an open configuration of the outer housing 4810, illustrating a gap 4840 created by sliding and separating the module section 4820. The gap 4840 can be created to allow access to the interior of the thermal energy storage system for maintenance, replacement, and / or upgrade purposes. Figure 48B shows that the gap 4840 can be created in two different locations. Optionally, one larger gap can be created instead of two or more smaller gaps 4840.

[0212]

[0335] Figure 49 shows the possible airflow layout within the enclosure. Cooled air or fluid 4910 can circulate around the heat storage medium, while air or fluid 4920 is heated within the heat storage medium. As seen in Figure 49, at least a portion of the fluid is drawn in at the lower portion below the stack. Optionally, one implementation configuration uses ducts to guide the air or fluid within the TES system. Another implementation configuration uses the headspace within the enclosure between the heat storage medium and the external enclosure to guide the air or fluid flow within the TES system.

[0213]

[0336] In one implementation, the external housing functions as a pressurized vessel or enclosure. For example, the external enclosure can be configured to withstand internal pressurization (approximately 2 psi in one example), i.e., coupling hoops hold the enclosure section to rails when the system is pressurized. While 2 psi is used in this example, it should be understood that lower or higher pressures can also be implemented. Positive pressure facilitates configurations where the thermal output is designed as part of a direct air, direct gas, or direct fluid system, where the direct air, gas, or fluid is used directly in the thermal process, whereas the direct air, gas, or fluid is used as part of a steam generator and then uses that steam to drive the process. Pressurization can be carried out through a gas or fluid blower system to pressurize the enclosure. Some implementations may use induced draft blowers to assist the flow of gas or fluid through the system. During operation, the temperature inside the external enclosure may be approximately 150°C or higher. During abnormal conditions, this temperature can reach 270°C.

[0214]

[0337] Figure 50 is a perspective view of some components of a TES system. The TES system may include a heated thermal energy storage block 5010, an insulating block 5020, an unheated support block 5030 (see example in Figure 30), and a base support 5040 containing multiple components. Figure 51 shows that some components of the base support 5040 can be provided in sections or modules 5050 to facilitate transport to the deployment site.

[0215]

[0338] In some implementations, straps or other support structures can be attached to the insulating material or other material surrounding the thermal energy storage medium. This can be done at the inlet or the cold end 5060 of the storage medium. In some implementations, straps can be used at both ends of the thermal energy storage medium. Optionally, in some implementations, straps may be placed at the cold end of the storage medium. Optionally, in some implementations, straps may be placed at the end that does not have a pyramidal side contour. In one implementation, the thermal energy storage medium rests on top of a first insulating material, a second insulating material which may include air channels, a raft structure, and a floor layer of a substrate such as gravel, but is not limited to gravel.

[0216]

[0339] Figure 51 provides an enlarged view of a section or module 5050 used as part of a base support 5040. The base support section may include a first insulation layer 5120 using heat-resistant tiles, a second insulation layer including air channels 5110, and a third insulation layer which may use, but is not limited to, an insulating material such as calcium silicate insulation, or other suitable insulating materials which may or may not include air channels in the insulating material. A fourth insulation layer 5140 may be foamed glass insulation or other suitable insulating material. The insulating materials can be joined by adhesive or other suitable fasteners. All of this is provided on a platform 5150, such as a metal layer configured to include air channels 5160. The platform 5150 can be attached to other adjacent platforms by bolts or other suitable fasteners. The air channels 5110 and 5160 are arranged in a non-parallel configuration. In one implementation, the air channel 5110 is perpendicular to the air channel 5160. The channel 5110 is not limited to any specific arrangement or pattern in the second insulating layer, but one implementation configuration places the channel 5110 closer to the third insulating layer than to the first insulating layer in order to preferentially cool the interface between the second insulating layer and the third insulating layer.

[0217]

[0340] Figure 52A shows that components such as module 5050 can be stacked and containerized in an industry-compliant shipping container 5052 for transport from the factory to the deployment site. Module 5050 may be manufactured at the factory or other off-site location so that each module 5050 is manufactured in a controlled configuration and can be rapidly assembled at the deployment site.

[0218]

[0341] Figure 52B shows that components such as module 5050 can be arranged in different patterns to accommodate TES systems of different sizes. Some implementations may use a single column of a single module 5050 for this purpose.

[0219]

[0342] In one implementation, the base support may be a raft designed as “equipment” rather than a building. It can be situated on gravel rather than requiring a foundation. Optionally, all or part of the base support is situated on a foundation. The base support may have a modular design that allows all parts to fit into a standard marine or truck transport container. In one implementation, the base support is designed to fit within common transport container sizes to facilitate international transport. The modules of the base support can be designed for rapid assembly. In one implementation, the modules are positioned on-site by a crane and connected by “post-tensioning” or other rapid assembly processes. The base support can be designed to support predetermined members for different sections of the TES system, namely the lower block stack, the electronic house, and the central section. The base support is designed with a wide range of sites in mind. In one implementation, the base support is designed to thermally isolate the heat storage medium from the ground. The base support can be configured to minimize impact on the pad below, including soil heating and soil load reduction. The base support features vertical, axial, and lateral structural integrity and is designed with seismic issues in mind. This minimizes the adverse effects of ground waves on the heat storage medium and central section. The base support can provide a single support for the entire system, i.e., the E-house, the stack of heat storage blocks, and all inputs and outputs. In one implementation configuration, systems such as electrical systems, water supply systems, steam exhaust systems, and auxiliary systems are all piped and connected to the base support, such as a raft. The base support, such as a raft, can provide the main support structure and sealing surface for the external enclosure. The raft can also support rails or other hardware, allowing for the movement of rails and other sections of the external enclosure for maintenance and upkeep purposes.

[0220]

[0343] Figure 53 shows how different modules of the base support are modified based on the type of equipment supported on the base support. Module 5310 may be very basic, supporting a housing for electrical hardware and having a structure made of materials such as concrete, steel, or a combination of such materials. Module 5320 supports a heat storage medium or assembly and has multiple layers of insulation and air or fluid channels to minimize heating of the geological formation beneath this base support. Module 5330 supports hardware such as a steam generator that receives heat output from the heat storage medium. Module 5330 may include a predetermined structure for transferring the load of the hardware to the base portion of the module. Module 5330 may also include insulation material 5332 to minimize heat transfer to the geological formation beneath module 5330.

[0221]

[0344] In addition to selecting the material / thickness of the insulation material, the geometric shape takes into account the function of the raft, including one or more of the following: that, between platform sections, the layers can interlock with the key / insulation to limit heat loss between platforms; that tolerances and / or assembly work can be configured to ensure that tolerances between the precast concrete base and the upper insulation layer are matched; and that, since it is desirable that the block stack / blocks do not walk or move during heating / cooling, the tiles supporting the thermal blocks can be fused into the raft to prevent the blocks from moving relative to the raft.

[0222]

[0345] Figure 54A illustrates how modular sections of the base support can interact with each other. In the insulation layer, additional material can be added to minimize heat loss between platforms and to allow for ventilating airflow between modules. As seen in Figure 54A, there may be airflow or fluid channels 5410. The channels 5410 form bypass paths that allow airflow under the TES and act as additional insulation under the heat storage block. The flow in these channels 5410 can be active. This can be added to other bypass paths that may extend around the sides and / or top of the laminate of the heat storage block. This airflow in the channels 5410 is desirable because it helps to keep the soil and other materials under the laminate from overheating, which can lead to soil sedimentation and / or compression and impede the structural stability of the TES. The air or fluid flow may be active (e.g., driven by a blower) or passive in this cooling operation. Furthermore, the illustrated configuration has a large laminate of material with a path from the channel 5410 toward the bottom of the insulating layer 5412, so that cooling does not occur immediately next to the lowest level blocks near the surface 5414 (where heat could be drawn from those blocks). Layer 5412 may be a homogeneous layer of one insulating material, or optionally, multiple layers of the same or different material. Layer 5412 functions as an insulating, heat-resistant, and ventilated slab. In this exemplary implementation, there is a layer 5412 receiving heat, and toward the bottom, the path acts at a lower temperature at the bottom contact surface of layer 5412 adjacent to the next layer of the insulating body 5420. This material in layer 5420 is highly insulating, high-density, and high-strength. The base 5430 may also include an additional channel 5440 that provides further cooling. The base 5430 can be formed from concrete, steel, other suitable metals, or a combination thereof.

[0223]

[0346] Figure 54A also shows that a cooling channel plenum 5460 may be provided at the contact surface between modular sections to account for any offset or alignment issues between the channels 5410 between modules. Alignment keys 5464 may also be provided to help guide adjacent modules to be properly aligned.

[0224]

[0347] In one implementation, the air or fluid channels 5440 can utilize passive flow through them. This further set of channels 5440 is located beneath the insulating layer 5420. This set of air channels 5440 has a chimney side and an inlet side, where heated air rises through the chimney side by buoyancy and thus draws in cooling air from the inlet side. In one implementation, the inlet channel may be on the right side of the TES, and the outlet channel with a vertical channel or chimney may be on the left side, or vice versa. The chimney can be positioned alternately on the low-temperature side and the high-temperature side along the length of the TES system. These channels may extend perpendicular to the active cooling channels. Optionally, they may be at other angles to the active cooling channels. These channels are short enough to allow passive flow to move sufficient air, but a blower or other active flow device may be used. This flow helps prevent the formation of hot spots, providing passive safety protection due to the drawn-in air or fluid, and preventing overheating of the soil or other materials below. The chimney can be configured to exhaust to the surrounding environment or to reuse the air for any use, including feedback to the TES system. Given that there may be a temperature gradient within the flow path, this design maintains the temperature within an acceptable range for the materials above and / or below the flow path 5440.

[0225]

[0348] Structural heating, which causes soil overheating, ultimately burns away moisture from the soil. This reduces the soil's load-bearing capacity. In most areas where structural systems are designed to account for soil temperature which is localized, typical soils have moisture at some depth. As this moisture leaves the soil, the structure of the clay or other soil material that supported the soil changes, and soil cracks widen. As the cracks widen, the soil contracts. As the soil temperature rises and the soil releases organic matter, water is released as well. Structures in the soil (specifically clay, etc.) have a disc-like structure. When water is present in the soil, the soil maintains horizontal and vertical spacing. As water is pushed out of the soil, soil particles aggregate, they lose their load-bearing capacity, and as a result, structures such as foundations on the soil may collapse.

[0226]

[0349] To mitigate soil cohesiveness, an insulating material, such as that shown in Figure 54B, between the heated material and the soil slows the rate at which heat passes through the soil. If the soil below must dissipate heat from the heated central area, it is a long path, resulting in hot, buoyant soil beneath the central part of the foundation. As will be discussed later, one or more mechanisms are provided to dissipate the thermal energy before it reaches the soil.

[0227]

[0350] In some implementations, high-density sand additives are included in low-thermal-conductivity refractory materials, such as the cement used in the base support. A high specific heat is desirable in the base support because it increases the time it takes for the heat-resistant material to reach the desired temperature for cooling by airflow, thereby maintaining the base support within a temperature range that does not adversely affect the geological formations beneath it. The storage area material, capable of withstanding high temperatures, also allows the system to accommodate single-shift operation, where the thermal energy storage system does not actively output heat 24 hours a day, but only for a portion of that time. "Sand" can specifically refer to olivine, barite Sg4.48, or other mineral particles. The heat storage capacity Q can be calculated as Q = V·ρc·ΔT, where, v is the volume of the material, ρ is the density of the material, c is the specific heat, ΔT represents the change in temperature. This means that the amount of heat per unit volume is not a function of density alone, and that simply increasing density can be misleading, especially when considering transport costs.

[0228]

[0351] Figure 54A shows an insulating gasket 5450 at the joint between adjacent base support structures. This insulating gasket 5450 prevents cooler outside air from leaking into the thermal energy storage medium. The insulating gasket 5450 also prevents thermal energy or heated gas from leaking from the thermal energy storage medium into the gap between the base support structures. The gasket may extend to the height of the heat-resistant layer, as shown in Figure 54B, and may have openings or holes in the gasket so as not to block the opening 5410.

[0229]

[0352] Figure 55 shows one implementation for joining multiple modules of a base support using a post-tensioning technique with tension rods or cables 5510. This is used to join all of the individual rafts or base support sections 5050 together to improve the structural rigidity of the system. Post-tensioning uses a prestressing method in which tension is applied to tendons or cables after the concrete has hardened, and the prestressing force is transmitted to the concrete mainly through end fasteners 5520.

[0230]

[0353] Figure 56 shows a cross-sectional view of the implementation configuration of the insulation and support layers beneath the heat storage medium. Figure 56 also shows the temperature conditions that each layer may experience. The second insulation layer 5610, adjacent to (and below in this configuration) the first insulation layer 5620 having an active air or fluid channel 5622, is important. Layer 5610 is a layer of high-value / high-performance insulation material, such as foamed glass insulation material like Foamglas® insulation material. Unfortunately, Foamglass® insulation material 5610 can only withstand temperatures of up to 400°C, preferably about 300°C or less. This high-quality insulation material 5610 can be used in this implementation configuration because the active insulation with an air or gas channel 5622 above reduces the temperature of the heat to an acceptable range for this high-quality layer. This high-quality layer provides a given level of insulation with a much thinner thickness than other insulation materials, and therefore the height (or depth to the soil) of the bottom of the TES system is reduced. Optionally, some embodiments may be configured without active air passages 5622 and instead rely on a thicker insulation layer 5620 to prevent any downward heat conduction toward the geological formation. There may be tiles 5630 having protrusions or recesses for interacting with the bottom layer of the thermal energy storage assembly 5640. The support structure 5650 can be configured to support various insulation layers thereon. Tracks 5660 for movable modular components of an external housing (not shown) and / or channels 5670 for electrical cables can also be connected to the support structure 5650.

[0231]

[0354] Figure 57 shows that the active cooling channel 5622 in Figure 56 can be configured and shaped to direct the fluid flow toward the heat exchanger of the steam generator. This air or fluid flow mixes with the output from the heat storage assembly, and the mixture enters the heat exchanger 5710 or other equipment that receives thermal energy from the heat storage assembly. Figure 57 is a cross-sectional view showing one implementation of the airflow in the TES system active cooling within a base support. Relatively cool air or fluid flows over the top of the heat storage medium as indicated by arrow 5110, then part enters the thermal energy storage assembly, and another part 5112 enters the active cooling channel 5622, flows beneath the heat storage medium as indicated by arrow 5020, and then finally merges with the output 5720 from the thermal energy storage assembly and flows together into the heat exchanger 5710.

[0232]

[0355] Figure 58 shows a cross-sectional view of the TES system along its longitudinal axis. Figure 58 shows that at least a portion of the air or fluid flows through the active cooling channel 5622, as indicated by arrow 5810, travels along the bottom of the heat storage medium, and then turns upward at the hot end to enter the air or fluid that enters the heat exchanger or other hardware that receives thermal energy from the thermal energy storage medium. For ease of explanation, the portion of air or fluid flowing through the thermal energy storage assembly 5812 is not shown in Figure 58. Figure 58 also shows additional cooling channels 5440, which are positioned in a layer below the cooling channels 5820 and can be aligned along an axis non-parallel to the channels 5820 (optionally substantially orthogonal).

[0233]

[0356] It should be understood that there may be one or more rows of inlet air or fluid channels and one or more rows of upward outlet openings from the air or fluid channels 5820. Such openings redirect the air or fluid flow toward a heat exchanger or other device that receives thermal energy from the heat storage assembly. Additional air or fluid channels 5440 may also be present in other layers of the insulation.

[0234] Electrical arrangement

[0357] Figure 59 shows that a base support, such as a raft, can support electrical wiring for supplying power to the electrical hardware and / or heater elements of the TES system. Figure 59 is a perspective view of one implementation of electrical cabling in a TES. Electrical wiring 5910 can be laid to extend from the electrical hardware and extend outward through one or more pass-throughs 5920 within the base support, such as a raft, to connect to heating elements in the thermal energy storage medium. Figure 59 also shows that in one implementation, heating elements can be wired to extend along an axis extending upward through the thermal energy storage medium, as indicated by arrow 5930. There may also be an electrical connector 5940 extending outward from the thermal energy storage medium, which allows coupling to power from electrical hardware located outside the thermal energy storage assembly. Figure 59 also shows a quarter-turn valve 5950 that serves as a heat dissipation port between the external housing and the thermal energy storage assembly.

[0235]

[0358] Figure 60 shows one implementation of the electrical system used in a TES system. Power from the power grid, local generators, and / or renewable energy sources supplies electricity to the electrical hardware 6010 of the TES system. Cable cabinets or other routes 6020 lay electrical wiring below, above, and / or around the thermal energy storage medium. The wiring may extend upward relative to the thermal energy storage medium, as indicated by the lines 6030. Although only two lines 6030 are shown, it should be understood that there may be wiring corresponding to each “row” (a substantially vertical subset) of heating elements within the thermal storage assembly. The circuit is then completed by return wiring 6040 connecting back to the electrical hardware 6010 as needed. In one implementation, there may also be heater elements such as a resistance heater 6050, which are then connected to the wiring along the lines 6030 extending into the thermal storage assembly.

[0236]

[0359] Figure 61 shows a schematic diagram of various components of one implementation form of the electrical arrangement of a TES system. Figure 61 shows that the electrical system layout includes a number of electrical systems, controllers, and subsystems in group 6110. The electrical systems and controllers in group 6110 can control the heater 6120 of the heat storage system 6130, which can include the upper plenum, the stack or assembly of heat storage blocks, and the base of the bolster blocks supporting these items. Various downstream systems that use thermal energy from the heat storage system 6130, such as steam generators and associated components, may be in group 6140.

[0237] Base layer insulation

[0360] Figure 62 is a cross-sectional view of one implementation configuration of an insulating laminate beneath a thermal energy storage medium. In one implementation configuration, the insulating laminate includes at least four layers. Layer 6210 is located directly beneath the heat storage block and may be a tile having a stabilization mechanism to hold the block in place. The tiles of layer 6210 may have a design mechanism to hold the tiles in place, or they may be fixed to the rest of the raft with mortar. Layer 6220 may include an insulating material that reduces thermal conductivity. Layer 6230 may include a ventilated slab layer, which allows some bypass air in the channel 6232 to cool the floor. In one example, the temperature of the air or fluid in the channel 6232 may be in the range of about 150°C to 200°C. Layer 6240 may be an insulating material that reduces the temperature at the contact surface between layer 6240 and the ground or soil layer 6250 to 80°C or less. Currently, layer 6240 may contain Foamglas® insulation or other foamed glass insulation. The thermal conductivity of layer 6240 may be any of the following: approximately 0.1 W / mK or less, approximately 0.4 W / mK or less, approximately 0.35 W / mK or less, approximately 0.3 W / mK or less, approximately 0.2 W / mK or less, or approximately 0.15 W / mK or less.

[0238]

[0361] Figure 63 shows a side cross-sectional view of a heat storage assembly on a base support. In this embodiment, each platform 6310 of the base support is designed to extend across the width of several (in this case, about 3.5) heat storage blocks. Optionally, each platform is designed to support a predetermined number of blocks at the contact surface where the platform and the blocks engage with each other. The position of the tiles 6320 beneath the heat storage blocks 6330 is configured to allow the blocks 6330 to be positioned adjacent to each other.

[0239]

[0362] Figure 64 shows an implementation configuration in which the heat storage blocks 6410 are stacked in a configuration where the joints between the blocks 6410 are staggered. The staggered arrangement of the joints between the heat storage block 6410 platforms can help stabilize the stack on the platform 6420. Furthermore, for platform integration, the platforms 6410 can be placed adjacent to each other and pressed together. Post-tensioning allows all components to be quickly retrieved.

[0240]

[0363] Figure 65 shows a cross-sectional view of an insulating layer 6510, which includes, but is not limited to, a network of metal plates, metal traces, or segments that direct heat along specific heat paths to cooling areas such as heat sinks or air or fluid channels 6530. In an exemplary implementation, when the insulating layer 6510 is incorporated into a base support as part of a layer 5620, excess heat is preferentially directed to areas of the layer 5620, such as air channels, which then direct that heat outward, away from the base support. This minimizes heat transfer to the geological formation.

[0241]

[0364] Figure 66A shows that multiple sections of the base support may have offset portions 6620 and overhang portions 6610 provided to facilitate positioning and interlocking with adjacent sections. This may include implementations that provide overlap between raft platforms and restrict or block airflow. This may include staggered layers of platform to block radiation or fluid paths between platform layers. Figure 66B shows that several implementations can add rigidity by adding lift bars 6630 that extend over a portion, possibly a substantial portion, or the entire length of the platform. These may have offsets designed within them, and the lift points are optionally positioned at a certain distance from the assembly so as not to cause friction with the heat storage block.

[0242]

[0365] Figure 67A shows that there may be multiple rows of flow channels 6710 in one or more insulation layers. Figure 67B shows how the flow channels may have larger openings at the contact surfaces 6720 between platform sections to compensate for any misalignments resulting from manufacturing and / or assembly issues. These implementations may use cooling flow channels that may be in the form of a single ventilated slab with multiple layers. To ensure there is no loss of air or other problems due to misalignment, there may be a “plenum” (a sealed volume where air or fluid passes through and / or mixes with other air or fluid) at the passage point. Some implementations may use “ventilated flow channels” (air passages) through the floor. During discharge, it draws in ambient air. During charging, the flow channel expels air (which is essentially the temperature of the return water at that point), and the floor helps to extract energy from this flow and further reduce losses.

[0243]

[0366] Figure 68 shows a cross-sectional view in which there may be multiple ventilation layers 6810 and 6820 above or below other insulation layers. In one implementation configuration, the flow within ventilation layers 6810 and 6820 may all be in the same direction. Optionally, in some implementation configurations, the flow within ventilation layers 6810 and 6820 may be in opposite directions. Specifically, the implementation configuration in Figure 68 shows a first insulation layer, such as calcium silicate or other suitable insulating material, a second insulation layer 6832, made of the same material as the first layer 6830, positioned adjacent to (in this embodiment, below) the ventilation layer 6820, and a third insulation layer 6830, positioned adjacent to (in this embodiment, below) the ventilation layer 6840. The third layer 6840 can be made of Foamglas® insulation and / or other foamed glass insulation materials. Having two active channels 6810 and 6820 ensures that more heat is directed away from the system before it reaches the third layer 6840. The thermal conductivity of the third layer 6840 may be in the range of approximately 0.035 to 0.037 W / mK. To reduce the thermal energy reaching the geological or soil layer 6870, there may be a support structure 6850 below the third layer 6840 that has an internal air or gas channel 6860 for additional cooling to a lower temperature (e.g., in the range of approximately 30 to 40°C).

[0244] Heat dissipation port

[0367] Figure 69A shows a cross-sectional view of one implementation of a TES system equipped with a heat exhaust port (TEP) 6910. The TEP 6910 can allow the discharge of heated air or fluid from within the TES system when rapid shutdown or cooling is desired for proper system operation. The TEP is optionally configured to open automatically in the event of a power outage, as described in the fail-safe vent system described above in U.S. Patent No. 11,603,776.

[0245]

[0368] Figure 69B shows an enlarged perspective view of one implementation configuration of the TEP6910.

[0246]

[0369] Figure 70 shows yet another implementation configuration in which the TEP7010 exhausts into another enclosure 6910 that is sealed from the external environment. The enclosure 7010 may have one or more parts that are thermally conductive along the outer wall 7010 to release heat from the gas or fluid inside the enclosure 7020, but are still fluidly sealed from the surrounding environment. This results in a sealed heat exchanger with a path from an insulated area to a sealed non-insulated area having heat dissipation fins or zones. After reaching a desired predetermined temperature, cooler air or fluid is returned to the inner enclosure through a pump, valve or path 7020. This enables lead-lag operation with cooling in a sealed environment.

[0247]

[0370] A sealed heat exchanger allows for the use of nitrogen, argon, other noble gases, or even other fluids or gases in a TES, where releasing them into the ambient environment would otherwise incur exorbitant costs. Furthermore, if the TES has heaters or other components that degrade or malfunction when exposed to ambient air, allowing outside air to enter the TES may be undesirable. Optionally, the heater element in the TES may be a graphite heater. By operating the system in a sealed environment including nitrogen, argon, or other noble gases, or an inert environment, graphite heaters can be used in a TES system, which further means storing heat at higher temperatures, such as 1300°C or above, allowing for 60% more heat storage in a TES of the same size, or enabling the TES system to store the same heat in a much smaller footprint TES operating at higher temperatures. Although only one TEP is shown, it should be understood that multiple TEP units may be used to provide the desired cooling for the TES system. Naturally, the TEP6910 can be used with other types of valves or ports, such as quarter-turn valves or other suitable valves, though not limited to them.

[0248]

[0371] The raft or base support structure may have a mechanism that integrates and becomes part of a “bottle-up” protection system when there is little to no airflow through the heat storage assembly. In one implementation, there is an air passage that connects to an external structural air passage (a cavity in the sheet metal panel and a mineral wool insulation layer) on the opposite side of the raft, providing ventilation to a larger space within the TES system. In this bottle-up protection mechanism, the adjacent air passage, in other words, the next section of the air passage or cavity in the external structure, will have airflow in the opposite direction. This balances the airflow.

[0249]

[0372] In one implementation, recharging of the TES system after shutdown or bottle-up can be performed using a control scheme involving horizontal segmentation of the power input. This is desirable for the graphite elements in each circuit, as the resistance of graphite is greater than that of some metal heater elements. In one example, an 11-element series loop of 7 parallel wires used for the metal elements becomes five sets of parallel graphite loops of 2 or 3 elements in series. Each parallel loop has the same resistance. More specifically, each of the 24 thyristors is followed by at least three switches, each on a parallel circuit of 2 or 3 elements in series, controlling the upper seven elements. The lower four elements are directly connected as two circuits of 2 elements in series, without any switches. All five circuits have substantially the same resistance. Restarting in a state of degraded temperature stratification is performed with the upper three circuits switched off. Optionally, other implementations may use a different number of circuits that are switched off. When the lower circuit reaches the same temperature as the middle circuit, the middle circuit also becomes operational, and similarly the two upper circuits become operational, so that all blocks reach the same temperature when charged.

[0250]

[0373] Here again, if the temperature stratification is degraded, the lower loop will receive more power than the upper loop, and each inclined column of the block will reach the same temperature once charging is complete. In this example, there is no need to waste energy preparing to resume charging. This combination of thermal vapor lock and the use of parallel elements with horizontal heating control eliminates the need for any cooling of the lamination, nor the need for emergency lamination or roof cooling by a boiler.

[0251]

[0374] Thermal vapor lock eliminates emergency heat dump and energy waste to protect the boiler. If the increase in parasitic losses due to this thermal vapor lock becomes unacceptably large, a damper may be installed on the exhaust side of the fan that locks the plenum, which, along with "bottle-up" of the cooling end of the block stack, and building cooling due to the active insulating effect, prevents the emergency stack from being used. Optionally, a backup feedwater pump of much lower capacity may be used to maintain boiler idling.

[0252] Heating element wiring configuration

[0375] Figure 71 shows a side cross-sectional view of a heat storage assembly 7110, which includes a plurality of thermal energy storage blocks 7120 and a plurality of support blocks 7130 that are not adjacent to the heating element 7140. The heating element 7140 is aligned to operate in an orientation substantially coinciding with the dotted line 7142 (only one set of heating elements 7140 is shown for ease of illustration, but it should be understood that all gaps or receiving channels between the heat storage blocks 7120 can be filled with heating elements 7140). The dotted line 7142 is aligned substantially parallel to the fluid isotherm for a desired substantially horizontal temperature stratification in the heat storage medium. By aligning the heating element 7140 parallel to the fluid isotherm at the temperature stratification angle (either a non-parallel angle as shown in Figure 71, or an arbitrarily selected substantially orthogonal angle), the system can avoid imbalances that could cause problems in the operation of the heating element in the storage medium, such as some heater elements overheating due to a portion of the heating element along line 7142 becoming too hot compared to other heating elements along the same line. As seen in Figure 71, the heater element line 7142 can be substantially parallel to line 7144, which aligns with the outlet surface of the heat storage assembly, and this includes a substantially right angle to the longitudinal dimension of the heat storage assembly (which is substantially parallel to the temperature stratification), regardless of the angle at which the outlet surface is located. Thus, in this configuration, the angle of the temperature stratification isotherm coincides with the orientation of the heater element.

[0253]

[0376] Figure 72 shows another implementation of the heat storage assembly 7210, which includes a plurality of thermal energy storage blocks 7220 and a plurality of extension blocks 7230 that are not adjacent to the heating element 7240. The extension blocks 7230 are longer than the blocks 7220 so as to form a flat surface for the ends of the block assembly. Without the extension blocks 7230, the ends of the heat storage medium may have a jagged contour due to the alternating stacking of the heat storage blocks.

[0254]

[0377] In this implementation, the heating elements 7240 are wired in an alternating zigzag pattern, but the overall configuration is vertical, as shown by the dotted line 7242. In this way, the angles of the isotherms of temperature stratification over at least a large portion of the heat storage medium coincide with the orientation of the heater phase. As seen in Figure 72, the line 7242 of the heater elements can be parallel to the line 7244 that aligns with the outlet surface of the heat storage medium.

[0255]

[0378] Resistance heaters can be controlled to selectively heat the laminate. For example, vertical temperature stratification may occur when the system has not been charged for a period of time (e.g., due to the buoyancy of hot air being discharged from the outlet end of the assembly, rising and heating the hotter parts, which can occur even if the horizontal flow paths are fluidically sealed to each other). In this case, the lower part of the laminate can be selectively heated if the lower part is not yet at the desired temperature, i.e., there are no fluid vertical isotherms. Other selective heating modes may be used, for example, if the assembly is at a substantially uniform temperature (e.g., starting from a low temperature), the front part of the assembly (closer to the outlet) may be heated stepwise with preference over the rear part to generate temperature stratification from the fluid inlet end to the outlet end. This "primes" the temperature stratification. As air or other fluid passes through the assembly, the desired horizontal temperature stratification is generated (when starting from a low temperature) or enhanced and increased if primed by differential heating. Thus, the controller can control different parts of the laminate separately. This can be achieved by providing different amounts of total power to different heaters within a given time, for example, by turning heaters located in different places on and off for different durations to generate differential heating. The controller can set the power, temperature, and timing for heating the layers of the laminate based on sensor feedback, measurements of the resulting steam, and / or other empirical measurements, and / or system simulations.

[0256] Fault-tolerant heating element

[0379] Figure 73 shows one implementation configuration of a heating element 7310 positioned between two or more heat storage blocks 7320 and 7322. The heating element 7310 includes one or more heater wires 7312 and one or more wire supports 7314 and 7316. In one implementation configuration, one of the wire supports 7314 supports the multiple heater wires 7312. In some implementation configurations, it should be understood that the heater wires 7312 can loop over one or more supports 7314 in a repeating or wavy manner. One or more wire supports 7314 can be positioned so as not to block air or gas flow openings 7330 within the heat storage block 7320. Figure 73 shows only a portion of the heating element 7310. For ease of illustration, not all wire supports 7314 and heater wires 7312 are shown. The heating element 7310 can be configured to extend across the entire space between block 7320 and block 7322, and it should be understood that it repeats the pattern of the heater wire 7312 and wire supports 7314 and 7316 as shown in Figure 73.

[0257]

[0380] In one non-limiting example, one or more heater wires 7312 may be made of a material that is electrically resistant to generate heat. Optionally, some implementations may use a material such as graphite, which can also generate heat when electricity flows through it. Naturally, other suitable materials that can generate thermal energy when electricity is guided through them may be used. Furthermore, other types of materials that generate heat or provide thermal energy without the use of electricity may be used. For example, some implementations may use conduits that transport molten salt, hot steam, or other hot materials in the space between the heat blocks 7320.

[0258]

[0381] Figure 74 shows an implementation configuration of heater element 7410 to improve the fault tolerance of the heater element. In this example, all four wires 7412 each contribute a quarter of the entire circuit. If one of the four wires 7412 is broken, damaged, or otherwise faulty, the remaining wires 7412 will bear the entire load, causing the temperature of each wire to rise and shortening their lifespan. When the wires become hot, they may begin to overheat the heat storage block 7320 around the wires, which can create undesirable hot spots within the thermal energy storage system.

[0259]

[0382] In this implementation, the bottom heater element support 7420 may be made of a conductive metal or other material such as a conductive ceramic. Optionally, the support 7420 may be made of a ceramic material (whether conductive or not) with a metal busbar or connector that electrically connects all of the heater wires 7412 together. In this way, the bottom metal heater element support 7420 rebalances the voltage potential of all four wires if one or more of the heater wires 7412 fail. This localizes the fault to the section of the heater wire where the fault occurred, minimizing the distance to the nearest metal bottom heater element support 7420. Optionally, some but not all of the bottom wire support 7420 may be conductive or support conductive bars or other connections. All or some of these conductive bottom wire support 7420 may be punched, forged, or otherwise formed from a conductive material such as high-temperature steel, iron alloy, FeCrAl, or other suitable conductive material, but are not limited to. Optionally, one or more of the top heater wire supports 7422 may also include a portion of the metal or other conductive material described above to address any faults in the heater wire. Thus, in at least some implementations, instead of a single circuit, the heating element 7410 can be configured in parallel circuits in at least some parts of the heating element, providing redundancy and automatically electrically avoiding any defects in the heater wire that could otherwise cause undesirable overheating in one or more parts of the thermal energy storage system.

[0260]

[0383] As can be seen from Figures 75A and 75B, in this way, a fault F in any one of the heater elements 7410 does not negate the entire length of the heater element because the conductive heater element support 7420 provides one or more electrical paths to rebalance the voltage potential. Figure 75A shows an end view of the heating element 7410, and Figure 75B shows a side view of the same heating element 7410. In this configuration, the fault F is limited to affecting the heater wire 7412 in the area indicated by the dashed box 7520 in Figure 75B. The conductive wire support 7420 provides a path parallel to the fault F, rebalancing the voltage potential. This minimizes the amount of overheating that could occur if three heater wires instead of four were handling the electrical load, which could result in more heat being transferred to these heater wires because they are carrying more electrical load than if all four wires were fully functional and the electrical load were distributed across all four wires. Without the redundancy provided via the conductive wire support 7420, the area affected by excessive heating associated with carrying the load with three heater wires instead of four would be much larger than that shown by the dashed box 7520.

[0261] Figure 76 is a schematic top view of the heating element 7410, showing a configuration for conducting current around any fault F in one or more heater wires 7412 through connections in the conductive wire support 7420. Specifically, Figure 76 shows how the electrically parallel configuration provided by the conductive wire support 7420 allows for rebalancing of the voltage potential around any fault F that may occur in the heater wires 7412. Being able to operate the heat storage system even if there may be damage or fault in the heater wires 7412 extends the interval between system maintenance and allows the system to operate in a functional manner before being taken offline for repairs.

[0262] Heat storage block

[0384] Referring here to Figures 77 to 98, exemplary implementation configurations relate to thermal energy storage blocks, as well as associated support blocks and support slabs, used in thermal energy storage systems for various industrial applications.

[0263]

[0385] The structure and shape of a heat storage block are configured to repeatedly heat and cool for the purpose of storing energy. When implemented in a thermal energy storage system, the energy input is provided in the form of electrical energy, which heats wires, filaments, rods, other solid conductive materials, or other types of materials to release radiant thermal energy. The energy output is in the form of heat, which is supplied to a circulating gas or to conduits that carry gas or fluid, introduced in a part of the structure incorporating the block and moving away from another part of the structure at a higher temperature.

[0264]

[0386] The blocks may be in the form of one or more cast, pressed, or extruded shapes and may be arranged in alternating rows along both the vertical and horizontal axes. The structure comprises a number of open radiating cavities (also called radiating chambers) and blocks, each containing an air passage having at least one dimension much smaller than the other two dimensions. The passage opens into the radiating chambers, and its interior is exposed to the radiating surface heated by electrical resistance. Within the chambers, heat is transferred by thermal radiation from a relatively hot surface to a relatively cold surface according to the Stefan-Boltzmann law, and accordingly, the total energy radiated per unit surface area of ​​the blackbody per unit time (radiative divergence) is proportional to the fourth power of the blackbody temperature. Thus, heating (i.e., charging) of the thermal energy storage system by radiation is rapid and efficient. This is described in detail in U.S. Patent No. 11,603,776 mentioned above.

[0265]

[0387] Figure 77 shows a schematic perspective view of a thermal energy storage block 7700 in one implementation configuration. The block 7700 is formed of a thermal storage material which may be concrete and / or other heat-resistant material.

[0266]

[0388] The block 7700 includes fluid flow slots 7702 or channels provided in a first direction (horizontally) through a portion of the block. The fluid flow slots 7702 may have a shape in which the width is greater than the height and may have a substantially constant cross-section along their length. The fluid flow slots allow the passage of fluids such as air, nitrogen, argon, carbon dioxide (CO2), steam, process gas, inert gas, hydrogen, or other fluids.

[0267]

[0289] Furthermore, a thermal radiation cavity 7704 is provided within the block, defining the space, and thermal energy can be transferred to the exposed surface of the block by radiating thermal energy from an adjacent electric heater into this space. Each thermal radiation cavity 7704 extends in a second direction perpendicular to the first direction, from the lower solid base portion 7720 of the block to the upper solid platform portion 7730. By extending within the block, the thermal radiation cavity provides a large surface area, and thermal energy can be efficiently transferred to the material of the thermal energy storage block by radiating thermal energy from an adjacent heater element (not shown) onto it.

[0268]

[0390] The thermal radiation cavities 7704 are provided on opposing faces of the block in an alternating or offset configuration, with their openings located on two opposing faces. As a result, the faces of the block through which fluid flows in or out are defined by the alternating arrangement of fluid flow slots 7702 and thermal radiation cavities 7704.

[0269]

[0391] The concave side wall 7714 of block 7700 also forms a partial thermal radiation cavity 7706. The partial thermal radiation cavity 7706 becomes a complete radiation cavity when block 7700 is placed adjacent to another block 7700. In particular, the side wall of the adjacent block 7700 forms the remaining wall, converting the partial radiation cavity into a complete radiation cavity.

[0270]

[0392] A pair of fluid flow slots 7702 extend from each of the thermal radiation cavities 7704, including a partial thermal radiation cavity 7706, and are in fluid communication with each of the thermal radiation cavities 7704. As a result, the pair of fluid flow slots and each of the thermal radiation cavities together define a fluid flow path through the energy storage block. Such a path is generally in the first direction (horizontal).

[0271]

[0393] Block 7700 includes one or more integrated shelf sections 7710. The shelf sections 7710 can be used to support heater elements in the gaps between rows of the heat storage block 7700, adjacent to the heat radiation cavity, as will be discussed in more detail later.

[0272]

[0394] Block 7700 also includes apertures 7712 passing through the upper solid platform portion 7730 and the lower solid base portion 7720 of block 7700. These apertures 7712 may be the same size and / or shape as, or different in shape from, the other fluid flow slots 7702 in the thermal energy storage block 7700. The openings of different sizes are selected overall so that the flow rates are substantially the same between the different paths. The apertures 7712 may also be smaller in size to avoid air passing through any mechanisms in the block, such as recesses, that could obstruct fluid flow. The apertures 7712 can dissipate excess heat in the inherently solid sections of the storage block, reducing structural stresses that may occur if those solid sections retain excess heat compared to the rest of the thermal storage block. The apertures may extend throughout the block, thereby defining fluid flow paths through the block from one side of the storage block to the other side of the storage block. In the alternative implementation configuration, to improve structural strength, the upper solid platform portion 7730 and the lower solid base portion 7720 of block 7700 are closed without apertures or paths passing through them.

[0273]

[0395] Figure 77 also shows the interlocking mechanism 7708 provided on the upper surface of the upper solid platform portion 7730 of block 7700. As shown in Figure 78, a corresponding interlocking mechanism 7816 is provided on the underside of the lower solid base portion of block 7700, and they are configured or shaped to engage with the interlocking mechanism 7708 provided on the upper surface of block 7700. As a result, blocks can be stacked with the interlocking mechanism 7708 on the upper surface of one block engaged with the corresponding interlocking mechanism 7816 on the underside of the block above. The interlocking mechanism can resist lateral movement and maintain alignment even in the case of vertical movement.

[0274]

[0396] The interlocking mechanism may take the form of protrusions (or projections) 7708 and recesses 7816. As shown in Figures 77 and 78, the interlocking mechanisms are arranged on each surface in a regular pattern, such as a square or rectangular arrangement. The spacing between the interlocking mechanisms is provided to allow for an alternating, overlapping, stacked arrangement (as will be further discussed later).

[0275]

[0397] Figure 79 shows a front view of the thermal energy storage block 7700. As described above, this side of the block through which fluid flows in or out has an alternating arrangement of rows of fluid flow slots 7702 and rows of thermal radiation cavities 7704. As shown, fluid flow slots 7702 are also provided, extending from the far end of the radiation cavities 7704 through the interior of the block 7700 to the opposite side of the block 7700. As a result, the side of the block opposite to the side shown in Figure 79 has essentially the same appearance as the side shown.

[0276]

[0398] Figure 80 shows a cross-sectional view of the block along the cross-section EE as shown in Figure 79. As shown in Figure 80, the fluid flow slots 7702 extend from each thermal radiation cavity 7704 and are in fluid communication with each thermal radiation cavity 7704. The apertures 7712 also extend throughout the entire depth of the block, thereby defining further fluid flow paths through the block.

[0277]

[0399] Figure 81 shows a top view of block 7700. Viewed from above, block 7700 has an asymmetric shape with respect to the longitudinal axis indicated by the dotted line 8110. Block 7700 has two sides with straight edges 8130, 8132 and two molded edges 8120 8122 having shapes such as, but not limited to, a wavy or zigzag profile. In other words, edges 8120 and 8122 may have notches in the diagonally opposite regions.

[0278]

[0400] Figure 82A shows a side view of block 7700, corresponding to block 7700 as shown in Figure 79, rotated 90 degrees around the central vertical axis. A partial thermal radiation cavity 7706 on one side of the block is shown.

[0279]

[0401] Figure 82B shows a cross-sectional view of block 7700 along line DD as shown in Figure 82. The cross-section is between fluid flow slots 7702, and slots 7702 are not visible in the cross-sectional view. The cross-sectional view shows the staggered arrangement of thermal radiation cavities 7704 on both sides of block 7700. The thermal radiation cavities 7704 extend into the body of block 7700. As shown, the cavities can extend to nearly half the depth of the block. Widening openings 8210 may be provided in the thermal radiation cavities 7704. Such openings 8210 help to collect fluid into the cavities and ultimately into the fluid flow slots 7702.

[0280]

[0402] Figure 83A shows a side view of block 7700 corresponding to the diagram shown in Figure 82A. Figure 83B shows a cross-sectional view of block 7700 along line EE as shown in Figure 83A. This cross-section is at a different height than the cross-section shown in Figure 82B. In this case, the cross-section intersects with the layer of fluid flow slots 7702. As shown, the fluid flow slots 7702 extend from the rear of each of the thermal radiation cavities to the opposite side of the block, so that the thermal radiation cavities 7704, 7706 and the fluid flow slots 7702 together define a fluid flow path through the block.

[0281]

[0403] Figure 84A shows a side view of a stacked assembly 8400 or structure of blocks 7700. Each block 7700 is shown in a side view, as shown in Figures 82A and 83A, with fluid flow slots (not shown) extending horizontally. From the illustrated side view, there are gaps 8410 between each of the blocks 7700 in a row. The blocks in the upper layer are staggered or laterally offset from the blocks 7700 in the lower row.

[0282]

[0404] Figure 84B shows a cross-sectional view of the assembly along line AA as shown in Figure 84a. As shown in this cross-sectional view, there are no gaps between adjacent blocks in the same layer, as the blocks fill the space completely.

[0283]

[0405] Figure 84C shows an enlarged view of the region labeled "B" in Figure 84B. As shown, the projection 7708 on the upper surface of the lower block 7700 engages with the recess 7816 on the lower side of the upper block 7700 in the stacked arrangement.

[0284]

[0406] Figure 84D shows a plan view of the laminated assembly 8400. The blocks 7700 are arranged so as to fill the gaps without gaps to form rows in a first direction, and so as to have gaps 8410 between each such row in a given layer in a second direction perpendicular to the first direction. The blocks 7700 of the upper layer are offset laterally in both the first and second directions (perpendicular to the first direction) so that they span the gaps 8410. As a result, the gaps 8410 between adjacent layers of the laminate are also offset. Each block 7700 of the upper layer engages with four different blocks 7700 of the lower layer. As a result, a recess 7816 of a given block 7700 of the upper layer engages with a projection 7708 of four different blocks 7700 of the lower layer.

[0285]

[0407] Figure 85 shows a perspective view of the laminated assembly 8400, illustrating the offset, fill, and gaps between blocks 7700 as described above.

[0286]

[0408] As shown in Figure 86, the gaps between adjacent rows of blocks are provided to accommodate an electric heating element 8440 for transferring thermal energy to the blocks for storage. The electric heating element 8440 is positioned adjacent to the thermal radiation cavity 7704. The heating element 8440 can be positioned across rows of thermal energy storage blocks 7700. The heating element can be held by a support structure (not shown) that engages with an integrated shelf 7710 within the block. The support structure (not shown) may extend across the gaps between rows of blocks so as to engage with the integrated shelf 7710 on both sides of the gap.

[0287]

[0409] Figure 87 shows an alternative implementation of block 8700. Block 8700 has the same mechanism as block 7700, as described above. The corresponding mechanisms of the blocks are given the same reference number. Block 8700 is provided in a wider format than block 7700. In particular, the wider block 8700 has additional rows of thermal radiation cavities 7704 and fluid flow slots 7702. Visible on the illustrated surface are three thermal radiation cavities 7704, one partial radiation cavity 7706, and four sets (or rows) of fluid flow slots 7702. The corresponding cavities 7706 and slots 7702 are also formed on the opposite surface (not shown). A given block 8700 has eight projections 7708 on its upper surface and eight corresponding recesses (not shown) on its lower surface. The wider format of block 8700 allows for fewer blocks to be used when forming a stacked assembly of a given thermal storage capacity than when smaller blocks (such as block 7700) are used.

[0288]

[0410] Figures 88A to 88C show another alternative implementation of block 8800. Block 8800 has the same mechanism as block 7700, as described above. The corresponding mechanisms of the blocks are given the same reference number. Block 8800 is provided in a deeper format than block 7700. From the front view, block 8800 corresponds to block 7700 in terms of the number of rows of thermal radiation cavities and slots. In the deeper structure, the fluid flow slots 7702 and thermal radiation cavities 7704 also need to extend further between the side faces of the block separated by a longer distance. As shown in Figure 88C, block 8800 has six projections 7708 on its upper surface and six corresponding projections 7816 on its lower side.

[0289]

[0411] Figures 89A and 89B show perspective views of the support block 1000 or pillow beam for supporting the thermal energy storage block described above. The support block 1000 is designed to provide fluid flow from below the thermal energy storage block and to insulate the thermal energy storage block from the surrounding medium. In particular, the thermal energy storage block may be heated to temperatures that the surrounding medium or structure cannot tolerate.

[0290]

[0412] As shown in Figure 89A, the support block 8900 is provided with an upper platform portion 8920, an opposite base portion 8930, and a hollow channel 8902 between the upper platform portion 8920 and the base portion 8930. The hollow channel 8920 defines a fluid flow path through the support block to allow fluid to flow around the stacked structure of the thermal energy storage block.

[0291]

[0413] Opposing first support wall 8940 and second support wall 8942 extend between the upper platform portion 8920 and the base portion 8930. The hollow channel 8902 is bounded by the upper platform portion, the base portion, and the opposing first and second support walls.

[0292]

[0414] The side walls 8930 of the block are concave or recessed so that when a support block is placed adjacent to another of the support blocks during use, one or more additional hollow channels are formed, thereby defining one or more additional fluid flow paths. In other words, the upper platform portion 8920 and the base portion 8930 extend laterally beyond the support walls 8940, 8942 to form concave regions that form partial channels.

[0293]

[0415] The support block 7700 is also provided with an interlocking mechanism in the form of a projection 8908 on the upper surface of the upper platform portion of the support block. The form and purpose of these projections 8908 correspond to those of the thermal energy storage block as described above. The projections 8908 engage with the recess 7816 on the lower side of the thermal energy storage block, thereby enabling the thermal energy storage block to be supported on the upper platform portion of the support block 8900. As shown in the figure, the four projections can be arranged in a square or rectangular configuration.

[0294]

[0416] As shown in Figure 89B, the support block 8900 may be provided with an interlocking mechanism on the underside of the base portion 8930 of the support block 8900. Such an interlocking mechanism may take the form of a recess 8916 into which a projection 8908 engages, is formed, and positioned.

[0295]

[0417] Figure 90A shows a front elevation view of the support block 8900. As shown, the hollow region 1002 provides a fluid flow path that extends through the support block.

[0296]

[0418] Figure 90B shows a plan view of the support block 8900. As shown in the figure, the protrusions 8908 are arranged in a grid pattern on the upper surface of the upper platform portion 8920 of the support block 1000.

[0297]

[0419] Figure 90C shows a view of the support block from below. As shown in the figure, the recesses 8916 are arranged in a grid pattern on the underside of the base portion of the support block 8900.

[0298]

[0420] Figure 91 shows a perspective view of another implementation configuration of the thermal energy storage block 9100. This implementation configuration facilitates faster manufacturing in light of its simpler design. In particular, the thermal radiation cavity is formed by the arrangement of multiple blocks 9100 (as will be discussed later) rather than being formed in the individual blocks themselves.

[0299]

[0421] The block 9100 is formed in a substantially parallelepiped or cuboid shape. Multiple fluid flow slots 9102 extend through the block 9100 in a first (horizontal) direction, thereby defining fluid flow paths that penetrate the block 9100 in a similar manner to the fluid flow slots described above. The block 9100 is also provided with two chamfered edges 9118 extending in a second (vertical) direction perpendicular to the first direction. The chamfered edges 9118 are configured such that, during use, the block 9100 abuts against at least one other part of the block 9100, and each chamfered edge engages to define a thermal radiation cavity.

[0300]

[0422] Block 9100 also includes an integrated shelf section 9110 configured to support the heating element in a similar manner to the integrated shelf section described above.

[0301]

[0423] The chamfered edges 9118 are both provided on the edges between the front surface of block 9100, where the fluid flow slots 9102 are formed, and the side surface 9120 of block 9100, which may be a relatively wide surface. The integrated shelf 9110 is provided on the opposite front surface 9130 of block 9100, where the fluid flow slots are formed. Block 9100 is symmetrical with respect to a vertical plane, which has a first and second direction, a normal to a third direction perpendicular to the first and second directions, and intersects the two front / end surfaces through their respective centers.

[0302]

[0424] Figure 92 shows an assembly of blocks 9100 arranged on a support slab 9700. The support slab will be described in more detail later. The blocks 9100 on the support slab 9700 are arranged in pairs of rows extending in a third direction (perpendicular to the first and second directions and parallel to the surface of the slab 9700), with gaps 9240 between the side surfaces 9120 of the blocks 9100 in a given row. The next row in a pair of rows is positioned directly adjacent to the first row and facing the first row, but offset in the third direction to align with the gap 9240 so that the chamfered edges engage. As a result, the gap 9240 forms a thermal radiation cavity bounded by the front / end face of one block 9100 and the side walls of the two other blocks 9100. Such a radiation cavity 9240 is in fluid communication with a fluid flow slot 9102 extending in the first direction through the block 9100. As a result, the thermal radiation cavity 9240, together with the fluid flow slot 9102, defines the fluid flow path through the assembly. The corresponding arrangement of block 9100 is also located on the underside of slab 9700.

[0303]

[0425] Pairs of rows of blocks 9100 on the slab 9700 are arranged with a gap 9260 between them, and their respective shelf portions 9110 facing each other. As a result, as shown in Figure 93, the electric heating element 9282 is positioned within the gap 9260 between pairs of rows of blocks 9100 so as to be adjacent to the heat radiation cavity 9240, and therein it can radiate thermal energy and thereby store thermal energy in the block 9100. The heating element 9282 is held by a support structure 9280 that engages with the integrated shelf portion 9110 in the block.

[0304]

[0426] Figure 94 shows a perspective cross-sectional view of the arrangement shown in Figure 91. This cross-section shows a fluid flow slot 9102 in the form of a channel, extending horizontally through block 9100 and communicating fluidly with the thermal radiation cavity 9240.

[0305]

[0427] Figure 95 shows a plan view of the arrangement of the blocks 9100 described above. The gaps 9240 and 9260 between the rows and blocks are shown, as is the engagement of the chamfered edges 9118.

[0306]

[0428] Figure 96 shows a side elevation view of the arrangement of the blocks 9100 described above. The blocks 9100 are provided in an alternating or offset arrangement both above and below the supporting slab 9700.

[0307]

[0429] Figure 97 shows an upper perspective view of the support slab 9700 used in the block 9100 as described above. The support slab 9700 has a plurality of concave bays 9702 formed on the upper surface of the slab, each concave bay being shaped and configured to hold a thermal energy storage block therein. The concave bays are spaced apart and arranged in rows, providing suitable gaps for spaced-apart thermal energy storage blocks in the manner described above, forming thermal radiation cavities and providing space for electric heater elements. Two of the support slabs 9700 can abut each other as shown in Figures 91 to 94 to form a pair of rows of the block 9100 as described above.

[0308]

[0430] In particular, the concave bays 9702 are formed in rows with spacing between them, and the concave bays 9702 of adjacent rows are offset so that when the blocks 9100 are placed in each bay 9702 as described above, the blocks 9100 form thermal radiation cavities between them. The concave bays 9702 of adjacent rows are offset so that the concave bays of one row align with the center of the gap between consecutive concave bays of adjacent rows. In this way, two of the supporting slabs 9700 can be combined to form a pair of rows of blocks 9100 having thermal radiation cavities 9240 as described above.

[0309]

[0431] Figure 98 is a lower perspective view of the support slab 9700 used in block 9100. Corresponding to the upper surface, the bottom side of the support slab 9700 also includes a concave bay 9704. The bays 9704, in their form and arrangement, correspond to the bays formed on the upper surface of the support slab 9700, but can be laterally offset to form the staggered configuration shown in Figure 95. This allows the support slab 9700 to enable a stacked arrangement of thermal energy storage blocks 9100 having support slabs between adjacent layers of the stack.

[0310]

[0432] Summary of Claims relating to Implementation Modes of the Invention

[0433] TES with raft support layer

[0434] A thermal energy storage (TES) system, Thermal energy storage medium, A support structure having multiple fluid channels, a base including a first insulating layer positioned on the support structure and configured to resist a first temperature without damage, and a second insulating layer adjacent to the first insulating layer and configured to resist a second temperature without damage, wherein the second temperature is higher than the first temperature, Multiple heater elements positioned to heat the thermal energy storage medium via energy radiated onto at least one radiation chamber of the thermal energy storage medium, A TES system including this.

[0311]

[0435] The TES system can be configured to include one or more of the following features: The storage medium is formed from layers of interlocking heat storage blocks. The support structure is positioned on a gravel foundation. • The support structure includes metal. The support structure includes multiple fluid channels. • The supporting structure includes reinforced concrete. • The supporting structure includes reinforced concrete and metal. • An insulating layer positioned adjacent to the storage medium. • A fixing strap positioned on the outer surface of the insulation layer and configured to secure the storage medium against earthquakes. A segmented external enclosure detachably mounted to a foundation, wherein each segment of the external enclosure is configured to be removed and / or opened independently of the other segments. The external enclosure includes the upper frame, end walls, and insulation layer. • One end of the storage medium includes at least two different types of heat storage blocks. • The TES includes a plenum at the rectangular or stepped end of the storage medium. The TES includes one or more support blocks below the inverted terrace end of the storage medium. The TES includes one or more support blocks below the inverted ziggurat end of the storage medium. The term "inverted ziggurat" is used here to refer to an inverted stepped configuration in which the upper layer protrudes over the edge of the lower layer, as shown, for example, in the area of ​​support block 3322 in Figure 33 and support block 4022 in Figure 40A. The support tiles are positioned below the storage medium, but above the insulation layer of the raft. • The piping can transport water or other fluids for cooling the support structure.

[0312]

[0436] TES with multiple storage assemblies and a common heat exchanger / steam generator

[0437] A thermal energy storage (TES) system, The first assembly of the heat storage material, The second assembly of the heat storage material, A heat exchanger assembly that is in fluid communication with the first assembly and the second assembly, Includes, The first assembly is configured to provide a first thermal output to the heat exchanger assembly. A TES system in which a second assembly is configured to provide a second heat output to a heat exchanger assembly.

[0313]

[0438] The TES system can be configured to include one or more of the following features: The first assembly includes multiple thermal energy storage blocks made from a thermal storage material. The second assembly includes multiple thermal energy storage blocks made from thermal storage material. • At least one of the first assembly and the second assembly is configured to have a rectangular end. • At least one of the first and second assemblies is configured to have a ziggurat (stepped) end. • At least one of the first and second assemblies is configured to have an inverted ziggurat (inverted stepped) end. A housing for enclosing at least one of the first assembly and the second assembly, configured to withstand pressure exceeding atmospheric pressure. • The heat exchanger assembly includes a steam generator.

[0314]

[0439] TES with controlled horizontal temperature stratification

[0440] A thermal energy storage (TES) system, A thermal energy storage assembly including multiple substantially horizontal fluid flow paths, A fluid transfer system configured to provide fluid flow of a fluid through a fluid flow path, Includes, A TES system in which the fluid transfer system is configured to control the flow rate of the fluid flow so as to generate a substantially horizontal temperature stratification through a thermal energy storage assembly.

[0315]

[0441] In another implementation, the system is configured to maintain temperature stratification along substantially constant isotherms of the fluid at an angle to the horizontal over most of the thermal energy storage assembly.

[0316]

[0442] The TES system can be configured to include one or more of the following features: The fluid transfer system is further configured to generate substantially uniform isotherms across a substantially vertical plane of the storage assembly. The fluid transfer system is further configured to generate substantially constant isotherms of the fluid at an isotherm angle substantially similar to the outlet angle with respect to the horizontal at the end of the storage assembly from which the fluid flow emerges. The TES system is configured to adjust separate portions of the fluid flow to multiple horizontal levels within the thermal energy storage assembly. The fluid flow transfer system includes at least one orifice plate positioned at at least one end of the thermal energy storage system, the orifice plate including a variable-size orifice configured to allow a variable flow rate of the fluid. Fluid flow regulation is achieved using at least one orifice plate having orifices of varying sizes and / or shapes within one or more orifice plates, or by using a rotating orifice plate assembly. The fluid flow transfer system includes at least one of the following: adjustable valves, louvers, gates and / or other fluid flow control devices configured to be operated to regulate the fluid flow through the fluid flow path. The fluid flow path is substantially equal in length, passing through the selected heated portion of the storage assembly. Multiple blowers configured to regulate the fluid flow rate through multiple fluid flow paths of a storage assembly. • The TES system may include multiple heating elements that extend from the lower part of the storage assembly to the higher part of the storage assembly. The TES system includes a blower at a first end of the storage assembly configured to guide fluid into the storage assembly to generate heated fluid, and at least one duct at a second end of the storage assembly configured to receive heated fluid from the storage assembly. The thermal energy storage medium within the TES system includes a structured medium having multiple lateral pathways defining multiple layers within the storage assembly, the pathways being configured such that pathways in at least several different layers do not communicate with each other, thereby establishing substantially independent fluid pathways within different layers. The heat storage medium can be configured to include multiple heat storage blocks positioned within a ziggurat stack. The heat storage assembly is configured to include a plurality of heat storage blocks positioned in a stepped configuration. • The fluid transfer system of the TES system may include an air distribution system. The TES system includes a housing configured to accommodate a pressurized environment exceeding atmospheric pressure around the heat storage assembly. The enclosure is configured to accommodate a pressure at least 2 PSI higher than the ambient pressure outside the enclosure.

[0317]

[0443] Multilayer bottom insulation and support

[0444] A thermal energy storage (TES) system, A thermal energy storage assembly positioned on a multilayer support structure, A heating system configured to heat a storage assembly, A fluid flow system configured to heat a fluid using heat from a heated storage assembly, Includes, The support structure is The first insulation layer, A first path set within a first insulating layer, the first path set configured to provide a relatively low-temperature fluid flow within the first path set, The second insulation layer is adjacent to the first insulation layer, A third layer adjacent to the second insulation layer, having a second path set that forms a certain angle with respect to the first path set, The TES system, including

[0318]

[0445] The support structure may be configured to include one or more of the following features: The first insulation layer is made of calcium silicate. A first path set positioned in the portion of the first insulation layer close to the second insulation layer, and configured to cool the contact surface between the first and second insulation layers. The first path set is configured to guide a bypass fluid from one end of the storage medium to the other end in order to mix with the high-temperature fluid exiting the storage medium. The fluid flow system includes an outlet region of the storage assembly, and the first path set is configured to provide a bypass channel that supplies a relatively cool fluid from one end of the storage assembly and mixes it with the heated fluid in the outlet region. The second path set is passively driven by the buoyancy of the hot fluid rising at one end of the path and is configured to draw cooler air into the second path set. The second insulation layer contains foamed glass material. The temperature of the contact surface between the first insulation layer and the second insulation layer shall not exceed 400°C. The temperature of the contact surface between the first insulation layer and the second insulation layer shall not exceed 300°C.

[0319]

[0446] Closed heat exchanger

[0447] A thermal energy storage (TES) system, The thermal energy storage medium inside the first enclosure, An exhaust port in the first enclosure opens into the second enclosure, which is insulated from the first enclosure, Includes, A TES system in which the second housing has at least one heat exchange surface configured to guide thermal energy away from the first housing.

[0320]

[0448] The TES system can be configured to have one or more of the following features: The second housing may have a return port for guiding the fluid back into the first housing. This configuration allows the fluid in the first enclosure to be cooled by being guided into the second enclosure, but the fluid in the second enclosure is not directly mixed with any fluid or environment outside the TES system.

[0321]

[0449] Fault-tolerant heating element

[0450] A heating system, Multiple electric heating elements, Multiple heating element supports, Includes, Each element is configured to extend from one of the supports to another of the heating element supports. A heating system in which at least one of the heating element supports includes a material that is sufficiently conductive to form parallel electrical connections between all heating elements in contact with the material of the heating element support, and is configured such that when one of the heating elements fails, this material contacts the material of the support without failure to carry electricity to the heating elements and rebalance the voltage potential of the system.

[0322]

[0451] The heating system may be configured to have one or more of the following features: The heating element includes one or more metal wires. The heating element is made from graphite. The heating element support includes a non-conductive material. A sufficiently conductive material is formed as a busbar on one of the heating element supports.

[0323]

[0452] method

[0453] A method for storing thermal energy, To provide a thermal energy storage medium comprising multiple layers of thermal energy storage blocks, wherein each layer defines multiple substantially horizontal flow paths through the storage medium, Heating the thermal energy storage block using one or more heater elements, A gas or fluid is flowed through a storage medium through at least one of a plurality of substantially horizontal flow paths, wherein each of the flow paths is fluidically isolated from one another within the storage medium. Includes, A method for traversing at least one flow path, at least one radiation chamber, and at least one heating element receiving channel in one of storage blocks, wherein the gas or fluid in one of the flow paths is entirely within one layer of the storage medium.

[0324]

[0454] This method, The step of heating the thermal energy storage block includes radiating thermal energy from one or more of the heater elements onto one or more surfaces of the thermal energy storage block, and / or • Enclosing a storage medium in a sealed housing, and / or • The material must be heat-resistant. It can further include

[0325]

[0455] Method for manufacturing thermal blocks

[0456] A method for manufacturing a thermal energy storage block, To prepare thermal energy storage materials, Forming multiple thermal radiation chambers within the material, Forming a first set of substantially horizontal channels within the material, wherein the channels are in fluid communication with at least one of the thermal radiation chambers, A method comprising forming a second set of substantially horizontal channels within a material, wherein the channels are in fluid communication with at least another of the thermal radiation chambers, and shaping the material such that the block has an outer peripheral shape asymmetric with respect to the longitudinal axis of the storage block.

[0457] This method, - To form one or more protrusions or recesses within the material that are configured to engage with another energy storage block, • The material is heat-resistant, It can further include

[0326]

[0458] Earthquake stability method

[0459] A method for improving stability during earthquakes, To prepare a thermal energy storage medium formed from multiple layers of thermal energy storage blocks, A cap layer positioned on top of the uppermost part of the heat storage medium is attached, A method comprising positioning a plurality of support columns around a heat storage medium and connecting a cap layer to the support columns, wherein such connection is configured to minimize lateral movement of the heat storage medium.

[0327]

[0460] This method may further include connecting multiple cross braces to at least two of the support columns.

[0328]

[0461] Methods to minimize soil heating

[0462] A method to minimize soil heating, To prepare a thermal energy storage medium, Heating a thermal energy storage medium using one or more heating elements by radiating thermal energy onto one or more surfaces of the thermal energy storage medium, This method involves isolating the thermal energy storage medium from the soil by providing a support structure between the soil and the storage medium, wherein the support structure is A first insulation layer configured to withstand a first temperature without damage, A second insulating layer configured to withstand a second temperature without damage, wherein the second temperature is higher than the first temperature, Multiple fluid channels within the support structure, Including isolation, Methods that include...

[0329]

[0463] This method, • The second insulated layer includes a second set of fluid channels, • The first insulation layer includes a layer of heat-resistant tiles, • Forming a support structure from metal, It can further include

[0330]

[0464] Method using a common heat exchanger

[0465] A method for storing thermal energy, Heating the first assembly of the heat storage material, Heating the second assembly of the heat storage material, A heat exchanger assembly is provided that is in fluid communication with the first and second assemblies. To guide the first heat output from the first assembly to the heat exchanger assembly, To guide the second heat output from the second assembly to the heat exchanger assembly, In a heat exchanger assembly, the first and second heat outputs are combined, Methods that include...

[0331]

[0466] The first assembly may include multiple thermal energy storage blocks made from thermal storage material.

[0332]

[0467] Methods for maintaining horizontal temperature stratification

[0468] A method for storing thermal energy, The preparation of a thermal energy storage medium, wherein the thermal energy storage medium includes multiple substantially horizontal flow paths through the storage medium. Using a fluid transfer system to guide gas or fluid through a substantially horizontal flow path, A method comprising adjusting the flow rate of a fluid transfer system such that a substantially horizontally oriented temperature stratification is maintained through a thermal energy storage medium in a consistent isothermal profile.

[0333]

[0469] This method may further include the following: The fluid transfer system is configured to maintain a temperature stratification through the majority of the thermal energy storage medium in a substantially uniform isothermal profile and angle relative to the horizontal. • Using an orifice plate as part of a fluid transfer system to regulate flow through a thermal energy storage medium. The first flow rate passing through the uppermost part of the thermal energy storage medium is greater than the second flow rate passing through the lower part of the thermal energy storage medium. • Set the flow rate individually for each level of thermal energy storage medium. Multiple blowers are used to regulate the flow rate, with each blower setting the flow rate for one level of the thermal energy storage medium. Multiple valves are used to regulate the flow rate, with each valve setting the flow rate for one level of the thermal energy storage medium. Multiple orifice groups are used to regulate the flow rate, with each orifice group being used to set the flow rate for one level of the thermal energy storage medium.

[0334]

[0470] A method to minimize soil heating using multiple airflow channels.

[0471] A method to minimize soil heating, To prepare a thermal energy storage medium, Heating a thermal energy storage medium using one or more heating elements by radiating thermal energy onto one or more surfaces of the thermal energy storage medium, The thermal energy storage medium is isolated from the soil by providing a multi-layer support structure between the soil and the storage medium, and the multi-layer support structure is The first insulation layer, A first set of pathways within a first insulating layer, configured to provide cooling by fluid flow within the pathways, and a second insulating layer, Second insulation layer and A third layer having a second set of paths at a certain angle, which is substantially orthogonal to the first set of paths, Including isolation, Methods that include...

[0335]

[0472] This method may further include the following: • Actively cool a portion of the first insulation layer by blowing air or gas through the first path set. • Passively cool a portion of the third insulating layer by using convection to guide air or gas into the second path set.

[0336]

[0473] Method using a sealed heat exchanger

[0474] A method for storing thermal energy, A thermal energy storage medium is provided within the first enclosure, This involves opening an exhaust port on the first enclosure, such that the exhaust port opens into the second enclosure surrounding the first enclosure. Inducing air or gas from the first enclosure to the second enclosure, Cooling the air or gas inside the second enclosure to generate cooled air or gas, The process of returning cooled air or gas to the first housing through an inlet port connecting the first housing to the second housing, wherein the inlet port is positioned lower on the first housing than the exhaust port. Methods that include...

[0337]

[0475] This method may further include the following: • The exhaust port must be a quarter-turn valve. The second housing has at least one heat exchange surface configured to guide thermal energy away from the first housing.

[0338]

[0476] How to handle heater element failures

[0477] A method for dealing with a heater element failure, By providing multiple electric heating elements, The present invention provides a plurality of heating element supports connected to a heating element, wherein at least one of the heating element supports contains a material that is sufficiently conductive to form parallel electrical connections between all the heating elements in contact with the material of the heating element support. When one of the heating elements fails, the system's voltage potential is rebalanced by using a heating element support having the above material to transfer electricity to the other unfaulty heating elements in contact with the material within the support. Methods that include...

[0339]

[0478] The heating element may include one or more metal wires.

[0340]

[0479] The claimable subject matter includes any of the systems or methods in the exemplary claims. Optionally, a method is provided that includes at least one technical feature from any of the prior features. Optionally, the method includes at least any two technical features from any of the prior features. Optionally, an apparatus is provided that includes at least one technical feature from any of the prior features. Optionally, the apparatus comprises at least any two technical features from any of the prior features. Optionally, a system is provided that includes at least one technical feature from any of the prior features. Optionally, the system includes at least any two technical features from any of the prior features.

[0341]

[0480] term

[0481] Unless otherwise defined below, terms used in the claims should be given the broadest definition that a person skilled in the art would have given them at the time of filing, as reflected in printed publications and issued patents. For example, the following terms may be used synonymously as understood by a person skilled in the art:

[0482] A ampere

[0483] AC alternating current

[0484] DC direct current

[0485] DFB two-column fluidized bed

[0486] EAR Enhanced Recovery Method

[0487] EV (Electric Vehicle)

[0488] GT Gas Turbine

[0489] HRSG Heat Recovery Steam Generator

[0490] kV (kilovolt)

[0491] kW (kilowatt)

[0492] MED Multiple Effects

[0493] MPPT (Maximum Power Point Tracking)

[0494] MSF Multi-stage Flash

[0495] MW (megawatts)

[0496] OTSG Once-Through Steam Generator

[0497] PE proton exchange membrane

[0498] PV solar power

[0499] RSOC Reversible Solid Oxide Cell

[0500] SOEC Solid Oxide Electrolytic Cell

[0501] SOFC (Solid Oxide Fuel Cell)

[0502] ST Steam Turbine

[0503] TES Thermal Energy Storage Unit

[0504] TSU Heat Storage Unit

[0342]

[0505] Furthermore, the term “heater” is used to refer to a conductive element that generates heat. For example, as used in this exemplary implementation, the term “heater” may include, but is not limited to, wires, ribbons, tapes, or other structures that can conduct electricity to generate heat. The composition of the heater may be (coated or uncoated metal), ceramic, graphite, or other composition that can generate heat. Optionally, some embodiments may use metal or other heat-conducting conduits that carry molten salt, hot air, hot fluid, hot gas, or other media to conduct heat through the conduit.

[0343]

[0506] Furthermore, the terms furnace and reactor can be used synonymously in the above work, for example, in the case of DRI production, where the term furnace may be used in reference to the methods of the art, and which is intended to refer to a reactor in a material processing system.

[0344]

[0507] Similarly, terms describing fluid compression devices (including, but not limited to, blowers, compressors, fans, and pumps) can be used synonymously.

[0345]

[0508] The terms air, fluid, and gas are used interchangeably herein to refer to any suitable type of fluid heat transfer medium, including various types of gases (alone or in combination, air, CO2, oxygen, and other gases), and it should be understood that where one is referred to, others can be used as well. Therefore, for example, “air” can be any suitable fluid or gas, or a combination of fluids or gases.

[0346]

[0509] While the exemplary embodiments described above may refer to “air,” the concept of the present invention is not limited to this composition, and other fluid flows may be used instead of air for additional industrial applications, including but not limited to enhanced recovery methods, sterilization, drying, chemical production, desalination and hydrothermal treatments related to healthcare or food and beverages (e.g., the Bayer process). The Bayer process includes a calcination step. The composition of the fluid flow may be selected to improve the yield or efficiency of the product or to control the exhaust flow.

[0347]

[0510] In any of the heat storage units, the working fluid composition can be changed from time to time for a number of purposes, including material maintenance or readjustment. Multiple units can be used synergistically to improve charging or discharging characteristics, sizing, or ease of installation, integration, or maintenance. As will be understood by those skilled in the art, other heat storage units having desired characteristics and functions may be used instead of the heat storage units disclosed herein, and the results may vary depending on the method and scale of the heat storage unit combination.

[0348]

[0511] As used herein and / or in subsequent claims, the singular forms “a, an” and “the” refer to multiple objects unless otherwise explicitly indicated by the context. Furthermore, as used herein, “in” means both “in” and “on” unless otherwise explicitly indicated by the context.

[0349]

[0512] The enumeration of value ranges in this specification is intended merely as a concise way of individually referring to each distinct value that falls within that range. Unless otherwise indicated herein, each individual value is incorporated herein as if it were individually enumerated.

[0350]

[0513] All methods described herein may be carried out in any suitable order, unless otherwise indicated herein or unless it is clearly inconsistent with the context. The use of any examples or exemplary phrases (e.g., "etc.") provided herein with respect to some exemplary implementations is intended merely to make the exemplary implementations more apparent and not to limit the scope of the exemplary implementations described otherwise in the claims. Nothing in this specification should be construed as indicating that any element not described in the claims is essential to carrying out the exemplary implementations.

[0351]

[0514] The grouping of alternative elements or exemplary implementations disclosed herein should not be construed as limitation. Each component of a group may be referenced and claimed individually or in any combination with other components of a group or other elements described herein. For convenience and / or patentability reasons, one or more components of a group may be included in or removed from a group. In any such inclusion or exclusion, this specification shall be deemed to include the modified groups and thus satisfy the description of all groups used in the appended claims.

[0352]

[0515] In this specification, the apparatus may refer to the spatial relationships between various components and the spatial orientation of various aspects of the components, as shown in the accompanying drawings. However, as a person skilled in the art will understand after reading this application, the apparatus, components, devices, etc. described herein can be positioned in any desired orientation. Therefore, if the apparatus described herein can be oriented in any desired direction, the use of terms such as “up,” “down,” “above,” “downward,” “first,” “second,” or other similar terms used to describe the spatial relationships between various components or the spatial orientation of aspects of such components should be understood to describe the relative relationships between components or the spatial orientation of aspects of such components, respectively.

[0353]

[0516] In interpreting this specification, all terms should be interpreted in the broadest possible sense, consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to an element, component, or process in a non-exclusive manner, meaning that the referenced element, component, or process may be combined with other elements, components, or processes that exist, are used, or are not expressly referenced. Where the claims of this specification refer to at least one selected from the group consisting of A, B, C… and N, the statement should be interpreted as requiring only one element from that group, and not A and N, or B and N, etc.

[0354]

[0517] The following patent applications and patents relate to the relevant technology: U.S. Patent Application No. 17 / 537,407 (filed November 29, 2021, issued as U.S. Patent No. 11,603,776 on March 14, 2023), and International Patent Application No. PCT / US2021 / 061041 (filed November 29, 2021). The aforementioned applications and patents are incorporated herein by reference in their entirety for all purposes.

[0355]

[0518] While the foregoing description outlines various exemplary implementations of the exemplary implementations, other and further exemplary implementations of the exemplary implementations may be devised without deviating from their basic scope. The scope of the exemplary implementations is determined by the following claims. The exemplary implementations are not limited to the exemplary implementations, versions, or examples described, and are included to enable a person skilled in the art to create and use the exemplary implementations in combination with information and knowledge available to them.

Claims

1. A thermal energy storage (TES) system, A thermal energy storage medium comprising multiple layers of thermal energy storage blocks, wherein each of the layers defines a plurality of substantially horizontal fluid flow paths through the storage medium, One or more heater elements, One or more receiving channels in the storage medium for receiving the heater element, Includes, At least one first fluid channel, at least one first radiation chamber, and at least one first receiving channel in one of the storage blocks are configured to form a first fluid flow path positioned within the first layer. At least one second fluid channel, at least one second radiation chamber, and at least one second receiving channel in one of the storage blocks are configured to form a second fluid flow path positioned within the second layer. A system in which the first fluid channel and the second fluid flow path are fluidically isolated from each other.

2. The system according to claim 1, wherein at least one of the heater elements is positioned in one of the receiving channels to heat the storage medium by thermal energy radiated onto one or more surfaces of the thermal energy storage block.

3. The system according to claim 1 or 2, further comprising an external housing configured to enclose the storage medium.

4. The system according to claim 3, wherein the housing is sealed to provide a pressurized environment for the storage medium.

5. The system according to any one of claims 1 to 4, further comprising a heat exchanger configured to receive thermal output from the storage medium.

6. The system according to any one of claims 1 to 5, wherein at least some of the storage blocks include a plurality of radiation chambers configured to receive thermal energy radiated from one or more heater elements.

7. The system according to any one of claims 1 to 6, wherein at least some of the storage blocks include a plurality of flow channels extending through at least a portion of the storage blocks.

8. The system according to any one of claims 1 to 7, wherein at least some of the storage blocks include a plurality of air passages of different sizes that extend substantially horizontally through at least a portion of the storage blocks.

9. The system according to claim 8, wherein at least some of the flow channels within the storage block are in fluid communication with one or more of the radiation chambers of the storage block.

10. The system according to any one of claims 1 to 9, wherein a first storage block in one layer of the storage medium is configured to interlock with a second storage block in a second layer, forming a first interlocking region that defines one surface of the heater element receiving channel.

11. The system according to claim 10, wherein the first storage block is configured to interlock with a third storage block in the third layer, forming a second interlocking region that defines another surface of the heater element receiving channel.

12. The system according to any one of claims 1 to 11, wherein a storage block in one layer of the storage medium is configured to interlock with at least two other storage blocks in another layer to maintain a predetermined range of spacing between rows of storage blocks, the spacing defining the heater element receiving channel.

13. The system according to any one of claims 1 to 12, wherein the storage medium has a substantially trapezoidal cross-sectional shape.

14. The system according to any one of claims 1 to 12, wherein the storage medium substantially has a ziggurat cross-sectional shape.

15. The system according to any one of claims 1 to 14, wherein the flow path is defined in at least part by the storage block.

16. The system according to any one of claims 1 to 15, wherein at least some of the receiving channels extend at an angle that is not parallel to the longitudinal axis of the thermal energy storage medium.

17. The system according to any one of claims 1 to 16, wherein at least some of the receiving channels are alternately distributed between the receiving channels and the heat storage block in an alternating pattern throughout the storage medium.

18. The system according to any one of claims 1 to 17, wherein at least one radiation chamber is defined by a first heat storage block and a second heat storage block positioned adjacent to each other, and the first side wall of the first heat storage block and the second side wall of the second heat storage block define the side wall of the radiation chamber.

19. The system according to any one of claims 1 to 18, wherein one thermal energy storage block in one layer is positioned to interlock with at least four thermal energy storage blocks in another layer.

20. A thermal energy storage block, Multiple thermal radiation chambers, A first set of substantially horizontal flow channels that are in fluid communication with at least one of the thermal radiation chambers, A second set of substantially horizontal flow channels that are in fluid communication with at least one of the thermal radiation chambers, One or more protrusions or recesses configured to engage with another energy storage block, A thermal energy storage block, including a thermal energy storage block.

21. The thermal energy storage block according to the claim, wherein the block has an outer peripheral shape asymmetrical with respect to the longitudinal axis of the storage block, and the asymmetrical outer peripheral shape complements a substantially similar asymmetrical outer peripheral shape of another storage block, and when positioned together, forms a connected radiating chamber and a fluid-connected horizontal flow channel.

22. The thermal energy storage block according to claim 20, further comprising a third set of horizontal channels extending through a portion of the storage block.

23. The thermal energy storage block according to claim 21, further comprising a fourth set of horizontal channels extending through a portion of the storage block.

24. The thermal energy storage block according to any one of claims 20 to 23, wherein the thermal energy storage block is formed from a heat-resistant material.

25. The thermal energy storage block according to any one of claims 20 to 24, wherein at least some of the flow channels are configured to have openings of a different size than the other openings of the other flow channels.

26. The thermal energy storage block according to any one of claims 20 to 25, wherein at least one side wall of the storage block is configured to define one wall of a radiation chamber when the storage block is positioned adjacent to another storage block.

27. A thermal energy storage block according to any one of claims 20 to 26, comprising a first portion defining a first set of air passages, a second portion defining a second set of air passages, and a radiation chamber defined between the first portion and the second portion.

28. The thermal energy storage block according to any one of claims 20 to 27, wherein at least one surface of the block is shaped to define a support surface configured to support a heating element.

29. A thermal energy storage (TES) system with improved seismic stability, Heat storage assembly and A base structure that supports the aforementioned heat storage assembly, A cap layer positioned on the uppermost part of the heat storage assembly, A plurality of support columns positioned around the heat storage assembly, each of which is connected to the cap layer and configured to minimize lateral movement of the heat storage assembly, A system that includes this.

30. The system according to claim 29, further comprising at least one plurality of cross braces connected to at least two of the support columns.

31. The system according to claim 29 or 30, wherein the heat storage assembly includes at least two types of storage blocks configured to form a shear key contact surface with a storage block in another layer in one layer.

32. The system according to any one of claims 29 to 31, wherein the heat storage assembly includes a plurality of storage blocks in a first layer and at least one base layer block configured to support the heat storage assembly, and at least some of the blocks in the first layer are configured to form a shear key contact surface with the base layer block.

33. The system according to any one of claims 29 to 32, further comprising a support beam configured to support the base structure.

34. The system according to any one of claims 29 to 33, wherein the heat storage assembly includes a plurality of energy storage blocks, each including an interlocking mechanism configured to improve seismic stability.

35. A thermal energy storage (TES) system, Thermal energy storage medium, A support structure having multiple fluid channels, a first insulating layer positioned on the support structure and configured to resist a first temperature without damage, and a second insulating layer adjacent to the first insulating layer and configured to resist a second temperature without damage, wherein the second temperature is higher than the first temperature, and the base includes the second insulating layer. A plurality of heater elements positioned to heat the thermal energy storage medium via energy radiated onto at least one radiation chamber of the thermal energy storage medium, A system that includes this.

36. The system according to claim 35, wherein the storage medium is formed from layers of interlocking heat storage blocks.

37. The system according to claim 35 or 36, wherein the support structure is positioned on a gravel foundation.

38. The system according to claim 36 or 37, wherein the support structure includes metal.

39. The system according to any one of claims 35 to 38, wherein the support structure includes a plurality of fluid channels.

40. The system according to any one of claims 35 to 39, wherein the support structure includes reinforced concrete.

41. The system according to any one of claims 35 to 40, wherein the support structure includes reinforced concrete and metal.

42. The system according to any one of claims 35 to 41, further comprising a heat insulating layer positioned adjacent to the storage medium.

43. The system according to claim 42, comprising a fixing strap positioned on the outer surface of the insulating layer and configured to secure the storage medium against earthquakes.

44. The system according to any one of claims 35 to 43, comprising a segmented external housing detachably attached to the base, wherein each of the segments of the external housing is configured to be removed and / or opened independently of the other segments.

45. The system according to claim 44, wherein the external housing includes an upper frame, an end wall, and a thermal insulation layer.

46. The system according to any one of claims 35 to 45, wherein one end of the storage medium includes at least two different types of heat storage blocks.

47. The system according to any one of claims 35 to 46, wherein the TES includes a plenum at the rectangular or stepped end of the storage medium.

48. The system according to any one of claims 35 to 47, wherein the TES includes one or more support blocks below the inverted stepped end of the storage medium.

49. The system according to claim 35 or 48, further comprising a support tile positioned below the storage medium but on the insulation layer of the raft.

50. A thermal energy storage (TES) system, The first assembly of the heat storage material, The second assembly of the heat storage material, A heat exchanger assembly that is in fluid communication with the first assembly and the second assembly, Includes, The first assembly is configured to provide a first thermal output to the heat exchanger assembly, A system in which the second assembly is configured to provide a second thermal output to the heat exchanger assembly.

51. The system according to claim 50, wherein the first assembly includes a plurality of thermal energy storage blocks made from the thermal storage material.

52. The system according to claim 50 or 51, wherein the second assembly includes a plurality of thermal energy storage blocks made from the thermal storage material.

53. The system according to any one of claims 50 to 52, wherein at least one of the first assembly and the second assembly is configured to have a rectangular end.

54. The system according to any one of claims 50 to 53, wherein at least one of the first assembly and the second assembly is configured to have stepped ends.

55. The system according to any one of claims 50 to 54, wherein at least one of the first assembly and the second assembly is configured to have an inverted stepped end.

56. The system according to any one of claims 50 to 55, further comprising a housing that encloses at least one of the first assembly and the second assembly, wherein the housing is configured to withstand pressure exceeding atmospheric pressure.

57. The system according to any one of claims 50 to 56, wherein the heat exchanger assembly includes a steam generator.

58. A thermal energy storage (TES) system, A thermal energy storage assembly that defines multiple substantially horizontal fluid flow paths and A fluid transfer system configured to provide fluid flow through the aforementioned fluid flow path, Includes, A system wherein the fluid transfer system is configured to control the flow rate of the fluid flow so as to generate a substantially horizontal temperature stratification through the thermal energy storage assembly.

59. The system according to claim 58, wherein the fluid transfer system is further configured to generate substantially uniform isotherms of the fluid at an angle with respect to the horizontal through most of the thermal energy storage assembly.

60. The system according to claim 58 or 59, wherein the fluid transfer system is further configured to generate the substantially uniform isotherms over a substantially vertical plane of the storage assembly.

61. The system according to any one of claims 58 to 60, wherein the fluid transfer system is further configured to generate the substantially uniform isotherms of the fluid at an isotherm angle qualitatively similar to the outlet angle with respect to the horizontal of the end of the storage assembly from which the fluid flow exits.

62. The system according to any one of claims 58 to 61, wherein the TES system is configured to adjust separate portions of the fluid flow to multiple horizontal levels in the thermal energy storage assembly.

63. The system according to any one of claims 58 to 62, wherein the fluid flow transfer system includes at least one orifice plate positioned at at least one end of the thermal energy storage system, the orifice plate includes a variable-size orifice configured to allow a variable flow rate of the fluid.

64. The system according to any one of claims 58 to 63, wherein the fluid flow rate adjustment is achieved using at least one rotating orifice plate assembly.

65. The system according to any one of claims 58 to 64, wherein the fluid flow transfer system includes at least one of an adjustable valve, louver, gate, and / or other fluid flow control device configured to be operated to regulate the fluid flow through the fluid flow path.

66. The system according to any one of claims 58 to 65, wherein the fluid flow path is substantially equal in length, passing through the selected heated portion of the storage assembly.

67. The system according to any one of claims 58 to 66, further comprising a plurality of blowers configured to adjust the fluid flow rate through a plurality of fluid flow paths of the storage assembly.

68. The system according to any one of claims 58 to 67, wherein the TES system includes a plurality of heating elements extending from a lower portion of the storage assembly to a higher portion of the storage assembly.

69. The system according to any one of claims 58 to 68, wherein the TES system comprises a blower configured at a first end of the storage assembly to guide fluid into the storage assembly to generate heated fluid, and at least one duct configured at a second end of the storage assembly to receive the heated fluid from the storage assembly.

70. The system according to any one of claims 58 to 69, wherein the thermal energy storage assembly in the TES system includes a structured medium having a plurality of lateral paths defining a plurality of layers in the storage assembly, the paths are configured such that the paths in at least a few different layers do not communicate with each other, thereby establishing substantially independent fluid paths in different layers.

71. The system according to any one of claims 58 to 70, wherein the heat storage assembly is configured to include a plurality of heat storage blocks positioned in a stepped configuration.

72. The system according to any one of claims 58 to 71, wherein the fluid transfer system includes an air distribution system.

73. The system according to any one of claims 58 to 72, further comprising a housing configured to accommodate a pressurized environment exceeding atmospheric pressure around the heat storage assembly.

74. The system according to claim 73, wherein the housing is configured to accommodate a pressure at least 2 PSI higher than the ambient pressure in the environment outside the housing.

75. A thermal energy storage (TES) system, A thermal energy storage assembly positioned on a multi-layer insulated support structure, A heating system configured to heat the aforementioned storage assembly, A fluid flow system configured to heat a fluid using heat from the heated storage assembly, Including, The aforementioned support structure, The first insulation layer, A first path set in the first insulating layer, configured to provide a relatively low-temperature fluid flow within the first path set, A second insulation layer adjacent to the first insulation layer, A third layer having a second path set adjacent to the second insulation layer and forming a certain angle with respect to the first path set, A system that includes this.

76. The system according to claim 75, wherein the first insulating layer is formed from calcium silicate.

77. The system according to claim 75, wherein the first path set is positioned in a portion of the first insulation layer close to the second insulation layer and is configured to cool the contact surface between the first insulation layer and the second insulation layer.

78. The system according to any one of claims 75 to 77, wherein the fluid flow system includes an outlet region of the storage assembly, and the first path set is configured to provide a bypass path configured to supply the relatively cool fluid from one end of the storage assembly to mix with the fluid heated in the outlet region.

79. The system according to any one of claims 75 to 78, wherein the second path set is passively driven by the buoyancy of a high-temperature fluid rising at one end of the path, and is configured to draw lower-temperature air into the second path set.

80. The system according to any one of claims 75 to 79, wherein the second insulating layer includes a foamed glass material.

81. A thermal energy storage (TES) system, Thermal energy storage medium in the first enclosure and An exhaust port in the first housing opens into a second housing which is insulated from the first housing, Includes, A system wherein the second housing has at least one heat exchange surface configured to guide thermal energy away from the first housing.

82. The system according to claim 81, wherein the second housing includes a return port for guiding a fluid back into the first housing.

83. The system according to claim 81 or 82, wherein the system is cooled by the fluid in the first housing being guided into the second housing, but the fluid in the second housing is not directly mixed with any fluid or environment outside the TES system.

84. A heating system, Multiple electric heating elements, Multiple heating element supports, Includes, Each of the elements is configured to extend from one of the supports to another of the heating element supports. A heating system in which at least one of the heating element supports comprises a material, i.e., a material sufficiently conductive to form parallel electrical connections between all heating elements in contact with the material of the heating element support, and is configured such that when one of the heating elements fails, the material comes into contact with the material of the support without failure to transport electricity to the heating elements and rebalance the voltage potential of the system.

85. The system according to claim 84, wherein the heating element includes one or more metal wires.

86. The system according to claim 84 or 85, wherein the heating element is made of graphite.

87. The system according to any one of claims 84 to 86, wherein the heating element support comprises a non-conductive material.

88. The system according to any one of claims 84 to 87, wherein the sufficiently conductive material is formed as a busbar on one of the heating element supports.

89. A method for storing thermal energy, To provide a thermal energy storage medium comprising multiple layers of thermal energy storage blocks, wherein each of the layers defines a plurality of substantially horizontal flow paths through the storage medium, The aforementioned thermal energy storage block is heated using one or more heater elements, A gas or fluid is flowed through the storage medium through at least one of a plurality of substantially horizontal flow paths, wherein each of the flow paths is fluidically isolated from one another within the storage medium. Includes, A method wherein the gas or fluid in one of the flow paths traverses at least one flow path, at least one radiation chamber, and at least one heating element receiving channel in one of the storage blocks, all of which are located within one layer of the storage medium.

90. The method according to claim 89, wherein heating the thermal energy storage block includes radiating thermal energy from one or more of the heater elements onto one or more surfaces of the thermal energy storage block.

91. The method according to claim 89 or 90, further comprising sealing the storage medium within a sealed housing.

92. The method according to claim 91, further comprising pressurizing the atmosphere inside the housing.

93. A method for manufacturing a thermal energy storage block, To prepare thermal energy storage materials, Forming multiple thermal radiation chambers within the aforementioned material, To form a first set of substantially horizontal flow channels within the material, wherein the flow channels are in fluid communication with at least one of the thermal radiation chambers. Forming a second set of substantially horizontal channels within the material, wherein the channels are in fluid communication with at least one of the thermal radiation chambers, The material is molded such that the block has an outer peripheral shape asymmetrical with respect to the longitudinal axis of the storage block, Methods that include...

94. The method according to claim 93, further comprising forming one or more protrusions or recesses in the material configured to engage with another energy storage block.

95. The method according to claim 93 or 94, wherein the material is a heat-resistant material.

96. A method for improving stability during earthquakes, To prepare a thermal energy storage medium formed from multiple layers of thermal energy storage blocks, A cap layer positioned on the uppermost portion of the heat storage medium is attached, Positioning multiple support columns around the heat storage medium, The cap layer is connected to the support column, and such connection is configured to minimize the lateral movement of the heat storage medium. Methods that include...

97. The method according to claim 96, further comprising connecting a plurality of cross braces to at least two of the support columns.

98. A method to minimize soil heating, To prepare a thermal energy storage medium, Heating the thermal energy storage medium using one or more heating elements by radiating thermal energy onto one or more surfaces of the thermal energy storage medium, The thermal energy storage medium is isolated from the soil by providing a support structure between the soil and the storage medium, wherein the support structure is A first insulation layer configured to withstand a first temperature without damage, A second insulating layer configured to withstand a second temperature without damage, wherein the second temperature is higher than the first temperature, Multiple fluid passages within the support structure, Including isolation, Methods that include...

99. The method according to claim 98, further comprising a second set of fluid channels within the second insulating layer.

100. The method according to claim 98 or 99, further comprising a layer of heat-resistant tiles on the first insulating layer.

101. The method according to any one of claims 98 to 100, further comprising forming the support structure from metal.

102. A method for storing thermal energy, Heating the first assembly of the heat storage material, Heating the second assembly of the heat storage material, A heat exchanger assembly is provided that is in fluid communication with the first assembly and the second assembly. The first heat output from the first assembly is guided to the heat exchanger assembly, The second heat output from the second assembly is directed to the heat exchanger assembly, The heat exchanger assembly combines the first heat output and the second heat output, Methods including

103. The method according to claim 102, wherein the first assembly includes a plurality of thermal energy storage blocks made from the thermal storage material.

104. A method for storing thermal energy, To provide a thermal energy storage medium, wherein the thermal energy storage medium includes a plurality of substantially horizontal flow paths through the storage medium. Using a fluid transfer system to guide the gas or fluid through the substantially horizontal flow path, The flow rate of the fluid transfer system is adjusted so that a substantially horizontally oriented temperature stratification is maintained through the thermal energy storage medium in a consistent isothermal profile. Methods that include...

105. The method according to claim 104, wherein the fluid transfer system is configured to maintain the temperature stratification through most of the thermal energy storage medium in a substantially uniform isothermal profile and angle with respect to the horizontal.

106. The method according to claim 104 or 105, comprising using an orifice plate as part of the fluid transfer system to regulate the flow through the thermal energy storage medium.

107. The method according to any one of claims 104 to 106, wherein the first flow rate passing through the uppermost portion of the thermal energy storage medium is greater than the second flow rate passing through the lower portion of the thermal energy storage medium.

108. The method according to any one of claims 104 to 107, comprising setting the flow rate individually for each level of the thermal energy storage medium.

109. The method according to any one of claims 104 to 108, wherein a plurality of blowers are used to adjust the flow rate, and each of the blowers sets the flow rate for one level of the thermal energy storage medium.

110. The method according to any one of claims 104 to 109, wherein a plurality of valves are used to regulate the flow rate, and each of the valves sets the flow rate to one level of the thermal energy storage medium.

111. The method according to any one of claims 104 to 110, wherein a plurality of orifice groups are used to adjust the flow rate, and each of the orifice groups is used to set the flow rate to one level of the thermal energy storage medium.

112. A method to minimize soil heating, To prepare a thermal energy storage medium, Heating the thermal energy storage medium using one or more heating elements by radiating thermal energy onto one or more surfaces of the thermal energy storage medium, The thermal energy storage medium is isolated from the soil by providing a multilayer support structure between the soil and the storage medium, wherein the multilayer support structure is The first insulation layer, A first set of paths within the first insulating layer, configured to provide cooling by fluid flow within the paths, The second insulation layer, A third layer having a second set of paths at a certain angle that is substantially orthogonal to the first set of paths, Including isolation, Methods that include...

113. The method according to claim 112, further comprising blowing air or gas through the first path set to actively cool a portion of the first insulation layer.

114. The method according to claim 112 or 113, further comprising using convection to guide air or gas into the second set of pathways to passively cool a portion of the third insulating layer.

115. A method for storing thermal energy, A thermal energy storage medium is provided within the first enclosure, Opening an exhaust port on the first housing, wherein the exhaust port opens into the second housing surrounding the first housing, To guide air or gas from the first housing to the second housing, The air or gas inside the second housing is cooled to generate cooled air or gas, The cooled air or gas is returned to the first housing through an inlet port connecting the first housing to the second housing, wherein the inlet port is positioned lower on the first housing than the exhaust port. Methods that include...

116. The method according to claim 115, wherein the exhaust port is a quarter-turn valve.

117. The method according to claim 115 or 116, wherein the second housing has at least one heat exchange surface configured to guide thermal energy away from the first housing.

118. A method for dealing with a heater element failure, By providing multiple electric heating elements, The method involves providing a plurality of heating element supports connected to the heating element, wherein at least one of the heating element supports contains a material that is sufficiently conductive to form parallel electrical connections between all of the heating elements that are in contact with the material of the heating element support. If one of the heating elements fails, the voltage potential of the system is rebalanced by using the heating element support having the material to transfer electricity to the other heating elements that are in contact with the material within the support. Methods that include...

119. The method according to claim 118, wherein the heating element includes one or more metal wires.

Images