Brick Thermal Storage Control for Continuous High-Temperature Steam
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Solution Overview
Problem
Current thermal energy storage systems face challenges in efficiently storing and delivering thermal energy from variable renewable electricity sources, including high costs, thermal runaway issues, and inadequate control over charging and discharging processes, which limits their ability to provide continuous and reliable heat for industrial applications.
Innovation Solution
A thermal energy storage system that uses vertically oriented thermal storage units with stacked bricks and resistive heaters, connected via switching circuitry, and a dynamic insulation system to manage temperature uniformity and airflow, allowing for efficient charging and discharging of thermal energy while minimizing costs and preventing thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thermal energy storage systems use variable renewable electricity sources, then energy storage capacity is improved, but system reliability deteriorates due to variability and intermittency
Solution Approach 1:
The system performs preliminary charging of thermal energy storage during periods when variable renewable electricity is available, storing energy in advance for later discharge. This allows the system to build up energy reserves proactively rather than reactively, improving reliability by ensuring energy availability even when renewable sources are intermittent.
Solution Approach 2:
The control system continuously monitors the state of charge, temperature, and power availability, using feedback signals to adjust charging and discharging rates. This feedback mechanism ensures the system maintains optimal operation and reliability by responding dynamically to changing conditions in the renewable energy supply and thermal demand.
2Productivity
If thermal energy storage systems increase charging and discharging rates, then productivity is improved, but thermal runaway risk increases
Solution Approach 1:
The system dynamically adjusts charging and discharging rates based on real-time conditions, allowing high productivity when conditions permit while automatically reducing rates to prevent thermal runaway when temperature thresholds or other safety parameters are approached. This dynamic control enables the system to optimize productivity without compromising safety.
Solution Approach 2:
Temperature sensors and control systems provide continuous feedback on thermal conditions, enabling the system to modulate power rates in response to temperature changes. When temperatures approach critical levels, the feedback loop automatically reduces charging or increases discharging to maintain safe operating margins, preventing thermal runaway while maximizing productivity during normal operation.
3Quantity of substance
If thermal energy storage systems use high temperatures, then energy density is improved, but component lifespan deteriorates
Solution Approach 1:
The system changes operational parameters by cycling between high-temperature charging phases (for energy storage) and lower-temperature discharging phases (to reduce thermal stress on components). This parameter modulation allows the system to achieve high energy density when needed while reducing the average thermal load on components, thereby extending their lifespan.
Solution Approach 2:
The system employs periodic charging and discharging cycles that allow components to experience high temperatures only intermittently rather than continuously. These periodic thermal cycles enable high energy density storage during charging phases while providing cooling periods during discharging, reducing cumulative thermal stress and extending component service life.
4Reliability
If thermal energy storage systems implement advanced control mechanisms, then system reliability is improved, but device complexity increases
Solution Approach 1:
The control system incorporates self-regulating features where the thermal storage medium itself provides feedback on its state (temperature, charge level), allowing the system to automatically adjust operation without complex external control. This self-service approach improves reliability through autonomous response to changing conditions while minimizing the complexity of external control mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient storage and delivery of high-temperature thermal energy, reducing costs and extending the lifespan of components by maintaining temperature uniformity and preventing thermal runaway, thus providing a reliable and continuous energy supply for industrial processes.
Implementation Method 1
vertically oriented thermal storage units with stacked bricks and resistive heaters
Implementation Method 2
A thermal energy storage system that uses vertically oriented thermal storage units with stacked bricks
Implementation Method 3
a dynamic insulation system to manage temperature uniformity and airflow
Data Source
AI summary
An energy storage system converts variable renewable electricity (VRE) to continuous heat at over 1000° C. Intermittent electrical energy heats a solid medium. Heat from the solid medium is delivered continuously on demand. An array of bricks incorporating internal radiation cavities is directly heated by thermal radiation. The cavities facilitate rapid, uniform heating via reradiation. Heat delivery via flowing gas establishes a thermocline which maintains high outlet temperature throughout discharge. Gas flows through structured pathways within the array, delivering heat which may be used for processes including calcination, hydrogen electrolysis, steam generation, and thermal power generation and cogeneration. Groups of thermal storage arrays may be controlled and operated at high temperatures without thermal runaway via deep-discharge sequencing. Forecast-based control enables continuous, year-round heat supply using current and advance information of weather and VRE availability. High-voltage DC power conversion and distribution circuitry improves the efficiency of VRE power transfer into the system.