Brick Thermal Storage Cavities for Continuous 1000°C Heat
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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, particularly due to issues like thermal runaway, high costs, and the inability to maintain sufficient outlet temperatures using lower-cost solid media, while also struggling with rapid charging and discharging requirements for industrial applications.
Innovation Solution
The implementation of a thermal energy storage system that uses vertically oriented thermal storage units with stacks of bricks and resistive heaters connected via switching circuitry, an insulative layer, and a blower for air or gas flow, along with a controller managing energy based on ambient conditions, to achieve efficient heat transfer and uniform heating, thereby addressing thermal runaway and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal energy storage systems use lower-cost solid media, then cost is reduced, but the ability to maintain sufficient outlet temperatures deteriorates
Solution Approach 1:
The system divides the thermal storage function into separate components: heating elements directly contact the solid media (bricks or rocks) to heat them, while a fluid circulation system separately handles heat transfer to maintain outlet temperatures. This segmentation allows use of low-cost solid media while preserving temperature control capability through the dedicated fluid heating system.
2Productivity
If thermal energy storage systems are designed for rapid charging and discharging, then productivity is improved, but thermal runaway risk increases
Solution Approach 1:
A fluid intermediary (water or other heat transfer fluid) is introduced as a buffer between the solid thermal storage media and the heating elements. The fluid circulates through channels in the solid media, absorbing and transporting heat gradually. This intermediary prevents direct thermal contact that could cause runaway heating, while still enabling rapid energy transfer to meet productivity requirements.
Solution Approach 2:
The system incorporates temperature sensors and control systems that continuously monitor the thermal state of the solid media and fluid circulation. When temperature thresholds are approached, the control system automatically adjusts heating element power or fluid flow rates, providing negative feedback that prevents thermal runaway while maintaining optimal charging rates for high productivity.
3Temperature
If heating elements operate at high temperatures to maintain outlet temperature, then temperature output is improved, but heating element life deteriorates
Solution Approach 1:
The fluid circulation system acts as a thermal intermediary, allowing heating elements to operate at moderate temperatures while still delivering high-temperature output through the heated fluid. The fluid absorbs heat from the elements and transports it to the outlet, reducing thermal stress on the heating elements and extending their operational life while maintaining required outlet temperatures.
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
This system enables the efficient storage and delivery of high-temperature thermal energy, reducing costs and extending the life of heating elements by minimizing peak temperatures and optimizing charging rates, while ensuring continuous energy supply to industrial processes.
Implementation Method 1
resistive heaters connected via switching circuitry
Implementation Method 2
a blower for air or gas flow
Implementation Method 3
an insulative layer
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.