Brick Thermal Storage Assembly for Continuous High-Temperature 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, 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 stacks of bricks and resistive heaters connected via switching circuitry, employing radiative heat transfer for charging and convective heat discharge, along with a dynamic insulation system and a smart energy controller to manage temperature and energy flow based on forecasted conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If thermal energy storage systems use variable renewable electricity sources, then environmental sustainability is improved, but reliability of continuous heat supply deteriorates due to variability and intermittency
Solution Approach 1:
The system performs preliminary action by storing thermal energy in advance when renewable electricity is available. Thermal storage units accumulate heat during periods of high renewable generation, preparing energy reserves before demand occurs, thus bridging the gap between intermittent supply and continuous demand.
Solution Approach 2:
The patent introduces thermal energy storage as an intermediary between variable renewable electricity sources and continuous heat demand. The storage system mediates the mismatch by decoupling generation from consumption, allowing energy to be transferred across time while maintaining reliability.
2Speed
If electrochemical energy storage systems are used, then rapid response to supply and demand changes is improved, but cost increases significantly
Solution Approach 1:
The system employs cost-effective thermal storage media such as rocks, sand, or water that can be replaced or replenished relatively inexpensively. These simpler, shorter-lived thermal storage materials substitute for expensive electrochemical batteries, reducing overall system cost while maintaining functional performance.
Solution Approach 2:
The patent changes the energy storage parameter from electrochemical to thermal, fundamentally altering the storage mechanism. This parameter change enables the use of abundant, low-cost materials like rocks and water instead of expensive battery chemicals, significantly reducing system cost.
3Quantity of substance
If thermal energy is stored in bulk underground, then storage capacity is improved, but control and retrieval precision deteriorates
Solution Approach 1:
The system segments the thermal storage into multiple discrete units containing individual brick stacks, each with its own heating and cooling channels. This segmentation enables independent control of each unit, allowing precise temperature management while maintaining large aggregate storage capacity.
Solution Approach 2:
The patent applies local quality by providing differentiated heating and cooling pathways for different regions of the storage system. Each brick stack can be independently heated or cooled based on local demands, enabling precise spatial and temporal temperature control throughout the entire storage capacity.
4Device complexity
If thermal energy storage systems use conventional designs, then simplicity is maintained, but thermal runaway issues and inadequate control increase
Solution Approach 1:
The system implements feedback control by continuously monitoring temperatures in thermal storage units and automatically adjusting heating and cooling rates. Sensors detect temperature conditions and feed this information back to controllers, which modulate energy input to prevent thermal runaway and maintain stable operation.
Solution Approach 2:
The patent introduces an intermediary control system that mediates between energy input and thermal storage materials. This control layer prevents direct, uncontrolled energy input that could cause thermal runaway, instead using gradual, regulated energy transfer through intermediate heat exchange 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, cost-effective storage and delivery of high-temperature thermal energy, mitigating thermal runaway and ensuring reliable operation over long periods, while reducing reliance on fossil fuels and optimizing energy use based on variable renewable energy availability.
Implementation Method 1
resistive heaters attached to the exterior surfaces of opposing sides of each of the brick stacks and configured to heat the brick stacks
Implementation Method 2
employing radiative heat transfer for charging
Implementation Method 3
convective heat discharge
Implementation Method 4
an insulative layer interposed between the plurality of TSUs, the roof and at least one of the sides
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.