Brick Thermal Storage Arrays With Thermocline Deep Discharge
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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 high-temperature 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 transfer for discharging, 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
1Loss of energy
If thermal energy storage systems use variable renewable electricity sources for charging, then energy cost is reduced and sustainability is improved, but the variability and intermittency of these sources make it difficult to provide continuous and reliable energy supply
Solution Approach 1:
The system performs preliminary charging of thermal energy storage units during periods when renewable energy is available and costs are low, storing energy in advance for later use. The controller predicts energy availability and prices to optimize charging timing, ensuring energy is stored before demand peaks or renewable sources become unavailable.
Solution Approach 2:
The controller continuously monitors the state of charge, temperature, and energy availability from renewable sources, adjusting charging and discharging operations in real-time. This feedback mechanism ensures reliable energy supply by balancing storage operations with variable input conditions and demand requirements.
2Productivity
If thermal energy storage systems operate at high temperatures for industrial applications, then energy density and efficiency are improved, but thermal runaway issues and safety risks increase
Solution Approach 1:
The thermal energy storage system is divided into multiple independent storage units, each equipped with its own heating elements and temperature sensors. This segmentation isolates potential thermal runaway events to individual units, preventing system-wide failures while maintaining high operating temperatures for improved energy density.
Solution Approach 2:
The system implements predictive thermal management that monitors temperature trends and predicts potential thermal runaway conditions before they occur. The controller adjusts heating power and activates cooling measures in advance, creating a safety buffer that prevents thermal runaway while allowing high-temperature operation for improved productivity.
3Device complexity
If thermal energy storage systems use simple charging and discharging controls, then device complexity is reduced and ease of operation is improved, but inadequate control limits the ability to optimize energy flow and manage temperature effectively
Solution Approach 1:
The control system dynamically adjusts charging and discharging rates based on real-time conditions including renewable energy availability, storage unit state of charge, temperature, and demand forecasts. This dynamic control optimizes energy flow and thermal management without requiring complex manual intervention, achieving high productivity through adaptive automation.
Solution Approach 2:
The controller autonomously manages the thermal energy storage system, making decisions about charging, discharging, and temperature regulation based on sensor data and predictive algorithms. This self-service capability eliminates the need for complex external control systems while optimizing energy flow and maintaining effective temperature management.
4Speed
If thermal energy storage systems use electrochemical storage methods like lithium-ion batteries, then rapid response to supply and demand changes is achieved, but high costs limit wide adoption
Solution Approach 1:
The system uses cost-effective thermal energy storage media such as phase-change materials or sensible heat storage in tanks, which are significantly cheaper than electrochemical batteries. While the response speed is slower, the system compensates through optimized thermal management and predictive control, achieving acceptable performance at much lower cost for wide-scale adoption.
Solution Approach 2:
The system changes the operating parameters of thermal storage units, adjusting temperature ranges and heat transfer rates to optimize response speed within the constraints of thermal physics. By operating at elevated temperatures and using high-conductivity materials, the system achieves faster thermal response without the high costs of electrochemical storage.
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 preventing thermal runaway, while ensuring continuous and reliable energy supply to industrial processes despite variations in renewable energy sources.
Implementation Method 1
resistive heaters connected via switching circuitry, employing radiative heat transfer for charging
Implementation Method 2
vertically oriented thermal storage units with stacks of bricks
Implementation Method 3
employing radiative heat transfer for charging and convective heat transfer for discharging
Implementation Method 4
dynamic insulation system to manage temperature and energy flow
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.