Ceramic Base Support for High-Temperature Graphite Thermal Storage
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Solution Overview
Problem
Graphite-based thermal energy storage systems are limited by the thermal tolerance of downstream equipment and supporting structures, which restrict the maximum operating temperature of the graphite medium to around 700°C, despite its theoretical capability to operate at temperatures exceeding 3000°C, due to the limitations of traditional connecting components and heat exchangers.
Innovation Solution
A high-temperature thermal energy storage unit that utilizes a ceramic support block with minimal thermal expansion and insulating properties to reduce conductive heat loss, along with a mixing manifold and fluid distributing manifold to control the temperature of the output thermal energy transfer fluid, allowing operation above 700°C while ensuring the fluid temperature remains within tolerable limits for external components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the graphite storage body operates at temperatures exceeding 700°C, then the thermal energy storage capacity and efficiency are improved, but the downstream equipment (connecting components and heat exchangers) cannot tolerate the temperature
Solution Approach 1:
A fluid mixing manifold is introduced as an intermediary device between the high-temperature graphite storage body and the downstream equipment. This manifold mixes the hot thermal energy transfer fluid from the graphite body with cooler fluid, thereby reducing the temperature of the fluid entering downstream equipment to acceptable levels while allowing the graphite body to operate at optimal high temperatures
Solution Approach 2:
The thermal energy transfer fluid flow is segmented into multiple streams within the mixing manifold - a hot stream from the graphite storage body and a cooler stream that is mixed with the hot stream. This segmentation allows temperature control of the fluid delivered to downstream equipment while maintaining high temperature operation in the graphite body
2Loss of energy
If carbon foam insulation is used to insulate the outer vessel from the high temperature core, then the thermal insulation is improved, but the support structure requires stronger materials with lower insulating capabilities due to the weight of the graphite core
Solution Approach 1:
The support blocks are designed with non-uniform geometry, featuring a larger cross-sectional area at the top (contacting the graphite core) that tapers to a smaller cross-sectional area at the bottom. This local variation in geometry provides enhanced structural support where the graphite core weight is greatest while minimizing the volume of support material, thereby reducing heat conduction paths and improving thermal insulation performance
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
Enables the effective operation of graphite-based thermal energy storage systems at temperatures exceeding 1000°C without exceeding the thermal tolerances of external components, allowing for the use of stronger, less insulative materials for support and efficient energy transfer to conventional equipment.
Implementation Method 1
a ceramic support block with minimal thermal expansion and insulating properties to reduce conductive heat loss
Implementation Method 2
a mixing manifold and fluid distributing manifold to control the temperature of the output thermal energy transfer fluid
Data Source
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AI summary
It is disclosed a high temperature thermal storage unit (12) having a high temperature storage segment (4) with a series of heat transfer passages (121) extending there through for energy offloading to a thermal energy transfer fluid passing through the heat transfer passages (121) and a series of electrical powered heaters (30) located within said high temperature storage segment for heating thereof. The high temperature thermal storage unit (12) includes a high temperature ceramic base (6) located below and supporting the high temperature storage segment (4). The ceramic base (6) includes a top surface in contact with the high temperature storage segment (4), side walls extending downwardly from the top surface and supporting the top surface along a length thereof. The ceramic base (6) includes two or more cavities (6d, 6e) between the sidewalls and extending parallel to the length of the top surface. At least one of the cavities acts as a pathway for distributing the thermal energy transfer fluid to an inlet end of the high temperature storage segment.