Thermal Energy Storage Heater Control for Uniform High-Temperature Output
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Solution Overview
Problem
Current thermal energy storage systems face challenges in efficiently storing and delivering thermal energy from variable renewable energy sources due to issues such as thermal runaway, non-uniform heating and cooling, high costs, and the need for flexible and cost-effective energy storage solutions that can handle intermittent energy supply while maintaining sufficient outlet temperature and seismic stability.
Innovation Solution
A thermal energy storage system with modular design, dynamic insulation, and advanced control systems that utilize thyristor-free switching and staged mechanical switches to manage energy flow, ensuring efficient charging and discharging, reducing thermal imbalances, and integrating with existing infrastructure for seamless integration with renewable energy sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal energy storage systems use conventional heating methods, then thermal energy can be stored, but thermal runaway and non-uniform heating occur reducing system reliability
Solution Approach 1:
The heating system is divided into multiple independent heater zones that can be controlled separately. Each zone has its own temperature sensors and control logic, allowing localized adjustment to prevent thermal runaway and ensure uniform heating across the entire thermal storage medium.
Solution Approach 2:
Different regions of the thermal storage system receive differentiated heating control. Zones prone to thermal runaway are monitored more closely and receive modulated heating, while cooler zones receive increased heating power, creating non-uniform control strategy that achieves uniform thermal distribution and prevents harmful thermal effects.
2Adaptability or versatility
If variable renewable energy sources are used for thermal energy storage, then clean energy utilization is improved, but intermittent supply causes challenges in meeting continuous industrial demands
Solution Approach 1:
The system performs preliminary heating of the thermal storage medium when renewable energy is available, storing thermal energy in advance for later use. Temperature sensors monitor charge levels and control heaters to pre-heat the storage medium, ensuring energy availability even when renewable supply is intermittent.
Solution Approach 2:
The system maintains continuous useful action by switching between renewable energy charging and controlled discharging phases. Thermal energy stored in the medium provides continuous supply to industrial processes, while the control system continuously manages the balance between charging from renewable sources and discharging to meet demand.
3Productivity
If high power heating is applied to thermal storage systems, then charging speed is improved, but thermal runaway risk increases reducing safety
Solution Approach 1:
The heating system applies periodic heating cycles rather than continuous high power heating. Controllers modulate heater operation in cycles, providing high power intermittently to achieve fast charging while allowing cooling periods that prevent thermal runaway. This periodic action maintains productivity while enhancing safety.
Solution Approach 2:
Temperature sensors provide continuous feedback to the control system, which adjusts heater power in real-time based on measured temperatures. When temperatures approach critical thresholds, the system automatically reduces or shuts off heating power, preventing thermal runaway while maintaining optimal charging speed within safe operating limits.
4Ease of operation
If conventional control systems with thyristors are used, then power control is achieved, but system complexity and cost increase
Solution Approach 1:
The system extracts and removes complex thyristor-based power control components, replacing them with simpler solid-state switching devices. This extraction of unnecessary complexity reduces system cost and maintenance requirements while retaining adequate power control capability through modern, simpler electronic components.
Solution Approach 2:
The control system uses inexpensive, easily replaceable solid-state switches instead of expensive, complex thyristor assemblies. While individual switching components have limited lifetimes, their low cost and simplicity make them more economical than expensive thyristor systems, aligning with the principle of using cheap, replaceable components rather than expensive, complex ones.
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 effectively stores and delivers thermal energy at high temperatures, reducing costs and maintaining reliability and efficiency, while allowing for flexible operation and integration with existing industrial systems, enhancing seismic stability and reducing reliance on fossil fuels.
Implementation Method 1
heaters attached to a plurality of stacks of thermal storage blocks
Implementation Method 2
storage of energy as sensible heat in tanks of liquid, including water, oils, and molten salts; sensible heat in solid media, including rock, sand, concrete and refractory materials
Implementation Method 3
latent heat in the change of phase between gaseous, liquid, and solid phases of metals, waxes, salts and water
Implementation Method 4
a blower that blows relatively cooler fluid such as air or another gas (e.g. CO2) along the flow path
Implementation Method 5
thermal energy in industrial, commercial, and residential applications may be collected during one time period, stored in a storage device
Implementation Method 6
The radiation chamber structure provides a key advance in the design and production of effective thermal energy storage systems that are charged by electrical energy
Data Source
AI summary
A thermal energy storage (TES) system converts variable renewable electricity (VRE) to continuous heat at over 900° C. Intermittent electrical energy heats a solid medium. Heat from the solid medium is delivered continuously on demand. Heat delivery via flowing gas establishes a thermocline which maintains high outlet temperature throughout discharge. The delivered heat which may be used for processes including power generation and cogeneration. The TES system is configured to include control system components that reduce thermal losses associated with component inefficiency.