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CANDIDATE THERMAL ENERGY

STORAGE TECHNOLOGIES FOR

SOLAR INDUSTRIAL PROCESS

HEAT APPLICATIONS(van-Ts-81380) CANDIDATE TDERNAL `INEB6T 580-1556STORAGE TECHNOLOGIES FOB SOLAR INDUSTRIALPROCESS NEAT APPLICATIONS (NASA) 112 pHC A02/87 A01 CSCL 106 Uaclas

03/44 46560

Edward R. FurmanNational Aeronautics and Space AdministrationLewis Research Center

Work performed forU.S. DEPARTMENT OF ENERGYEnergy TechnologyEnergy Storage Systems Division

Prepared forSolar Industrial Process Heat Conferencesponsored by the Solar Energy Research Institute`_:Oakland, California, October 31 - November 2, 1979

h

NOTICE

This report was prepared to document work sponsored by

the United States Government. Neither the United States

nor its agent, the United states Department of Energy,

nor any Federal employees, nor any of their contractors,

subcontractors or their employees, makes any warranty,

express or implied, or assumes any legal liability or

responsibility for the accuracy, completeness, or useful-

ness of any information, apparatus, product or process

disclosed, or represents that its use would not infringe

privately owned rights.

r

i i

DOEINASA11034-7916NASA TM-81380

CANDIDATE THERMAL ENERGY

STORAGE TECHNOLOGIES FOR

SOLAR INDUSTRIAL PROCESS

HEAT APPLICATIONS

Edward R. FurmanNational Aeronautics and Space AdministrationLewis Research CenterCleveland, Ohio 44135

Work performed forU. S. DEPARTMENT OF ENERGYEnergy TechnologyEnergy Storage Systems DivisionWashington, D.C. 20545Under Interagency Agreement EC-77-A-31-1034

Solar Industrial Process Heat Conferencesponsored by the Solar Energy Research InstituteOakland, California, October 31- November 2, 1979

CANDIDATE THERMAL ENERGY STORAGE TECHNOLOGIES FORSOLAR INDUSTRIAL PROCESS HEAT APPLICATIONS

E. FurmanNASA-Lewis Research Center

Cleveland, Ohio

ABSTRACT

The successful application of solar industrial process heat (SIPH)will depend, in part, on the use of thermal energy storage (TES) toprovide continuous operation during periods of solar isolation. Anumber of candidate TES system elements have been identified ashaving the potential of meeting this need. These elements whichinclude storage media, containment and heat exchange are shown.

in

Recently completed system studies on selected industries have

N

identified a number of processes where TES appears attractive. These

w systems and the suggested TES subsystems are shown and discussed.

INTRODUCTION

A necessary requirement for the successful application of solarthermal energy to industrial processes is the need to providecontinuous operation of the processes during periods of solarisolation. The degree of acceptance and utilization of solar energyWill therefore depend upon the successful development and integrationoR thermal energy storage (TES) subsystems with the solar industrialprocess heat (SIPH) installation. The technology base for candidateTES subsystems is being investisated and expanded by DOE-fundedprograms to include a wide selection of media, containment, and heatexchange in a temperature range of 250-11000C.(500-20000F).Current TES emphasis for solar application is on buffered storage (.5to 2 hours), however, some of the same technologies could be appliedto larger storage capacities (diurnal applications). Studies anddevelopment of advanced storage subsystems are being undertaken toidentify solar industrial process heat systems in the intermediate tohigh temperature range. These activities will provide the basis fora detailed technical and economic evaluation of the most promisingstorage subsystems. Selected storage approaches will be coupled withspecific applications and analyzed in detail.

The Department of Energy Division of Energy Storage Systems(DOE/STOR) has the responsibility for formulating and managingresearch and development in energy storage technologies. Majorresponsibility for project management in selected areas has beenassigned to DOE national laboratories and other government agencies.The current management structure and major area of development forthe lead laboratories is shown in Figure 1. The lead center willprovide overall management for the TES program including planning,integration and coordination of the involved lead laboratories. Leadlaboratories will be delegated prime responsibility and appropriateauthority for the day-to-day management and implementation ofactivities in their designated areas.

THERMAL ENERGY STORAGE TECHNOLOGIES

Figure 2 illustrates the interdependency of the various systemelements. The end use application will define the TES subsystemdesign and operational requirements. The designer's function will beto select the TES subsystem elements which best meets theserequirements while considering the many constraints includingtechnical, economic, environmental, institutional and other factors.It is evident that with the variety of storage media available andvarious types of containment and heat exchange, a large number ofcombinations are possible. To minimize the development complexityand costs, it has been necessary to limit the number of TESconcepts. For near-term applications, the major development efforthas been directed to the utilization of existing technologies. Thishas included sensible heat media, low pressure containment and aboveground installations. For advanced systems, both sensible and latentheat media are being studied and tested. Figures 3a, b and cillustrate the variety of media currently being considered, theplanned operational temperature range for the media and theinvestigators or proponents for the concept. An attempt is beingmade to cover the anticipated end use operational temperature rangewith the selection of at least one medium for a given temperature.This is shown in Figures 3a, b and c, where various types of mediahave been selected to cover any given temperature range.

TES Containment, Figure 4, shows the divergent technologies whichhave been proposed for TES media containment. Most of these advancedconcepts have addressed the containment problem associated with hightemperature, high pressure water. Descriptions for the variousconcepts can be obtained from the designated references. Similarly,for latent heat applications of molten salts a variety of heatexchange concepts have been proposed, Figure 5. The withdrawal ofheat energy from the molten salt at the solidification temperaturesresults in the deposition'of a solid salt layer on the heat transfersurface. Since salts generally have low heat transfer coefficients,this results in a high and variable resistance to heat transfer. Theactive heat exchange concepts are being developed to minimize this

2

problem. Figure 6 illustrates a concept currently underinvestigation at Honeywell Inc. The system employs a moltenNaNO3-NaOH mixture as the energy source. The molten salt is pumpedinto the refiux Filer and water from the condensate stream isdirectly injected into the salt. The saturated water vapor which isgenerated is conducted to the condenser as a result of the existingpressure differential within tho system and the energy is transferredto the cycle working fluid. The molten salt in passing through theboiler loses only a small mount of its energy. 'Under theseconditions, the selected salt mixture (a dilute eutectic) forms atwo-phase slush which is returned to the storage tank where phaseseparation occurs and the molten salt is recycled.

INDUSTRIAL PROCESS AND REJECT HEAT APPLICATIONS

The "Energy Policy and Conservation Act" (EPCA) Public Law 97-163 waspassed by the 94th Congress on December 22, 1975. Part D of TitleIII of this Act required that FEA establish a program to promoteincreased energy efficiency in the United States industry. Thisprogram included the identification and ranking of majorenergy-consuming manufacturing industries, the establishment ofenergy efficiency improvement targets for the ten most energyconsumptive industries, and the identification of majorenergy-consuming corporations within the targeted industries for thepurpose of reporting industry progress in improving energy efficiency.

DOE assigned with the responsibility of conservation released aProgram Research and Development Announcement (PRDA) in January 1911to identify industrial processes where process or reject heatrecovery systems using TES could be beneficial. Recently completedsystem studies on selected industries have identified a number ofprocesses where TES appears attractive. These included the foodprocessing, paper and pulp, iron and steel, and cement industries.Subsequent to these studies, it was discovered that the Scandinavianpaper and pulp industry and a few companies within the United Statesare already using TES in their processes. As a result, a contracthas been placed for the collection and dissemination of the availableTES information to the American paper and pulp industry.

Food Processing

The food processing industry is a major user of low temperature(below 12000 process heat. The industry requires energy at therate of 1x10 5 BTU/YR (1 Quad), and this places the industry sixthamong the nations largest energy consumers. Within the food industrythe tanning segments (SIC 2032 and 2033, c nned specialties andcanned fruits and vegetables) require 70x102 BTU input annuallywhich represents about 7% of the food industry total. Low pressuresteam 0.7 MPa ( 100 psig) produced on site is generally the sourceof energy, and it is directly used by infusion and by processes that

3

require a steam atmosphere. Other processes require hot water whichis produced by steam/water heat exchange or by cold water-steaminfusion. These processes or process-related operations include:cooking, sterilizing, pasteurizing, can- washing and clean- up. Thisstudy was performed by the Westinghouse Electric Corporation incooperation with the Heinz USA - Pittsburgh Division of the H. J.Heinz Company and was funded by the U.S. Department of Energy(Contract EC-77-C-01-5002) and managed by the Oak Ridge NationalLaboratory. A schematic of a proposed TES/Waste Heat Recovery Systemin a Food Processing Plant is shown in Figure 7 for the Heinz USA -Pittsburgh plant. Waste heat from these operations are in the40-950C (100-2000F) temperature range and can be separated intohigh temperature (above 60 0C) and low temperature (below 600C)streams. The energy in the high temperature stream only will be usedrecuperatively through conventional heat exchange to fresh water.This isolation will prevent contamination of the water used in thefood processes. The recuperated fresh water is sent to the TESmodule for later usage or heated to process temperatures by stemsheat exchange or hot water infusion and returned to the process.Water that is accumulated in storage during the production periodwill be used for clean-up operations during the night shift. Theestimated eT8rgy savings for this installation is in excess of 32TJ/YR ( 3x10 BTU/YR), and based on a duplicate system cost of$190,000 the return-on-investment is computed to be better than 30%.A sole-source procurement is currently being negotiateo with HeinzUSA to install a demonstration system in their Pittsburgh facility.

Iron and Steel

The primary iron and steel industry consumes about 11% of the totalnational industrial energy usage. The Rocket Research Company withsupport from the Bethlehem Steel Company and the City of SeattleLighting Department conducted a study entitled "Application ofThermal Energy Storage Techniques to Process Heat and Waste Recoveryin the Iron and Steel Industry". Waste heat recovery in thetemperature range of 315 - 15400C ( 600-28000F) was indicated asbeing potentially recoverable. The system selected in the study isshown in Figure 8. Waste energy from the primary arc furnaceevacuation system is passed through an operational store TES modulewhich acts as a buffer to dampen the temperature variations which areinherent in the furnace discharge. The fume stream is then passedthrough the peaking store TES module where the energy is stored assensible heat in a packed bed (refractory brick, slag or scrap steel)and is exhausted through the baghouse. During discharge fromstorage, the gas flow in the peaking store TES loop is reversed andthe heated gases are blended with the discharge gases from theoperational store TES discharge in the mixing valve, passes throughthe heat exchanger and into another mixing valve. Part of the flowis recirculated through the peaking store TES module and theremainder passes to the baghouse. A steam-driven turbine operates togenerate power for peak shaving (either in-plant or for utility areademand peaks).

4

_. _^

L

The proposed conceptual system for the Bethlehem plant could resultin an estimated payback period of five years depending on thecombination of electricity costs and the size of the power generationequipment. Assuming fossil fuel is used to produce peak power, thepotential oil savings for a 7 MW generator operating 300 days/yearwoul be 16,000 bbl. Overall inSustry oil savings could approach2x100 bbl.

Cement

The cement industry is the sixth largest user of industrial energy inthe United States. The majority of this ener

le (80%) is consumed as

fuel in the operation of the kilns, however, ss than 50% of theenergy input is required in the chemical reaction to form clinkers.Martin Marietta Aerospace with team members Martin Marietta Cementand the Portland Cement Association, investigated the use of TES inconjunction with current reject heat usage in the cement industry.Details of this study are contained in the final report "Applicationof Thermal Energy Storage in the Cement Industry% Waste heat fromthe kiln is obtained from the gas effluent and from the clinkercooler excess air. This is illustrated in Figure 9 where two TESmodules using solid sensible heat storage material, such as, magnesiabrick, granite, limestone or cement clinkers are shown. The exhaustgas heats the high temperature bed to 8150C (15000F) while the

clinker cooling gases heats the low temperature bed to about 23500(4500F). The modules are discharged in a series flow to supply

ambient air heated to 65000 (12000F) to the waste heat boiler

where steam is generated to produce electricity. A 10 MW outputis planned to operate continuously. This requires that 88-90% of theexhaust flow go directly to the boiler with the balance going intostorage. At this rate, storage would be fully charged (240 MWehrcapacity) in one week.

The economic analyses of the system indicates that for the proposedinstallation the cost would be 10 million dollars and a ROI of 90% isanticipated for a 30 year system life and an average energy cost of2.8t/kwh. About 15% of this ROI is attributed to the TES s tem.The potential energy savings for the cement industry is 4x10 bblof oil.

SOLAR POWER GENERATION

A concept which utilizes a moving bed of free-flowing solid granulesor microspheres as a mechanism for heat absorption, storage, andtransfer to a working fluid has been proposed by the Babcock andWilcox Company for Solar application. This concept is shorn inFigure 10. Silica sand or.fused silica microspheres are transferredupward by Archimedes pumps from the steam generator discharge to thesolar collector where the free-flowing sand is heated to 54000(10000F) as it flows downward through vertical tubes in the

5

collector. A portion of this heated sand is directed to the steamgenerator via the central supply tube and the remainder is put intostorage. The heated sand refills the storage bin as cool sand isdisplaced from the bottom until the heating cycle is completed.During the night, high temperature sand from storage supplies theenergy input to the boiler. The solar collector is by-passed duringthis period by opening the sliding baffle in the upper pump conduit.The lift pump speed is controlled to maintain the desired temperatureprofiles in the cycle. Sufficient inergy is collected and stored toprovide 28.5 MWt continuously over a 24 hour period. This energyis converted to steam at 5.2 MPa, 43000 (750 psia, 8000F) and toan electrical output of 10 MW.

CONCLUDING REMARKS

Industrial production energy requirements are about 40% of the totalenergy consumed in the United States. The major share of the energyis derived from fossil fuels and significant savings are possiblethrough the use of solar generated process heat coupled with thermalenergy storage. DOE/STOR's current activities are directed to thedevelopment of generic storage subsystems which will be applicable tosolar industrial process heat systems in the intermediate to hightemperature range. In-house studies are planned durng the currentfiscal period to identify technology requirements for SIPHapplications. These studies will provide the course for futureresearch and directed development efforts. The ultimate objective ofthis effort is the demonstration of cost-effective thermal energystorage systems capable of complementing the solar generated processheat source and contributing to energy conservation in the industrialsector.

In addition to the contents of this paper, a panel summary on Storagefor Solar Process Heat should also be noted (reference 11). Thepanel recommended that primary emphasis for the near-term (1980-85)and mid-term (1985-90) should be directed to the transfer ofdeveloped industrial process heat storage technologies to solarapplications. In support of SIPH applications for the far term(beyond 1990), an aggressive program should be planned andimplemented within the next five years to develop the technologiesrequired for the transport of solar process heat to the industrialusers (via chemical reactions or hydrogen).

REFERENCES

1. First Annual Thermal Eneray Storage Contractors' Information Exchan eeet n9, Lewis Research Center, Cleveland, Ohio, September d.

2. S cond Annual Thermal Energy Storage Contractors' Information

beer

M tom, Oak Ridge National Laboratory, t inburg, Tennessee,29-30, 1977, CONF-770955, 1977.

3. Third Annual Thermal Enera Stora ge Contractors' Information Exchan

met no, Springfieli, Virginia, December 5-5, 1978, C NF- 19%.

4. Hausz, W.. Berkowitz, B. J.. and Hare, R. C.. "Conceptual Design ofThermal Energy Storage Systems for Near Term Electric Utility Applica-tions, Volume Two: Appendices - Screening of Concepts," General Elec-tric Company, GE78TMP-60-Vol. 2, DOE/NASA/0012-78/1-Vol. 2, NASA CR-159411-Vol. 2. October 1978.

S. Lundberg, W. L. and Wojnar, F.. "Applications of Thermal Energy Storageto Waste Heat Recovery in the Food Processing Industry," presented atthe 14th Intersociety Energy Conversion En ginegring Conference, Boston,Massachusetts, August 5-10, 1979, ACS Paper 799099.

6. "Cost Study, Shop Assembly Versus Field Assembly of Heavy Wall CoalGasifier Reactor Vessels," Energy Research and Development Administra-tion, FE-2009-13, December 1976.

7. MacCracken, C. D., "Sodium Sulfate Thermal Storage," Contract NAS3-20986, Calmac Manufacturing Corporation, June 1978.

8. Burolla, V. P. and Bartel, J. J., "The High Temperature Compatibilityof Nitrate Salts, Granite Rock and Pelletized Iron Ore," Sandia Labs.,SAND79-8634, August 1979.

9. Schluderberg, D. C. and Thornton, T. A., "Moving Bed Heat Transfer forAdvanced Power Reactor Applications," presented at Miami InternationalConference on Alternative Energy Sources, Volume 9, Hemisphere Publish-ing Corporation, 1978. pp. 3959-3980.

10. Davidson, W. W., et al., "Closed Brayton Cycle Advanced Central Re-ceiver, Solar-Electric Power System, Volume II." U.S. Department ofEnergy, SAN/1726-1, November 1978.

11. "Proceedings of Solar Enerqj Storage Options Workshop," San Antonio,Texas. March 19-ZO,F- J cto er 1979.

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Prepared under Interagency Agreement EC-77-A-31-1034. Work performed for Solar IndustrialProds Heat Conference sponsored by the solar Energy Research Institute, Oakland,California October 31 - November 2 1979.

16. Abwm

The successful application of solar industrial process heat ($1PH) will depend, in part, on theuse of thermal energy storage ( TES) to provide continuous operation during periods of solarIsolation. A number of candidate TES system elements have been identified as having thepotential of meeting this need. These elements which include storage media, containment andheat exchange are shown. Rscertly completed system studies to selected industries haveidentified a number of processes where TES appears attractive. These systems and the sug-gested TES subsystems are shown and discussed.

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Thermal energy storage Unclassified - unlimitedSensible hest STAR Category 44

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Industrial process beat

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