HIGH TEMPERATURE THERMAL ENERGY STORAGE, A METHOD OF BUILDING AND A METHOD OF OPERATING SAID STORAGE
20180003445 · 2018-01-04
Assignee
Inventors
Cpc classification
Y02E60/14
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F28D20/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D20/021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D1/0477
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D20/0034
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D2020/0021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D2020/0082
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D2020/0078
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D20/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
High temperature thermal energy storage, distinctive in that the storage comprises: a thermally insulated foundation, at least one self-supported cassette arranged on said foundation, which cassette is a self-supporting frame or structure containing a number of concrete thermal energy storage elements, some or all of said elements comprising embedded heat exchangers, a pipe system, the pipe system comprising an inlet and an outlet for thermal input to and output from the storage, respectively, and connections to said heat exchangers for circulating fluid through said heat exchangers for thermal energy input to or output from said thermal energy storage elements, and thermal insulation around and on top of the at least one self-supported cassette with concrete thermal storage elements. The invention also provides a method of building and methods of operating the storage.
Claims
1. A method for building a high temperature thermal energy storage, the method comprising: to build a thermally insulated foundation for the storage, to build at least one self-supported cassette, which cassette is a self-supporting frame or structure containing a number of concrete thermal energy storage elements, by building the frame or structure, by building a number of individual concrete thermal energy storage elements, some or all of the elements comprising heat exchangers embedded in the concrete, and by arranging the elements in the frame or structure, to arrange and/or build the at least one cassette on the foundation, to build and operatively connect a pipe system, the pipe system comprising an inlet and an outlet for thermal input to and output from the storage, respectively, and connections to the heat exchangers for circulating fluid through the heat exchangers for thermal energy input to or output from the thermal energy storage elements, and to arrange thermal insulation around and on top of the self-supporting cassettes containing concrete thermal energy storage elements.
2. The method according to claim 1, comprising at least one of the following steps: to stack a number of cassettes vertically on the foundation, building one or several stacks of cassettes arranged as one or several rows of stacks; to arrange the stack or stacks of cassettes so that the concrete thermal energy storage elements are horizontally oriented; to arrange cassettes with concrete thermal energy storage elements vertically standing on the foundation, which is particularly feasible with gas as heat transfer fluid, and preferably including the step to build the cassettes with the elements as vertically standing on the foundation, to arrange the pipe system on one side of the cassette or stack of cassettes; to connect the vertical cassettes in series via pipes that connect to the heat exchangers in the cassettes; to arrange the pipe system so that several stacks of cassettes are coupled in parallel; to arrange the pipe system and cassettes or stacks of cassettes in blocks, so that each block can be isolated from the rest of the storage by operating valves of the pipe system; to stack and arrange cassettes packed so that a ratio of the outer surface area to volume is minimized, achieving a closely packed volume of the storage with small footprint, to arrange the cassettes so that the concrete thermal energy storage elements are horizontally oriented and the pipe system is arranged on one side of the cassettes in a row of cassettes, facing one side of the storage, to combine an outer metal shell of the concrete thermal energy storage element and the cassette frame as one structure functioning as a form for casting of concrete, armoring for the concrete, heat transfer fluid leakage catcher and the self-supporting modular cassette structure, to arrange or build a heat exchanger for one cassette or one concrete thermal energy storage element as one structure.
3. The method according to claim 1, wherein the step to build at least one self-supported cassette comprises the steps: to build a frame, to arrange outer metal shells of thermal energy storage elements in the frame, the outer metal shells of the thermal energy storage elements being a combined casting form, reinforcement and containment of fluid for thermal energy input or output if fluid leakage occur; to arrange heat exchangers and optional electric heaters into he metal shells; with the outer metal shells oriented in a vertically standing position and with an open upper end, to fill grout or concrete mixture up to a prescribed level at which level the ends or connections of the heat exchangers extend up over the top of the elements as standing vertical; to cure the grout or concrete, and to handle and transport the cassette, placing the cassette at its intended position and orientation in the storage, whereby wherein the frame is used not only as a fixture for casting and curing the concrete thermal energy storage elements, and a structure for facilitating handling and transport of the elements, but also as a self-supporting structure for the storage itself and the stacks of cassettes in the storage.
4. The method according to claim 1, comprising at least one of the following steps: to build elongated concrete thermal energy storage elements and elongated cassette frames, and orienting the elements and cassette horizontally when arranging the cassettes with elements in the storage, to arrange the pipe system for thermal energy input and output so that the inlet and the outlet to the storage can be changed reversibly and so that at least one inlet or outlet is arranged at a high elevation of the storage and at least one inlet or outlet is arranged at a low elevation of the storage, and arranging the connections and/or valves to the heat exchangers of the thermal energy elements so that fluid can be circulated through the heat exchangers gradually or stepwise vertically upwards or downwards or horizontally sideways; to arrange the cassettes in stacks or blocks with several stacks of cassettes, with the pipe system so that the pipe system is arranged only on one side of the stack or block of elements, preferably facing a wall of the storage to arrange self-supporting cassettes or structure with coupling parts for roof and/or wall elements, and thermally insulated roof and/or wall elements comprising coupling parts matching the cassette or structure coupling parts, arranging and coupling the elements as thermally insulated roof and walls, respectively.
5. The method according to claim 1, comprising at least one of the following steps: to arrange the concrete thermal energy storage elements in stacks within a frame comprising two opposing sidewalls and floor but no roof, the elements resting on elements below as contained horizontally orientated within the sidewalls, thereby providing cassettes that are open upwards but easily can be stacked on top of each other, to arrange the elements in stacks, with inlays, supports, shims or similar objects between the elements, at regular or irregular positions along the length of the elements, providing a distance between the elements, the inlays, supports, shims or similar objects between the elements comprising coupling parts providing a self-supporting cassette structure as stacked and coupled, to arrange the elements in stacks, with support system parts between the elements, the support system parts comprising coupling parts and are arranged at regular or irregular positions along the length of the elements, providing a distance between the elements, the support system parts as coupled provides a self-supporting structure including openings for elements, the openings having hexagonal shape, square shape, rectangular shape, round shape, elliptical shape, triangular shape or other shape into which the elements fit, P1 to arrange the elements in stacks, with support system layers between the elements, the support system layers comprising coupling parts at regular or irregular positions along the length of the elements, providing a distance between the elements, the support system layers as coupled provides a self-supporting structure including the support system layers as assembled or coupled and stacked, providing a support system with openings for elements, the openings having hexagonal shape, square shape, rectangular shape, round shape, elliptical shape, triangular shape or other shape into which the elements fit, to fill an active heat transfer and storage medium in the form of a phase change material, in the volume between the elements and a storage housing, or to fill an active heat transfer and storage medium in the form of a stagnant liquid, in the volume between the elements and a storage housing, or to fill an active heat transfer and storage medium in the form of a dynamic fluid, in the volume between the elements and a storage housing, so that the dynamic fluid can flow between the elements and cassettes from an inlet to the housing to an outlet from the housing.
6. A high temperature thermal energy storage comprising: a thermally insulated foundation, at least one self-supported cassette arranged on the foundation, which cassette is a self-supporting frame or structure containing a number of concrete thermal energy storage elements, some or all of the elements comprising heat exchangers embedded in the concrete of the concrete thermal energy storage elements, a pipe system, the pipe system comprising an inlet and an outlet for thermal input to and output from the storage, respectively, and connections to the heat exchangers for circulating fluid through saw the heat exchangers for thermal energy input to or output from the thermal energy storage elements, and thermal insulation around and on top of the at least one self-supported cassette with concrete thermal storage elements.
7. The high temperature thermal energy storage according to claim 6, comprising at least one of the following features: one or several vertical stacks of cassettes; stacks of cassettes arranged so that the concrete thermal energy storage elements are horizontally orientated; cassettes arranged with concrete thermal storage elements vertically standing on the foundation, which is particularly feasible with gas as heat transfer fluid, a pipe system on one side of the cassette or stack of cassettes; a pipe system arranged so that several stacks of cassettes are coupled in parallel; a pipe system and cassettes or stacks of cassettes arranged in blocks, so that each block can be isolated or bypassed, one after one or stepwise, from the rest of the storage by operating valves of the pipe system, a pipe system arranged so that individual thermal elements and individual cassettes can be isolated or bypassed, one after one or stepwise, from the rest of the storage, by operating valves of the pipe system, a stack or stacks of cassettes closely stacked and arranged so that a ratio of the storage outer surface area to volume is minimized, achieving a small footprint and heat loss of the storage, the cassettes arranged so that the concrete thermal energy storage elements are horizontally orientated and with the pipe system arranged on one side in a row of stacked cassettes, facing a side of the storage, a combined outer metal shell of the concrete thermal energy storage element and cassette frame as one structure functioning as a form for casting of concrete, armoring for the concrete, heat transfer fluid leakage catcher and the self-supporting modular cassette structure, a heat exchanger for one cassette or concrete thermal energy storage element as one structure.
8. The high temperature thermal energy storage according to claim 6 comprising: thermal energy storage elements comprising an outer metal shell, an embedded tube heat exchanger, hardened concrete or grout inside the shell, with ends or connections of heat exchangers extending out from the concrete, wherein the outer shell is a combined casting form, reinforcement and containment of fluid for thermal energy input or output in case of embedded heat exchanger leakage.
9. The high temperature thermal energy storage according to claim 6, comprising a pipe system for thermal energy input and output arranged so that the inlet and the outlet to the storage can be changed reversibly and so that at least one inlet or outlet is arranged at a high elevation of the storage and at least one inlet or outlet is arranged at a low elevation of the storage, and connections or valves to individual or groups of the heat exchangers of the thermal energy elements arranged so that fluid can be circulated through the heat exchangers gradually or stepwise upwards or downwards.
10. The high temperature thermal energy storage according to claim 6, comprising a stack of self-supported cassettes, the cassettes comprising a frame open in at least one end, containing closely packed concrete thermal energy storage elements with outer metal shell and tube heat exchangers embedded in the concrete, the elements arranged in horizontal orientation in vertical stacks of cassettes, wherein the frame is not only a fixture for casting and curing of the elements, and a structure for facilitating handling and transport, but also as a structure for the storage itself and the stacks of cassettes in the storage.
11. The high temperature thermal energy storage according to claim 6, comprising self-supporting cassette frames or structure with coupling parts for roof and/or wall elements, and thermally insulated roof and/or wall elements comprising coupling parts matching the cassette frame or structure coupling parts, arranged and coupled as thermally insulated roof and walls, respectively.
12. The high temperature thermal energy storage according to claim 6, comprising at least one of the following features: at least two support frames, made of assembled support frame parts vertically aligned, staggered or mirror-inverted from layer to layer, the thermal energy storage elements have been arranged into and are supported by the frames, cassettes comprising a frame comprising two opposing sidewalls and floor but no roof, with the concrete thermal energy storage elements stacked within, the elements resting on elements below as contained horizontally orientated within the sidewalls, thereby providing cassettes that are open upwards but easily can be stacked on top of each other, stacks, with inlays, supports, shims or similar objects between the elements, at regular or irregular positions along the length of the elements, providing a distance between the elements, the inlays, supports, shims or similar objects between the elements comprising coupling parts providing a self-supporting cassette structure as stacked and coupled, support system parts between the elements, the support system parts comprising coupling parts and are arranged at regular or irregular positions along the length of the elements, providing a distance between the elements, the support system parts as coupled providing a self-supporting structure including openings for elements, the openings having hexagonal shape, square shape, rectangular shape, round shape, elliptical shape, triangular shape or other shape into which the elements fit, support system layers between the elements, the support system layers comprising coupling parts at regular or irregular positions along the length of the elements, providing a distance between the elements, the support system layers as coupled providing a self-supporting structure including the support system layers as assembled or coupled and stacked, providing a support system with openings for elements, the openings having hexagonal shape, square shape, rectangular shape, round shape, elliptical shape, triangular shape or other shape into which the elements fit, an active heat transfer and storage medium in the form of a phase change material, in the volume between the elements and a housing, or an active heat transfer and storage medium in the form of a stagnant liquid, in the volume between the elements and a housing, or an active heat transfer and storage medium in the form of a dynamic fluid, in the volume between the elements and a housing, the dynamic fluid can flow from an inlet to the housing to an outlet from the housing.
13. A method of operating a high temperature thermal energy storage according to claim 6, the method comprising: to circulate warmer than the storage heat transfer fluid, for thermal energy input to the storage, stepwise or gradually from a higher elevation to a lower elevation in the storage, by operating the pipe system accordingly, and to circulate colder than the storage heat transfer fluid, for thermal energy output from the storage, stepwise or gradually from a lower elevation to a higher elevation in the storage, by operating the pipe system accordingly.
14. The method according to claim 13, wherein the storage contains a phase change material in the volume between the concrete thermal energy storage elements and the housing, and water is circulated through heat exchangers embedded in the elements when thermal energy is taken out from the storage, wherein the storage is operated at conditions so that the phase change material solidifies whilst the water evaporates, thereby using the heat of solidification of the phase change material as heat of evaporation for the water.
15. The method according to claim 13, for operating the storage with a thermal oil or other single-phase liquid as heat transfer fluid, wherein the circulation for thermal energy input to the storage, is via an inlet at a highest elevation of the storage, directing the warmer fluid to the uppermost elements or elements at an elevation with temperature lower than the warmer fluid; and the circulation for thermal energy output from the storage, is via an inlet at a lowest elevation of the storage, directing the colder fluid to the lowermost elements or elements at an elevation with temperature higher than the colder fluid, wherein the circulation is by pumping with a pump when a thermal oil or other one-phase liquid is the circulated heat transfer fluid.
16. The method of operating a high temperature thermal energy storage according to claim 6, for operating the storage with water/steam, LPG or other two-phase liquid-gas mixture as heat transfer fluid, with concrete thermal energy storage elements oriented horizontally and with a liquid/gas separator connected at a high elevation and connected with at least one pipes externally to the inlet pipe(s) at a low elevation, enabling natural circulation by gravity without the use of a pump, the storage acting as a condenser when the storage is charging and a boiler when the storage is discharging thermal energy, by the method comprising: to add steam or other gas via an inlet at a lowest elevation of the storage, wherein the gas is added to the liquid either through a pipe or generated via electrical resistors inside the pipe, when charging thermal energy, to add water or other liquid via an inlet at the highest elevation of the storage, wherein water or other liquid is added to a gas/liquid separator such as a steam drum, alternatively the water or other liquid is added at the lowest elevation of the storage, and steam or other gas is extracted from the liquid/gas separator at the top wherein liquid flows downwards in the external pipe (s) and liquid-gas mix flows upwards in the storage, in both charge and discharge mode.
Description
FIGURES
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DETAILED DESCRIPTION
[0086] Reference is made to
[0087] The illustrated storage comprises a support system 11, allowing a large number of thermal elements 2 to be stacked whilst still allowing operation at high temperature. The illustrated support system 11 comprises a honeycomb support structure 12 and a support steel frame 13. The honeycomb support structure consists of honeycomb support layers 14, arranged layer by layer, “valley over hill”. The honeycomb layers provide a self-supporting structure, in addition to preferably being supported also by the support frame toward the sidewalls and the floor below. Neighboring columns of elements are vertically staggered, as illustrated, allowing a simplified pipe system. The support system must be dimensioned to provide structural strength over the operating conditions and life of the storage, allowing thermal expansion of the elements at a sufficient degree to avoid cracking of the elements. The support system as assembled, more precisely the self-supporting structure, containing concrete thermal energy storage elements containing embedded heat exchangers, is in this context termed a cassette. In
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[0089] In a preferable embodiment of the invention, an outer metal shell of the concrete thermal energy storage element and a cassette frame are combined as one structure functioning as a form for casting of concrete, armoring for the concrete, heat transfer fluid leakage catcher and the self-supporting modular cassette structure in a thermal energy storage of the invention. Said combined structure can be combined with a single structure heat exchanger for one cassette, preferably preassembled and tested, for example as illustrated on
[0090] However, concrete thermal energy storage elements with large diameter or cross section area, particularly with an outer metal shell, the outer shell combined or not with the cassette frame, may have several disadvantages in practice. Firstly, the period for curing and drying for high temperature service may become excessively long. Secondly, the risk of cracking and other quality problems increases. Thirdly, the outer shell/self-supporting frame must be excessively solid/strong with increasing size. Fourthly, and probably most important, given a similar configuration of the embedded heat exchanger piping, the temperature distribution in a large element or cassette becomes uniform, where the energy (energy that is available to be used) is reduced which actually reduces the efficiency compared to the standard concrete thermal energy element design with about 250 mm diameter round elements or similar. This relates to period/frequency of loading/unloading of thermal energy, temperature difference between hot-cold fluid and concrete, which influence dynamic response and specific storage efficiency, such as cost per stored or cycled energy unit,
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[0093] For clarity, only some of identical or similar features are provided with numerical references in the figures.
[0094] The self-supporting structure in a storage of the invention, facilitate building and reduced cost compared to prior art storages, irrespective of the self-supporting structure comprises a honeycomb support structure or similar assembled while building it, for example as illustrated in
[0095] The figures illustrate only some of numerous embodiments of the storage, features therein, and methods of the invention. For small storages, or storages with small stacks of elements, the elements can be self-supporting, particularly if they comprise an outer metal shell being a combined casting form and reinforcement. Elements with hexagonal, quadratic or rectangular cross section shape are most feasible for stacking of self-supporting cassettes and elements as combined, quadratic elements can be rotated 45 around the longitudinal axis to provide a position adjusting wedge shape upwards, facilitating building the storage. More comprehensive and solid support systems are required for larger storages and for higher operating temperatures.
[0096] Parts that are to be coupled, preferably comprises coupling parts such as guide posts/cones and guide pins/posts, or similar male-female coupling parts.
[0097] The term “high temperature” in the context of the invention do not mean that the storage must be used for high temperature, but preferably is used for high temperature operation, which in this context is from 100° C. up to 570° C. for storages with exposed element steel shells and pipe systems, and up to 1000-1200° C. or even 1500° C. for storages with elements without steel shells or exposed steel pipe system parts, the otherwise exposed metal parts preferably being insulated or made of high temperature resistant alloys or material. The storage of the invention can operate at very high dynamic temperature range, including large temperature differences between fluid and elements, compared to prior art storages.
[0098] The high temperature thermal energy storage of the invention can include any feature as here described or illustrated, in any operative combination, each such operative combination is an embodiment of the invention. The method of building a high temperature thermal energy storage of the invention can include any feature or step as here described or illustrated, in any operative combination, each such operative combination is an embodiment of the invention. The methods of operating a high temperature thermal energy storage of the invention can include any feature or step as here described or illustrated, in any operative combination, each such operative combination is an embodiment of the invention.