Solar thermal plants typically undergo trough operational cycles spanning between 20 and 25 years, highlighting the critical need for accurate assessments of long-term component evolution. Among these components, the heat storage media (molten salt) is crucial in plant design, as it significantly influences both the thermophysical properties of the working fluid and the corrosion of the steel components in thermal storage systems. Our research focused on evaluating the long-term effects of operating a low-melting-point ternary mixture consisting of 30 wt% LiNO₃, 57 wt% KNO₃, and 13 wt% NaNO₃. The ternary mixture exhibited a melting point of 129 °C and thermal stability above 550 °C. Over 15,000 h, the heat capacity decreased from 1.794 to 1.409 J/g °C. Additionally, saline components such as CaCO₃ and MgCO₃, as well as lithium oxides (LiO and LiO₂), were detected due to the separation of the ternary mixture. A 30,000 h exposure resulted in the formation of Fe₂O₃ and the presence of Cl, indicating prolonged interaction with the marine environment. This investigation highlights the necessity of analyzing properties under actual operating conditions to accurately predict the lifespan and select the appropriate materials for molten salt-based thermal storage systems.

The fast-paced depletion of fossil fuels and environmental concerns have intensified interest in renewable energies, with dispatchable solar energy emerging as a key alternative. Concentrated solar power (CSP) technology, utilizing thermal energy storage (TES) systems with molten salts at 560 °C, offers significant potential for large-scale energy generation. However, these extreme conditions pose challenges related to material corrosion, which is critical for maintaining the efficiency and lifespan of CSP. This research modeled the corrosion process of 347H stainless steel in molten solar salt (60% NaNO₃ + 40% KNO₃) melted at 400 °C using a cellular automaton (CA) algorithm. The CA model simulated oxide growth under pilot-plant conditions in a lattice of 400 × 400 cells. SEM-EDS imaging compared the model with a mean squared error of 2%, corresponding to a corrosion layer of 4.25 µm after 168 h. The simulation applied von Neumann and Margolus neighborhoods for the ion movement and reaction rules, achieving a cell size of 0.125 µm and 10.08 s per iteration. This study demonstrates the CA model’s effectiveness in replicating corrosion processes, offering a tool to optimize material performance in CSP systems. Additionally, continuing this investigation could contribute to the development of industrial applications, enabling the design of preventive strategies for large-scale operations.

The two-tank molten salt thermal storage system is the most common storage solution in concentrated solar power (CSP) plants. Solar salt (60% NaNO₃ + 40% KNO₃) is the most widely used energy storage material in solar thermal plants. In solar tower technology, where the molten salts must operate at temperatures ranging from 290 °C to 565 °C, several issues related to tank failures have emerged in recent years, with some of these failures attributed to the welding process. The welding process of joints in 316L stainless steel (ASS) probes exposed to a moving flow of a binary mixture containing 60% NaNO₃ and 40% KNO₃ (solar salt) is analysed. The results were evaluated using scanning electron microscopy (SEM) at 120, 500, 1000, 1500, and 2300 h of exposure. It was identified that arc mechanical oscillations significantly improve the microstructural properties and geometrical characteristics of welded joints, reducing structural defects and improving corrosion resistance. The technique promotes uniform thermal distribution, refined dendrite morphology, and homogeneous alloying element distribution, resulting in lower mass loss in high-temperature molten salt environments. Additionally, oscillation welding optimises the bead geometry, with reduced wetting angles and controlled penetration, making it ideal for high-precision industrial applications and extreme environments, such as molten salt thermal storage systems.

The fast-paced depletion of fossil fuels and environmental concerns have intensified interest in renewable energies, with dispatchable solar energy emerging as a key alternative. Concentrated solar power (CSP) technology, utilizing thermal energy storage (TES) systems with molten salts at 560°C, offers significant potential for large-scale energy generation. However, these extreme conditions pose challenges related to material corrosion, critical for maintaining CSP efficiency and lifespan. This research models the corrosion process of 347H stainless steel in molten solar salt (60% NaNO3 + 40% KNO3) melted at 400°C using a cellular automaton (CA) algorithm. The CA model simulates oxide growth under pilot plant conditions in a lattice of 400x400 cells. SEM-EDS imaging compared the model with a mean squared error of 2%, corresponding to a corrosion layer of 4.25 µm after 168 hours. The simulation applied von Neumann and Margolus neighborhoods for ion movement and reaction rules, achieving a cell size of 0.125 µm and 10.08 seconds per iteration. This study demonstrates the CA model’s effectiveness in replicating corrosion processes, offering a tool to optimize material performance in CSP systems.