Thermal energy storage (TES) systems are key components for concentrated solar power plants to improve their dispatchability and for shifting the energy production efficiently to high revenue periods. The commercial state of the art is the molten salt two tank storage technology. However, this TES confronts some issues like freezing and decomposition, which require continued technical attention. Furthermore, the molten salt itself is very expensive compared to other storage materials. A TES option that possesses a high cost reduction potential and the ability to increase the whole power plant efficiency is the regenerator-type energy storage. Here, a packed bed inventory of waste metallurgical slag from electric arc furnace (EAF) can achieve further cost reduction. Despite previous studies regarding the use of steelmaking slag as an inventory material for thermal energy storages, there are still basic questions to be answered. This work presents experimental thermal performance and thermo-structural stability studies of slag-based TES, obtained during the European project REslag. The EAF slag and different insulation options were tested for their thermomechanical strength in a uniaxial compression test rig. The thermal cyclic behavior was investigated in a pilot TES plant with temperatures up to 700 °C. The experimental results confirm the suitability of steelmaking slag as thermal energy storage inventory material. Furthermore, a comparison of experimental and simulation model results shows an agreement of over 90%.

By using metallurgical slag from an electric arc furnace that is otherwise not recycled but deposited as an inventory material in thermal energy storage for concentrated solar power plants, it is possible to make a significant step forward in two transformation processes: energy and raw materials. As this type of slag has not been considered as an inventory material for this purpose, it is important to clarify fundamental questions about this low-cost material and its storage design. In this paper, design studies of slag-based thermal energy storage are carried out. Different slag-specific design concepts are developed, calculated and evaluated by a method based on established management tools. Finally, concepts for further investigations are defined. The highest aptitude value and the lowest risk value are achieved by the vertical storage design with axial flow direction. Therefore, it is taken as the lead concept and will be considered in complete detail in further research. Also, a closer look, but not as detailed as the lead concept, is taken at the horizontal storage with axial flow and the vertical storage with radial flow direction.

The basic methodology of a novel, time‐saving approach for critical thermomechanical design studies of ceramic high temperature plate‐fin heat exchanger is presented. This approach allows the determination of local displacements, by applying the outer heat exchanger boundary conditions on a substitute model. These displacements are then used for detailed calculation of local stresses. The methodology is based on the effective Young's modulus, effective shear modulus, and effective Poisson ratio. Simulation models have been developed to determine these effective substitute properties. A model verification has been performed with a compression test rig. The simulation predicts the experimental results with deviations below 3%, which proves the feasibility and reliability of the effective material models. In order to reduce the parametric effort of the substitute simulation model, information about the material behavior is important. Here, the results indicate an orthotropic material behavior of the fin structure. This reduces the independent substitute material properties required for the characterization of the substitute model, which also reduces the overall simulation time.

Solar power towers with thermal energy storage based on direct-flow regenerators have the potential to generate cost-effective base-load electricity. An inventory option that opens up further cost-saving potential but has not yet been extensively investigated for this application is slag from electric arc furnace. This use has not only economic advantages, but also serves environmental protection, since a large proportion of this type of slag is currently not used any further, but is disposed of in landfills. In the completed EU project REslag, various subsequent uses of the slag were investigated, including the possibility presented here of using sintered slag pebbles as an inventory for regenerators in solar power towers with air as the heat transfer fluid. The main results from the different phases of the project are presented, with a focus on the investigations not yet published. In addition to results from thermal simulations on different designs and on the partial load and off-design behavior of the storage lead concept “Axial flow—standing”, these are mainly results from fluid mechanical calculations on the distributor design of the storage and from material investigations on the slag. In summary, it can be stated that the sintered slag pebbles are thermally, mechanically and chemically competitive with conventional inventory materials and the principle feasibility of a slag-based storage was confirmed by the results of these investigations. The defined storage lead concept was elaborated in detail and the performance of the design was confirmed by simulations and experiments.