Statement of the Problem: Tower-mounted, particle-based receivers are intended to allow higher receiver outlet temperatures, hence higher overall system efficiency, than molten-salt or steam-based receivers. The durability and performance of current particle-based receivers is limited by the maximum temperature at which the materials of construction can operate before oxidation or erosion cause failureError! Bookmark not defined.. To solve these issues, USNC proposes to apply a novel manufacturing route for complex, oxidation-resistant silicon carbide composite components that will enable higher receiver material temperatures, implementation of novel designs for efficient heat transfer that are not limited by traditional manufacturing methods, and improved resistance to erosion. Objective of the Phase I Project The objective of the project is to fabricate prototypical components, using commercial-scale production equipment at USNCs Advanced Ceramic Manufacturing facility, to demonstrate the viability of a novel, additive manufacturing approach for manufacturing silicon carbide composite components with temperature capabilities, heat transfer properties, and erosion resistance to enable particle-based receiver designs with particle temperatures in excess of 700°C, to provide high system efficiency, and perform key testing to demonstrate heat transfer and thermomechical durability. Description of Phase I Work: In Phase I, process parameters to fabricate fiber-reinforced, additively manufactured printed silicon carbide components will be developed. The strength and the erosion resistance of the additively manufactured material will be measured. Test samples will be characterized in a narrow-channel particle heat transfer test rig at The Colorado School of Mines. Parameters determined from heat transfer testing will be used to produce a conceptual design for bench-scale manufacturing scaleup and testing. Commercial Applications: The primary commercial benefit will be affordable, reliable, high performance solar receivers for particle-based CSP systems capable of producing carbon-free electricity and heat at competitive costs. The work will also support development of methods for manufacturing silicon carbide composite components for aerospace and microelectronic applications. Additionally, the technology will improve efficiency of turbines and other high temperature processes.
