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HEIndividual fellowship2023–2025

MAX4LES · Analysis of Molten Salt-Air Heat Exchangers for Large Scale Energy Storage Technologies

Horizon Europe — Marie Skłodowska-Curie Actions

Duration
2023-09-01 → 2025-08-31
EU contribution
€230,774
Participants
2
Scheme
HORIZON-TMA-MSCA-PF-EF

Lines connect the coordinator with its partners.

Results in brief

Analysis of Molten Salt-Air Heat Exchangers for Large Scale Energy Storage Technologies

The MAX4LES project addressed a critical challenge in Europe’s clean energy transition: predicting mitigation strategies for the solidification of molten salts inside air-cooled shell and tube heat exchangers used in large-scale thermal energy storage systems. Molten salts are essential for technologies such as concentrated solar power (CSP) plants, pumped thermal energy storage (PTES) systems, liquid air energy storage (LAES) systems, and other high-temperature industrial processes due to their high heat capacity and cost-effectiveness. However, their high freezing point makes them vulnerable under abnormal operating conditions, such as pump failure, heat tracing malfunction, or sudden drops in temperature. In such scenarios, molten salts can solidify in the tubes of shell and tube heat exchangers leading to blockages, efficiency losses, and costly operational interruptions. These risks ultimately threaten the reliability and economic viability of large-scale energy storage solutions. This project sets out to develop scientific benchmarks, design and operational strategies to prevent salt solidification in molten salt-air shell and tube heat exchangers by combining advanced numerical modelling, comparative performance studies, and trace heating evaluations. By advancing a computational proof-of-concept for solidification prevention measures, the project lays the foundation for future experimental validation and industrial adoption. Addressing solidification risks brings multiple advantages: (i) it enhances the system reliability by reducing unplanned outages, (ii) improves economic viability by avoiding costly downtime and maintenance, and (iii) strengthens societal benefits by enabling greater penetration of renewable energy into the power grid. This work directly supports the EU Renewable Energy Directive (RED II) and the European Green Deal by enabling more reliable, efficient, and cost-effective renewable energy systems. In the long term, the results contribute to Europe’s ambition to achieve climate neutrality by 2050, while strengthening the competitiveness of European industries in clean energy technologies.

Data: CORDIS, © European Union

Project objective

Molten salt-air heat exchanger thermal sizing design influences the performance and, in turn, the cost-effectiveness of a range of emerging technologies (such as concentrated solar power integrated pumped thermal energy storage, process heating, and high-temperature processes like H2 production) supporting the green transition. As per 2019 reports, worldwide power generation capacity from molten salt storage in CSP plants was 60 GWh (thermal) and is expected to rise several folds by 2030 [1]. The primary goal of MAX4LES is to develop and provide a scientific benchmark for the optimal design of molten salt-air shell and tube heat exchangers. I aim to identify the cause and effect of freezing and time required for melting the solidified molten salt inside the tubes of molten salt-air heat exchangers. And to propose selective coatings to avoid the salt deposition on the tubes to prevent clogging that might lead to reduced performance and/or cause structural damage. The project outcomes will bridge the existing knowledge gap and support the future development of molten salt-air heat exchangers. The training at the host, Technical University of Denmark, Denmark, secondment at Eindhoven University of Technology, Netherlands, and the short stay and cooperation with the industrial partner, Aalborg CSP, Denmark, will provide me with the ideal technical, ethical, and cultural exchange and significantly strengthen my future career prospects. The intersectoral approach will provide the basis for implementing the research outcomes commercially. Overall, the project will set a foundation for me to continue focusing my expertise and skills to contribute toward meeting the long-term European Unions (EUs) Net-Zero decarbonization goals by 2030.

Original text from CORDIS.

Participants

  • DANMARKS TEKNISKE UNIVERSITET · Kongens LyngbyCoordinatorDenmark
  • TECHNISCHE UNIVERSITEIT EINDHOVEN · EindhovenNetherlands

Links

Data: CORDIS, © European Union