Thermal energy storage system coupled to a solid oxide system and a thermal cascade heat exchanger

Patent metadata

Field	Value
Publication number	US-2025389034-A1
Application number	US-202519249867-A
Country	US
Kind code	A1
Filing date	Jun 25, 2025
Priority date	Jun 25, 2024
Publication date	Dec 25, 2025
Grant date	—

Abstract

An energy storage system (TES) converts variable renewable electricity (VRE) to continuous heat. Intermittent electrical energy heats a solid medium. Heat from the solid medium is delivered continuously on demand. Heat delivery via flowing gas establishes a thermocline which maintains high outlet temperature throughout discharge. The delivered heat which may be used for processes including power generation and cogeneration. In one application, the energy storage system provides higher-temperature heat to a solid oxide system to maintain in an operating temperature range during operation and nonoperation, thereby increasing the efficiency of the temperature control.

First claim

What is claimed is:

1 . A solid oxide electrolysis system, including:
a thermal energy storage (TES) system configured to store thermal energy in a storage medium, the thermal energy being generated by conversion of input electricity from an energy source; a solid oxide (SO) unit; a steam cycle system including: a first heat exchanger; and a second heat exchanger configured to use thermal energy from the TES to heat input steam at a first pressure and to provide the input steam to a steam turbine; wherein the first heat exchanger is configured to use thermal energy from the TES to heat extracted steam from the steam turbine at a second pressure that is lower than the first pressure and to direct the heated extracted steam as an input to the SO unit.

2 . The system of claim 1 , wherein the first heat exchanger is configured as a first superheater.

3 . The system of claim 1 , wherein the second heat exchanger is configured as a second superheater.

4 . The system of claim 1 , wherein the SO unit is configured to receive thermal energy directly from the TES.

5 . The system of claim 1 , wherein the steam cycle system further includes a third heat exchanger configured to produce additional input steam using thermal energy recovered from the SO unit.

6 . The system of claim 1 , further including an additional heat exchanger configured to use thermal energy from the TES to further heat output steam from the turbine and to provide the further heated output steam as an input to the SO unit.

7 . The system of claim 1 , wherein the TES system is configured to provide thermal energy to maintain the SO unit within an acceptable operating temperature range during both an electrolysis mode and a standby mode of the SO unit.

8 . The system of claim 1 , wherein the steam turbine is configured to drive a generator, and the system is further configured to return at least a portion of the electrical energy produced by the generator as input electrical energy to the SO unit and/or to the TES system based on one or more predetermined parameters.

9 . The system of claim 1 , wherein the second heat exchanger is configured to heat the input steam to a temperature between about 650° C. and 950° C.

10 . The system of claim 1 , wherein the first heat exchanger is configured to heat the extracted steam to a temperature between about 650° C. and 1100° C.

11 . An electrolysis method, including:
converting electricity from a renewable energy source into thermal energy; storing the thermal energy in a thermal energy storage (TES) system; delivering the stored thermal energy to a solid oxide (SO) unit to maintain the SO unit within a specified temperature range; producing input steam using heat recovered from the SO unit and thermal energy from the TES system; directing the input steam to a steam turbine; extracting steam from the steam turbine; and superheating the extracted steam to provide superheated steam as an input to the SO unit.

12 . The method of claim 11 , further including the step of providing electricity produced by the steam turbine as input electricity for the SO unit and/or as electricity for conversion into heat for storage in the TES system.

13 . The method of claim 11 , further including the step of providing thermal energy recovered from the SO unit to the extracted steam from the steam turbine before it is circulated to the SO unit.

14 . The method of claim 11 , further including the step of providing thermal energy from the TES system to the output steam before it is circulated to the SO unit.

15 . The method of claim 11 , further including the steps of:
producing hydrogen when the SO unit is configured to operate in electrolysis mode; and producing electricity when the SO unit is configured to operate in fuel cell mode.

16 . A solid oxide electrolysis system, including:
a thermal energy storage (TES) system configured to store thermal energy in a storage medium, the thermal energy being generated by conversion of input electricity from an energy source; a solid oxide (SO) unit; a first heat exchanger configured to provide thermal energy from the TES to the SO unit and to maintain the SO unit within a specified thermally acceptable operating temperature range; a second heat exchanger; and a third heat exchanger configured to use thermal energy from the TES to heat a pressurized fluid for input to a turbine; wherein the second heat exchanger is configured to heat an output fluid extracted from the turbine using thermal energy recovered from the SO unit and/or thermal energy from the TES and configured to circulate the heated output fluid as an input to the SO unit.

17 . The system of claim 16 , further including a fourth heat exchanger configured to heat the pressurized fluid using thermal energy recovered from the SO unit and to provide the heated, pressurized fluid as input to the second heat exchanger.

18 . The system of claim 16 , further including a fifth heat exchanger.

19 . The system of claim 16 , wherein the turbine is a condensing steam turbine and further including a condenser configured to condense output from the steam turbine into a liquid.

20 . The system of claim 16 , wherein the energy source is a renewable energy source having intermittent availability.

21 . A solid oxide electrolysis system, including:
a thermal energy storage (TES) system configured to store thermal energy in a storage medium, the thermal energy being generated by conversion of input electricity from an energy source; a solid oxide (SO) unit configured to operate in electrolysis mode, the SO unit configured to receive a heat transfer fluid heated by the thermal energy to maintain the SO unit within a specified thermally acceptable operating range of temperatures; an energy conversion device; and a thermal cascade heat exchange assembly configured to receive the heat transfer fluid to heat at least the following portions of the heat exchange assembly: a first heat exchanger in fluid communication with the SO unit; and at least one additional heat exchanger in fluid communication with one another to thermally process a working fluid; wherein: the energy conversion device is in fluid communication with the additional heat exchanger and is configured to receive the processed working fluid; the system is configured to extract the processed working fluid from the energy conversion device and direct the extracted working fluid to the first heat exchanger; and the first heat exchanger is configured to provide heat from the heat transfer fluid to the extracted working fluid to produce an output working fluid and to direct the output working fluid to an input of the SO unit.

22 . The system of claim 21 , wherein the processed working fluid includes steam.

23 . The system of claim 21 , wherein the processed working fluid is at a temperature between about 650° C. and 1000° C.

24 . The system of claim 22 , further including a condenser:
wherein the condenser and the at least one additional heat exchanger define a steam loop; and the first heat exchanger is configured to superheat the extracted working fluid from the steam loop to form the output working fluid that is directed to the SO unit.

25 . The system of claim 21 , wherein the at least one additional heat exchanger includes at least a power steam superheater, an evaporator, and an economizer.

Assignees

• Rondo Energy Inc

Inventors

• O'Donnell John Setel
• Ferhani Yusef Desjardins

Classifications

• H01M8/04074

  Heat exchange unit structures specially adapted for fuel cell · CPC title

• H01M8/04052

  Storage of heat in the fuel cell system · CPC title

• H01M8/04014

  Heat exchange using gaseous fluids; Heat exchange by combustion of reactants · CPC title

• F28D20/0056

  using solid heat storage material (F28D20/0052 takes precedence) · CPC title

• F01K7/12

  of condensing type · CPC title