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Advanced Molten Glass for Heat Transfer and Thermal Energy StorageFull Application submitted in response to DE-FOA-0000471 (HEATS)

Prime Recipient SubcontractorHalotechnics, Inc. Pratt & Whitney Rocketdyne, Inc.

Abstract (1 page): Halotechnics proposes to develop a thermal storage system utilizing a low melting point molten glass as the heat transfer and thermal storage material. An advanced oxide glass promises a potential breakthrough in a low cost, earth abundant, and stable thermal storage material. This novel material will enable unprecedented efficiency with thermal energy storage exploiting sensible heat. We will develop a two-tank thermal storage system operating at a high temperature of 1200 °C and a low temperature of 400 °C. This project will leverage technology used in the modern glass industry, with decades of experience in handling high temperature viscous materials. Halotechnics will integrate its proven expertise in combinatorial chemistry with advanced techniques for handling molten glass. The molten glass thermal storage system has the potential to reduce thermal storage costs by a factor of ten once developed and deployed at commercial scale. Thermal storage at the target temperature can be integrated with existing high temperature gas turbines that significantly increase efficiencies over today’s steam turbine technology.

We will take a systematic approach to eliminating risk from critical components of the molten glass thermal storage system. The proposed project scope includes both the development and optimization of a novel molten glass for heat transfer and thermal storage, as well as the system to pump, heat, and store the novel material. The first aspect of this program is to develop an advanced glass with sufficiently low melting point, low viscosity, and low cost to achieve the performance targets of the program. We have identified a promising proof of concept material and measured its physical properties in our laboratory. Halotechnics is a proven leader in combinatorial chemistry and materials science and we will leverage our expertise to optimize the material for heat transfer and thermal energy storage at large scales. The second aspect of this program is to develop a prototype system to pump, heat, store, and discharge the molten glass fluid. Halotechnics staff has deep experience in thermal system design and high temperature engineering. We will leverage existing techniques borrowed from the glass industry to efficiently and reliably transfer and store heat in our prototype system. Halotechnics has formed a project team with Pratt & Whitney Rocketdyne, a proven leader in engineering for severe environments.

If successful this project will be both transformative and disruptive. We propose to translate technology developed by the glass industry and use it to transform a new sector – to develop cheap thermal energy storage for concentrating solar power (CSP). Once deployed, our technology will provide thermal energy storage at such a low cost that it will make today’s technology obsolete. Our proposed solution reduces the cost of CSP and thermal energy storage by two routes: 1) enabling significantly higher

HALOTECHNICS, INC. Page 1

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operating temperatures in the plants and more effective sensible heat thermal storage, and 2) enabling the use of a lower cost thermal storage material.

The SunShot Initiative sets the goal of making solar electricity cheaper than fossil fuels by 2020. To achieve this vision we must push for a breakthrough in low cost thermal energy storage. We must push for significantly higher operating temperature in CSP plants in order to use more efficient power conversion technology. Halotechnics has identified a pathway to enable this vision via advanced molten glass.

RD&D Tasks (1 page)

Task List

1. Glass screening workflow development2. Optimize glass material3. Piping material selection4. Corrosion testing5. Tank modeling6. Tank design and testing7. Pump modeling8. Pump design and testing9. Heat exchanger modeling10.Heat exchanger design and testing11.Furnace modeling12.Furnace testing13.Full system design and assembly14.System testing15.Technology transfer and outreach



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RD&D Strategy (20 pages)Innovation: Current commercially deployed thermal storage systems are two-tank sensible heat designs using molten salt as the thermal storage media [1].This technology has been deployed in many commercial CSP plants in Spain and others under construction in the U.S. The most significant drawback of this technology is its high capital cost – up to $120/kWht [2].This high cost represents a significant impediment for project developers seeking to finance and build plants with thermal storage. The high cost is due primarily to the inefficient use of the most expensive component of the system – the thermal storage media – which typically makes up 50-60% of the total cost of the storage system [3]. With sensible heat systems, the amount of thermal energy stored is directly proportional to the temperature difference of the storage material. Today’s plants using this technology have a small temperature difference between the hot tank (at 400 °C) and the cold tank (at 300 °C). Our innovation will increase by a factor of eight the temperature difference in the storage system, resulting in equal heat being stored with 1/8th the material relative to the state of the art technology. Furthermore, our advanced molten glass material could be 50% cheaper than the molten salt used for today’s technology. Based upon our estimates including the higher cost of high temperature structural materials, we anticipate a potential 10X reduction in the cost per unit energy stored with our proposed innovation – as low as $12/kWht once deployed at commercial scale.

The higher operating temperature enabled by the success of our innovation will dramatically increase the efficiency of the power block available to CSP project developers. Today’s steam turbines used for commercial CSP plants achieve a gross conversion efficiency of approximately 38% [4], constrained primarily by their lower operating temperature (under 400 °C). A combined cycle gas turbine with an inlet temperature of 1200 °C can achieve a conversion efficiency1 of 52%. The outlet temperature of the gas from the compressor of such a turbine is just under 400 °C, setting the temperature of the cold tank in our system. We will develop an optimized glass material and thermal storage system with operating temperatures tailored to commercially available gas turbines.

It is imperative that we reduce our usage of fossil fuels to address pressing societal concerns – climate change and environmental degradation, energy security and price volatility. If successful, our innovation would both reduce the cost of CSP and enable economic thermal storage, bringing the nation significantly closer to eliminating the use of coal and furthering ARPA-E’s Mission Areas. This will result in enhanced energy security for the United States – by enabling clean reliable solar electricity day and night.

Approach: Halotechnics has formed a project team with Pratt & Whitney Rocketdyne, a world leading engineering firm with experience in aerospace and power generation. We propose to design and build a complete system prototype of an advanced sensible heat thermal storage system, shown in Figure 1. In place of a central receiver we will use a standard laboratory tube furnace to heat the molten glass as it flows through the pipes. Rocketdyne will select the piping material and joining techniques for containing the advanced molten glass at 1200 °C.1 Mitsubishi D series combined cycle efficiency.



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GT/CC

1200 � C

400 � C

Critical components:1. Heat transfer fluid2. Piping material3. Tank design4. Molten glass pump5. Heat exchanger

Figure 1: System design of prototype 1200 °C thermal storage system with system boundary denoting project scope.

We have identified five critical components that must be developed and validated in order for our thermal storage system to be successful. Our strategy is to leverage the knowledge of an expert with world-class experience in each of these critical areas and utilize their skills as a consultant, employee, or project partner to accelerate the development of their respective subsystem. In this manner we will minimize the time necessary to quickly internalize previous work for each component and go beyond the current state of the art into advanced designs. We will take a two-step approach to developing the critical pump and heat exchanger components: 1) build a proof of concept alpha prototype that operates with a proxy fluid at ambient conditions, and 2) build a full temperature beta prototype operating with molten glass and building off the results of the alpha prototype.

Critical Component 1: Heat transfer and thermal storage fluidExpertise from Leo Finkelstein, low melting glass scientist

At the heart of our design is a pumpable molten glass – dirt cheap and stable. Glass is most commonly a mixture of oxides, the most abundant materials in the earth’s crust. Oxides are typically what one digs out of a mine – raw ore. A common glass such as Pyrex is a material made up of silicon dioxide, boron oxide, and sodium oxide. Oxide glasses have many compelling characteristics:

Very high thermal stability. As typical end products of thermal decomposition in air, metal oxides are stable against further decomposition up to very high temperatures, far beyond molten salt. Oxides typically have very low vapor pressure at high temperatures.

Very low cost. Production of oxide ores occurs worldwide, in quantities of millions of tons annually. Purified silicon dioxide, for example, sells for as low as $80 per ton.

Low environmental impact. Oxides are typically not water soluble and therefore represent a low risk of entering the water table in the event of a spill. They are very stable and typically do not react violently with other chemicals.

We have identified a promising proof of concept oxide mixture that is suitable for further development into an advanced heat transfer and thermal energy storage material. It is a composition of sodium oxide, phosphorous pentoxide, and molybdenum trioxide (Na2O-P2O5-MoO3), called the “moly glass.” We have performed sufficient analysis on the moly glass to verify that as a proof of concept material, it appears suitable for heat transfer and thermal storage applications from 400 °C up to 1200 °C. We will use it as a starting



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point from which to begin our high throughput combinatorial chemistry work and optimize its properties.

Critical Component 2: Piping materialExpertise from Pratt & Whitney Rocketdyne, leading aerospace engineering firm

Pratt & Whitney Rocketdyne will leverage its expertise with engineering materials selection for severe environments to address the critical issue of material selection for the molten glass piping. Molten glass is corrosive to pure iron, nickel, and cobalt, especially at high temperatures [5]. Furthermore, the creep resistance of common alloys is not sufficient for applications at 1200 °C. To solve this problem we will select from commercially available refractory alloys that are available in common tube and sheet sizes. Alloys of nickel, cobalt, tantalum, molybdenum, tungsten, niobium, and other metals are commercially available in sheets, tubes, and other forms. Piping of this design will have a higher per foot cost than stainless steel alloys when scaled up for commercial applications. This additional cost for molten glass service will be offset by the higher overall efficiency enabled by the high temperature operation of our system and the low cost of the glass material.

Critical Component 3: Tank design Expertise from RHI Monofrax, leading supplier of refractory ceramics

We propose to modify a commercially proven internally insulated tank design for storing molten glass at high temperature. Glass melting furnaces, operating for extended periods up to 1600 °C, are constructed of a refractory ceramic material known as “Monofrax.” This material contains zirconium oxide, fusion cast in graphite molds. It costs as low as $9/kg when purchased in bulk. Our concept for the hot tank is an internally insulated design using Monofrax in direct contact with the molten glass and surrounded by a low-cost insulation material. The exterior of the tank can be constructed of a steel alloy since it will be thermally isolated from the hot interior. We have had discussions with the staff of the leading U.S. supplier of refractories, RHI Monofrax in Falconer, New York. RHI is capable of custom designing the shape and composition of its Monofrax material. Halotechnics will work with RHI to procure the necessary materials for the construction of the hot thermal storage tank.

Critical Component 4: Molten glass pumpExpertise from Dr. Michael Tenhover, glass technology expert

The high viscosity of glass can be used to the designer’s advantage with a device called a “viscosity pump.” [6] This device uses a roller clad with a thin layer of refractory alloy that sits partially immersed in a pool of molten glass. As the roller spins the high viscosity of the glass causes it to be dragged along in the direction of rotation. The glass is skimmed off the roller by a wiper and directed into a passageway. In this manner a high pressure flow can be generated with a simple, elegant design that minimizes the use of expensive materials. We will design a small viscosity pump and demonstrate its functionality for both the hot tank and cold tank in our prototype system.

Critical Component 5: Heat exchangerExpertise from Dr. Adam Bruckner, one of the original inventors of the liquid droplet heat exchanger



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We propose to develop an internally insulated liquid droplet heat exchanger [7]. This type of device is used at large scale in the chemical industry and once validated with our prototype could be scaled up to commercial size for CSP applications. The direct contact design facilitates an extremely high heat transfer coefficient between the molten glass and the working fluid, and allows a compact design that minimizes the use of expensive construction materials. The design we propose is a vertical column of Monofrax bricks with an internal passage for the glass/air cross flow. Glass flows down in droplets produced from a nozzle, air flows up. The Monofrax is surrounded by low cost ceramic insulation, which is in turn enclosed by a steel column. In this manner the steel housing provides rupture strength but is insulated from the high temperature inside the column.

Technical Work Plan: The following tasks describe the step by step process we will follow in order to develop the critical components described above.

Task 1: Glass screening workflow developmentHalotechnics has developed world class experimental techniques, software tools, and data handling capabilities for combinatorial chemistry R&D. We have successfully used our techniques for a variety of applications in developing patent-pending heat transfer fluids [8]. Figure 2 shows the high throughput workflow we will utilize for rapidly screening thousands of candidate glasses for desirable properties and narrow the candidates down to one optimal material. Each stage is labeled with the approximate number of experiments to be performed. The workflow acts as a sieve and screens a large number of candidate materials, eliminating the majority at each stage and reducing the number of experiments necessary at the subsequent stage.

100

2500

25

5

Optimized molten glass

Melting point

Heat capacity

Viscosity

Corrosion

DSC

CorrosionViscometer

Figure 2: Screening workflow for advanced molten glass.

Formulation: The glass mixtures will be dispensed in powder form with the automated powder dispensing robot at Halotechnics (MTM Powdernium, Symyx Technologies, Santa Clara, CA). Glass mixtures will be dispensed onto a plate with 50 separate wells.



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The mixtures will be melted and homogenized in a furnace at 1200 °C for 12 hours. Once cooled a 20 mg sample of each mixture will be harvested and loaded onto an aluminum pan for melting point testing. Throughput: 50+ samples per day.

Melting point: Halotechnics will purchase a high performance differential scanning calorimeter (DSC) to function as the primary screening device (Discovery DSC, TA Instruments, New Castle, DE). With autosampling capability the DSC has the ability to screen 50 samples per day. In this manner we will rapidly measure the melting point of up to 2500 unique mixtures in search of optimal properties.

Heat capacity: The heat capacity is a critical property for a thermal storage material; a higher heat capacity means less material is needed to store a given amount of thermal energy. We will use the DSC to accurately measure the heat capacity of the hits resulting from primary screening. Each heat capacity test takes several hours and so must be done on a smaller number of samples in order to maintain high throughput. Throughput: 2-3 samples per day.

Viscosity: A low viscosity is desired to reduce parasitic pumping losses in the CSP plant. Halotechnics will purchase a molten glass viscometer capable of measuring a wide range of viscosity up to 1600 °C (RSV-1600, Orton Instruments, Westerville, OH). The device uses a spindle immersed in the glass melt which is contained in a platinum crucible. Throughput: 1-2 samples per day

Corrosion: Quantifying the corrosion behavior of the glass with common structural alloys is critical to understand for long term operation of CSP plants. Halotechnics has developed a device for measuring long term corrosion behavior with a variety of stainless steels or other alloys.

Equipment necessary to complete the high throughput workflow will be procured and set up at Halotechnics facilities. The methods necessary for sample preparation and accurate data acquisition will be developed. Experimental protocols will be developed to ensure consistent and reliable data handling.

Key risks and recovery plan: There is a risk that the methods necessary to properly synthesize the glass materials reduce the throughput of the workflow. For example, laborious mechanical mixing may be necessary after powder dispensing in order to later achieve a homogeneous glass melt. We will leverage the knowledge of the expert team at Halotechnics and their successful experience with similar materials in order to maximize the chance of success with method development.

Task 2: Optimize glass materialThe workflow developed in Task 1 will subsequently be used to optimize the advanced glass heat transfer and thermal storage material. Halotechnics will begin this process with the moly glass previously identified and subsequently reduce its cost and viscosity. See Figure 3 for a phase diagram containing the moly glass mixture. We have synthesized this material in our laboratory using commonly available chemicals. We have measured its melting at 349 °C, very close to the literature value. The moly glass is stable to at least 1200 °C. We have heated it to this temperature and held it for over one hour, then re-measured its thermal properties after the test. The melting point results and the weight of the sample were unchanged within experimental error. The



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moly glass forms a clear reddish brown melt and at 700 °C has a viscosity near water based upon qualitative observations. See Figure 4 for data from melting point and stability testing of this material.

We have performed sufficient analysis on the moly glass to verify that as a proof of concept material, it appears suitable for heat transfer and thermal storage applications from 400 °C up to 1200 °C. However in its current form it is too expensive (molybdenum oxide is the most expensive component at over $30/kg) and is too viscous at low

temperature (at 400 °C it has a higher viscosity than honey, based upon qualitative observations). The optimal combination of these properties with an acceptable melting point will be a primary focus of our work. Large changes in glass physical properties (hundreds of degrees in melting point, orders of magnitude in viscosity) can be induced by adding or removing components from a glass melt. Reducing the amount of molybdenum will significantly lower the cost. We will develop models for physical properties and materials cost to complement experimental work in our R&D program.

Figure 4: Moly glass testing (a) DSC with melting point, (b) TGA data showing stable behavior. Inset shows view inside furnace heating moly glass at 1200 °C.

Target: Low cost, low melting point, low viscosity: We will select from a variety of earth abundant components to lower the moly glass melting point and viscosity. These candidate components include alkali, alkaline earth, and transition metal oxides, such as silicon dioxide, iron oxide, manganese oxide, vanadium oxide, and many others. We will also consider additional non-oxide components, such as fluorides, chlorides,


Figure 3: Phase diagram of moly glass with eutectic region zoomed in [9].


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nitrides, or sulfides, which may have desirable effects on the physical properties of the fluid. We will target a melting point of 350 °C or below in order to achieve our desired cold tank temperature of 400 °C.

Our technique to develop advanced low melting point materials involves selecting a simple two component baseline mixture and adding a third component to that baseline mixture, measuring the resulting properties, and searching the phase space until the

ternary eutectic is found. We will continue this search with all feasible earth abundant components in three component mixtures. Then we will select the most promising components and begin the same process with four component (quaternary) mixtures to develop high order eutectics.

To begin the screening process we have eliminated the expensive molybdenum trioxide from our proof of concept glass mixture and selected a two component eutectic mixture consisting of sodium oxide and phosphorous pentoxide. This mixture, called E490, has a eutectic melting point at 490 °C as shown in Figure 5.

We have performed a preliminary literature review and have identified a list of earth abundant oxides that reduce the melting point when added to the E490 baseline. For

example, the addition of calcium oxide reduces the melting point by approximately 80 °C [9]. Other oxides have a similar effect: magnesium oxide, boron oxide, aluminum oxide, zinc oxide, potassium oxide, and others. We will first perform a complete literature review to assess the current knowledge with two or three component mixtures of the oxides of interest. Then we will systematically screen the melting point of ternary mixtures based on E490 with one additional component. The most promising components that had the biggest melting point reduction from 490 °C will then be combined to explore the quaternary phase space based upon E490. In this manner we have the ability to explore high order mixtures, including five components (quinary) and more. See Table 1 for the materials palette we will draw from as candidate glass mixture components. The materials are listed in approximate order of earth abundance. We are confident that we can eliminate the molybdenum in our advanced glass and replace it with two or three different oxides to maintain the melting point near 350 °C at a much lower cost.

Based upon our preliminary experimental work, some components increase the glass viscosity when used in higher proportions in the melt; others dramatically lower it [10]. We will use glass components that act as network modifiers, weakening the interactions between glass molecules (often referred to as inducing ‘fragility’ in the network) and thereby reducing viscosity [11]. For example, sodium oxide dramatically lowers the viscosity at a given temperature when added to a glass melt. Other alkali and alkaline


Figure 5: E490 phase diagram [9].


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earth oxides have a similar effect [12]. Silica on the other hand, greatly increases the viscosity of the melt; eliminating it entirely dramatically reduces the viscosity. We have identified a list of glass components that tend to lower the viscosity when used in larger

proportions in silica melts. We will use these materials as possible candidates with which to formulate our glass. Halotechnics’ superior capability in combinatorial materials synthesis will enable fast screening of the glass compositions with different modifiers to minimize and achieve optimum glass viscosity at 400 °C.

We will use the molten glass viscometer to measure the viscosity of approximately 25 hits resulting from the melting point and heat capacity screening process. We will measure the viscosity as a function of temperature across the full operating range of the fluid – from the melting point up to 1200 °C. In this manner we will develop a fundamental understanding of how the viscosity changes as a function of glass composition. We are targeting a maximum viscosity below 1000 cP for easy pumping and low parasitic losses. At this viscosity the ratio of delivered thermal power from the flowing glass to the mechanical power required to pump the glass is high. This translates to low parasitic losses from pumping the molten glass out of the cold tank, up the tower and through the receiver tubes, and into the hot storage tank. Assuming typical pipe geometries, a 500 MWt receiver would require less than 5 MW of pumping

power, or less than 1% parasitic loads. Pumping the glass out of the hot tank and through the heat exchanger will require much less power due to the low viscosity of the hot glass.

Phase 1 work will focus on developing an optimized glass formulation for subsequent system testing in Phase 2. In parallel to system testing, work will continue to develop alternative formulations for the glass to further improve the physical properties, logistics, or manufacturing techniques. These alternative formulations will improve the robustness of the heat transfer fluid to changing market conditions. For example, it may be possible to achieve the same target properties for the molten glass by using different earth abundant components than those first utilized in Phase 1. It is important to assess different routes for achieving the same goal in order to develop a robust heat transfer fluid. Supply chain disruptions, price volatility, or some other events may necessitate the use of alternative formulations.

Sufficient quantity of the optimized glass material will be synthesized and produced in powder form for easy melting in subsequent component tests. Halotechnics will work


Material name Formula

silicon dioxide SiO2

aluminum oxide Al2O3

iron (III) oxide Fe2O3

iron (II) oxide FeOcalcium oxide CaO

magnesium oxide MgOsodium oxide Na2O

potassium oxide K2Otitanium dioxide TiO2

phosphorous pentoxide P2O5

manganese dioxide MnO2

barium oxide BaOstrontium oxide SrO

zirconium dioxide ZrO2

vanadium oxide V2O5

chromium oxide Cr2O3

zinc oxide ZnOcopper oxide CuO

lead oxide PbOboron oxide B2O3

molybdenum trioxide MoO3

tungsten trioxide WO3

antimony (III) oxide Sb2O3

bismuth oxide Bi2O3

Table 1: Materials palette.


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with a toll manufacturer capable of producing small batches of specialty glass and then grinding it into a uniform powder.

Key risks and recovery plan: There is a risk that no glass materials tested in Phase 1 will conform to the project objectives. For example, there may be a family of oxide mixtures with low melting points but high viscosity. The risk from this possibility is likely low since we have obtained preliminary data showing candidate glass materials with favorable properties. This risk will be reduced by the throughput and flexibility of the workflow. If a system of oxides is not generating candidates that meet the criteria, the search may be expanded to include more components or oxides of a different variety.

There is a risk that the workflow will not achieve the throughput or sufficient weeks in operation to successfully screen the total number of desired formulations. This risk will be addressed during the discovery program by using a flexible design of experiments methodology. If during the discovery program the total number of experiments is not on track to meet the initial target, subsequent library designs will be adjusted appropriately. It is possible that the available design space may be sufficiently explored with a number of experiments smaller than the initially proposed target.

Task 3: Piping material selectionSeveral types of alloys are commercially available candidates for containing molten glass at 1200 °C. Rocketdyne will develop a matrix with candidate alloys, the relevant properties of each such as creep strength and density, joining techniques, and cost. Advanced coating techniques will be considered to improve oxidation resistance. Based upon a preliminary review, possible candidate materials include alloys of molybdenum (TZM), cobalt (Haynes 188), or nickel (Haynes 230).

Molybdenum has exceptional creep resistance at elevated temperatures. TZM, an alloy of Mo with small amounts of Ti and Zr, has improved mechanical properties versus the pure alloy and is easier to fabricate. However, molybdenum alloys must be protected from oxygen to prevent severe oxidation and spalling. To solve this we will passivate the moly with a commercially available siliciding process. This technique results in a thin layer of silica on the surface of the molybdenum which prevents oxidation. Welding molybdenum alloys is difficult and they are quite expensive.

We will consider cobalt and nickel alloys as alternative to molybdenum. Cobalt alloys have strength approaching molybdenum at high temperatures, with improved weldability and cost. Haynes 188 for example exhibits excellent strength and oxidation resistance for applications approaching 1100 °C. Nickel alloys are commonly used in gas turbine and other high temperature applications where long life is desired. Haynes 230 for example is rated for applications approaching 1150 °C. Alternative coating techniques are possible with these alloys. Depending on required creep resistance conditions, aluminum diffusion-coated alloys could work and can be prepared by a number of commercial coating outfits. This coating forms an alumina layer for protection and has good oxidation resistance.

Key risks and recovery plan: There is a risk that no commercially available alloys can meet the requirements of the proposed application due to insufficient strength or oxidation resistance at high temperature. We will consider alternatives such as ceramic



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and ceramic composite materials for the piping application; such materials are used at temperatures exceeding 1600 °C.

Task 4: Corrosion testingCorrosion testing of candidate structural alloys and refractory ceramics will be crucial in order to assess long term materials compatibility with molten glass at elevated temperatures. Silica is the primary component of most commercially relevant glass materials and is the cheapest material, but also the most corrosive. Other oxide components have varying degrees of corrosion behavior. Halotechnics has developed a four channel device called the Multichannel Corrosion Analysis Tool (MCAT) for testing molten salt corrosion up to 700 °C. A modified version of this device will be developed capable of extended operation at 1200 °C (see Figure 6). It will consist of four independently controlled crucible furnaces, with several kilograms of molten glass held in a refractory crucible. Metal coupons of alloys of interest will be immersed in the molten glass and held at 1200 °C for extended durations (up to 3000 hours). Thermal

cycling between 1200 °C and 400 °C to mimic the daily operation in a CSP plant will also be used as a test condition. Coupons will be periodically removed from the glass and subsequently analyzed for mass changes and cross sectional metallography. Samples of Monofrax will also be submerged in the glass and subsequently analyzed for mass loss and corrosion rates.

The measured corrosion rate will allow us to design the hot glass storage tank with sufficient Monofrax lining to provide for a 20+ year plant lifetime.

Due to the limited throughput of this method, this work will be performed on only a few glass materials resulting from primary and secondary screening late in Phase 1 and extending into the first half of Phase 2.

Key risks and recovery plan: Corrosion may be unacceptably high with all feasible alloys. Modifying the composition of the glass will significantly affect corrosion; this option will be used in order to develop a low-corrosion glass that is compatible with our chosen alloys. As a fallback plan it may be possible to form Monofrax into hollow cylinders and join them together to function as a pipe.

Task 5: Tank modelingThe hot tank operating at 1200 °C is a critical component of the prototype system. See Figure 7 for a cross sectional diagram of our proposed design as well as an image of the Monofrax material.


1200 C

Figure 6: Multichannel Corrosion Analysis Tool for testing alloy and glass compatibility at 1200 °C.


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Molten Glass

Tank Roof

Tank Shell

MonofraxLining

Ceramic Insulation

Figure 7: (a) Cross section of internally insulated tank. (b) Photo of Monofrax.

The first step in the completion of the hot tank design task is to develop a complete thermal-mechanical-economic model of the tank so its design can be optimized. The optimal design will involve calculating the minimum installed cost of the tank at an acceptable level of thermal losses. The SolidWorks 3D solid modeling software package will be used to design parts and make mechanical drawings for manufacturing. SolidWorks will also be used to simulate mechanical loading and thermal performance of an assembly of parts. The results of thermal and mechanical simulation will be

complemented by our supply chain analysis of the cost of materials and estimates of labor rates for tank construction at commercial scale.

Thermal issues: The thickness of the internal and external insulation affects the temperature of the steel housing and therefore will drive the materials selection of the tank. The optimal design is a balance of many tradeoffs [13]. Increasing the thickness of the external insulation decreases thermal losses (increasing charge/discharge efficiency) but also increases the temperature of the steel structure which may necessitate more expensive alloys. Similarly, increasing the thickness of the internal insulation reduces the temperature of the steel housing but requires more ceramic material and more labor expense to

construct the complete tank. See Figure 8 for a schematic of the temperature of the tank materials proceeding radially outward from the molten glass interior. The tank will be


Molten Glass

Monofrax Tank Insulation

Air

1200 � C

25 � C

Tank temp.

Figure 8: Temperature proceeding radially outward from center of tank.


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designed such that the temperature just inside of the steel shell is below the freezing point of the molten glass. In the event of a leak, as the glass permeates to this location it will freeze and form a self-sealing barrier.

Mechanical issues: The internal insulation must be able to transmit the hydrostatic pressure of the molten glass inventory directly to the steel structure. The rupture strength of the ceramic is a critical property and must be understood in order to produce a reliable design. At the same time the diameter and height of the tank affect the thickness required for the steel housing in order to keep stresses at an acceptable level. The tank interface to the molten glass pump must also be designed.

Economic issues: Materials and labor costs are key drivers in the tank economic performance. By using the internally insulated concept we project significant savings by eliminating the need for expensive nickel alloys in the tank construction since stainless steel costs approximately 1/8th as much per pound. Additional savings may be possible by using carbon steel (less than one half the cost per pound relative to stainless steel) for the tank housing, by increasing the internal insulation thickness and reducing the shell temperature to acceptable levels. However this must be balanced by the increased labor cost from installing thick ceramic bricks inside the tank.

Our innovation will achieve a high exergetic efficiency when charged and discharged. The thermal storage tanks at Andasol lose approximately 1 °C per day when full [1]. For our prototype we estimate 10 °C lost per day in the hot tank due to the higher storage temperature and smaller volume and 3 °C per day in the cold tank. This results in a round trip exergetic efficiency of 98% after storing heat for 12 hours. The expression for exergetic efficiency, assuming an incompressible fluid with an average specific heat simplifies to:

ε=|T do−Tdi−Tamb ln T doT diTco−T ci−T amb lnT coT ci

|Parameter Symbol Value (°C) Value (K)Charge Tin Tci 1200 1473

Charge Tout Tco 397 670Dischage Tin Tdi 400 673

Dischage Tout Tdo 1190 1463Tambient Tamb 27 300

where Tdo and Tdi are the temperature of the fluid during discharging (out and into the storage system), Tco and Tci are the temperature of the fluid during charging (out and into the storage system), and Tamb is the ambient temperature. Inserting the temperature targets for the hot and cold tank during charge and discharge results in a round trip exergetic efficiency η of 98%. This calculation neglects the parasitic pumping loads from the molten glass pumps. This load is expected to be small relative to the power output of the plant due to the high density of molten glass and the relatively short length of required piping in the proposed two-tank thermal storage system. The hot tank and cold tanks will be used as molten glass reservoirs for subsequent component testing.

Task 6: Tank design and testingHot tank: We will select materials for the internal insulation, tank housing, external insulation, and external skin of the hot tank. We will design the tank with internal immersion or radiative heaters to maintain the glass at high temperature for initial filling or other testing purposes. These heaters will be turned off during full system testing.



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The tank will be capable of draining the inventory using gravity to facilitate repair and maintenance.

Once we have modeled the tank and arrived at an optimal design, we will perform a detailed design and fabrication of the necessary components. The complete tank will be assembled and filled with a full inventory of molten glass for validation testing.

Validation test protocol:

1. Fill with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 1200 °C until equilibrated.4. Turn off internal heaters and measure temperature of glass over a 12 hour

period.5. Verify that thermal losses are below target level.

Cold tank: The cold tank design must be capable of operating at a temperature of 400 °C with the molten glass. We will use a scaled version of the commercially deployed hot tank designs in current CSP plants [1]. This design uses a stainless steel alloy with external insulation only, and a thin aluminum skin. Heat losses from this design can be reduced to negligible levels by designing sufficiently thick external insulation. A review of literature and any relevant testing data will be conducted first to verify the compatibility of the chosen steel alloy with molten glass at 400 °C. Tank modeling, detailed design, and validation testing will proceed in a similar fashion as the hot tank described above.


1. Fill with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 400 °C until equilibrated.4. Turn off internal heaters and measure temperature of glass over a 12 hour

period.5. Verify that thermal losses are below target level.

Key risks and recovery plan: For the hot tank, there is a risk that the internal insulation is not compatible with extended direct contact with molten glass. For example, if the glass permeates through the seams of the Monofrax bricks all the way to the external steel shell, the thermal conductivity may increase to unacceptable levels and result in greater heat losses, high shell temperatures, and shell corrosion. We will use advanced Monofrax sealing and joining techniques as a fallback, at an increased liner cost.

For the cold tank, there is a risk that steel is not compatible with the molten glass. This compatibility will be assessed first by a literature review and then by corrosion testing if necessary. We will use a nickel alloy as a fallback if steel proves inadequate.

There is additional risk that the tanks successfully hold the molten glass but have unacceptably high thermal losses, due to the small volume or the thermal leaks caused by instrumentation. We will attempt to create a conservative design with adequate thermal insulation in order to achieve the high efficiency we desire. We have also set a fallback target to hit if our aggressive target is not feasible.



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Task 7: Pump modelingThe viscosity pump concept is a unique pump design that was developed for the production of glass fiber. This process involves the extrusion of the glass at elevated pressure through nozzles. We will develop a theoretical model to predict the flow and efficiency of the pump as a function of glass viscosity. The focus of this modeling work

will not be on rigorous computational fluid dynamics or finite elements analysis; rather it will be a design tool only so we can verify the function of our design with adequate accuracy before fabricating the necessary components and building the system. The pump model will allow us to verify its suitability for both the hot and the cold tank.

Parasitic pumping losses are expected to be small at

commercial scale, likely less than 1% of gross plant output [7], since molten glass has a high volumetric heat capacity and therefore will have low volumetric flow rates. See Figure 9 for a schematic diagram of this concept.

Task 8: Pump design and testingOnce we have a complete model to be used as a design tool we will fabricate a proof of concept alpha prototype viscosity pump and use it to pump a fluid of similar viscosity at ambient temperature. For example, if we expect the molten glass to have a viscosity of 1000 cP at 400 °C we will select a proxy fluid with a viscosity of 1000 cP at room temperature in order to validate the functionality of our design. This low temperature prototype will be constructed from readily available materials such as plastic and aluminum as appropriate.

The design and fabrication of beta prototype viscosity pumps capable of operating at full temperature a (400 °C and 1200 °C) will be the next step in pump development. The overall geometry developed in the previous task will be used for this design, with modifications made to account for the high temperature operation. The design will consist of a drum with axial cooling passageways to keep moving parts at an acceptable temperature. The surface of the drum will be clad with a refractory metal such as molybdenum or alternatively a thin platinum or ceramic layer. The geometry for the cold pump (high viscosity, low temperature) will vary as necessary from the hot pump (low viscosity, high temperature) in order to achieve the desired flow and pressure.

Hot pump validation test protocol:

1. Fill hot tank with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 1200 °C until equilibrated.


Figure 9: Viscosity pump for pumping molten glass [6].


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4. Activate pump and pump molten glass into the cold tank or external storage vessel.

5. Verify satisfactory pump performance.

Cold pump validation test protocol:

1. Fill cold tank with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 400 °C until equilibrated.4. Activate pump and pump molten glass into the hot tank or external storage

vessel.5. Verify satisfactory pump performance.

Key risks and recovery plan: There is a risk that the viscosity pump concept cannot generate sufficient pressure or flow to achieve the desired performance for the prototype. Or the pump may function at very low efficiency. We will use a compressed gas method to force the molten glass through the pipes as a fallback plan. Pressurizing the cold tank with an inert gas such as argon would reliably move the glass through the heater. The method could similarly be used to move the glass from the hot tank through the heat exchanger. Positive displacement pumps made of stainless steel or nickel alloys (for the cold pump) or refractory alloys (for the hot pump) are another alternative design. If the glass is too viscous to pump at 400 °C, we will consider raising the minimum temperature of the cold tank in order to reduce the glass viscosity and enable satisfactory pump operation. A cold tank at 500 °C, for example, will still allow us to demonstrate the validity of our design.

Task 9: Heat exchanger modelingWe will develop a thermal model of the direct contact heat exchanger in order to predict its performance during system testing. We will first assess available literature on similar designs [14]. Again, our focus will be on design and not extended theoretical exercise. The goal of this task will be to develop a tool to predict the necessary height, flow rate, and droplet geometry of our design. The inlet manifold “showerhead” design will be modeled to understand methods for producing uniform droplet size. Sonication methods will be considered to achieve this if necessary. See Figure 10 for a schematic diagram of the liquid droplet heat exchanger (LDHX)

exchanging heat between falling glass droplets and pressurized air flowing up.


Hot Glass at 1200 � C

Cold Glass at 400 � C

Hot Air

Cold Air

MonofraxLining

Pressure Vessel

Figure 10: Liquid droplet heat exchanger.


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Task 10: Heat exchanger design and testingOnce we have completed the modeling work we will construct a proof of concept prototype heat exchanger to use at low temperature. This alpha prototype will consist of a vertical polycarbonate pipe (clear for visual observation of the droplets) with an inlet manifold and droplet nozzle at the top. At the bottom will be a collection manifold and inlet for cold air. We will use a proxy fluid with similar viscosity and density to the expected molten glass (such as glycerine or silicone oil). This fluid will be heated to a moderate temperature of approximately 80 °C and exchange heat with air pumped through the device at ambient temperature. The outlet for the heated air will be at the top of the device.

The design and fabrication of a LDHX beta prototype capable of operating at full temperature a (400 °C and 1200 °C) will be the final step in heat exchanger development. The overall geometry developed in the previous task will be used for this design, with modifications made to account for the high temperature operation. The vertical column will consist of a stainless steel shell lined with Monofrax bricks. Molten glass will enter the top of the column at 1200 °C and exchange heat with air flowing up the column. The glass will be collected at the bottom of the column at 400 °C. Air will be pre-heated to 400 °C and pumped into the bottom of the column. The hot air at temperatures approaching 1200 °C will exit the top of the column and be allowed to dissipate.

A full pressure prototype heat exchanger feeding hot gas to a small turbine is beyond the scope of this project, but is not necessary to prove the validity of the design. The pressure inside the column will be kept near ambient levels for safety and simplicity. Full scale designs must operate at the pressure of the outlet of the compressor on the gas turbine, typically 20-30 bar. Once our design has been proven to operate at full temperature, it will be readily scaled up and utilized at full pressure in future development efforts.


1. Fill hot tank with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 1200 °C until equilibrated.4. Activate pump and pump molten glass into the cold tank through the heat

exchanger.5. Measure heat output to verify adequate radiator performance.

Key risks and recovery plan: There is a risk that the LDHX will not achieve the desired heat flow out of the molten glass. The detailed design, with complex fluid dynamics and steep thermal gradients may require too many iterations to be successful within the project period. We will use a simple radiative heat sink as an alternative fallback design consisting of a series of small diameter molybdenum tubes in quartz sleeves through which the glass flows in parallel. A large aluminum panel rests behind the pipes. A fan blows across the pipes and the aluminum panel, producing a large heat transfer coefficient and allowing the heat flux to be controlled by varying the fan speed. We will use a powerful fan for forced convection. We will also consider a cold water jacket to



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achieve sufficient cooling, increasing the length of the cooling pipes, or increasing the allowable discharge period.

Task 11: Furnace modelingA key focus of the proposed project is to build a prototype thermal storage system that in every practical way mimics a full scale commercial CSP plant. We propose using a radiant heat source to heat the molten glass as it flows through a pipe, much like a full scale receiver would do when subjected to concentrated insolation. We will use a commercially available laboratory tube furnace as the heat source of our prototype system. Many models are available from manufacturers such as Blue M and others for maximum temperatures up to 1700 °C. However, these furnaces are designed to operate under near adiabatic conditions. We will be actively cooling the furnace with the flowing molten glass. We will develop a thermal model of the furnace and molten glass coolant to verify that we can reliably heat the glass to 1200 °C using radiative heat transfer. We will use MATLAB to develop a numerical model of the tube furnace, metal pipe, and flowing molten glass system. This modeling work will result in a design tool that we can use to verify the function of our design with adequate accuracy before purchasing the necessary components and building the system.

Task 12: Furnace testingValidation test protocol:

1. Fill cold tank with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 400 °C until equilibrated.4. Activate pump and pump molten glass into the hot tank through the tube furnace.5. Measure heat input to verify adequate furnace performance.

Key risks and recovery plan: There is a risk that the radiative heater tube furnace cannot achieve sufficient heat flow into the molten glass. We will reduce the flow rate and thermal power input of the molten glass as a fallback in order to achieve the desired temperature.

Task 13: Full system design and assemblyThe full system test of our thermal energy storage prototype is the final hardware deliverable of the proposed project. Phase 1 of this program focuses on developing the critical components necessary for the proposed thermal storage system. Phase 2 focuses on integrating the separate components into a complete prototype system, capable of heating, pumping, storing, and cooling the molten glass. We will fully instrument the prototype system, including measuring the temperature, pressure, and flow rate at key points. See Table 2 for a list of the instrumentation. Thermocouples will typically be K-type or another variety suitable for a molten glass environment. Pressure transducers will use a manometer design with the fluid column height measured by laser [15]. This design avoids direct contact with the hot molten glass. Flow sensors will be a thermal flow meter design which inputs a known heat flow and measures the temperature rise in the fluid. This data can be used to calculate the mass flow rate. All data from the instrumentation will be monitored and recorded with a data acquisition system operated with LabVIEW.



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The full system design includes important items such as balance of plant components, instrumentation, connectors/fittings, facilities, ventilation, and safety equipment/procedures. The facilities where we will assemble and test the full prototype will be capable of high voltage electrical service adequate for running the furnaces and pumps simultaneously. It will also have sufficient ventilation to dissipate the hot air generated by the process.

Name Process parameter Location Sensor typeT1 Temperature Glass, cold tank thermocoupleT2 Temperature Wall, cold tank thermocoupleT3 Temperature Glass, furnace inlet thermocoupleT4 Temperature Furnace, zone 1 thermocoupleT5 Temperature Furnace, zone 2 thermocoupleT6 Temperature Furnace, zone 3 thermocoupleT7 Temperature Glass, furnace outlet thermocoupleT8 Temperature Glass, hot tank thermocoupleT9 Temperature Wall, hot tank thermocouple

T10 Temperature Glass, LDHX hot end thermocoupleT11 Temperature Glass, LDHX cold end thermocoupleT12 Temperature Air, LDHX cold end thermocoupleT13 Temperature Air, LDHX hot end thermocoupleT14 Temperature Air, ambient thermocoupleP1 Pressure Glass, cold pump outlet laser manometerP2 Pressure Glass, hot pump outlet laser manometerP3 Pressure Air, LDHX cold end pressure transducerF1 Flow rate Glass, cold pump outlet thermal flow meterF2 Flow rate Glass, hot pump outlet thermal flow meter

F3 Flow rate Air, LDHX cold endvolumetric flow meter

Table 2: Instrumentation of thermal storage prototype system.

Task 14: System testingComplete system testing will verify the performance over a 24 hour period.


1. Fill cold tank with molten glass inventory (powder form).2. Heat tank using internal heaters. 3. Maintain temperature at 400 °C until equilibrated.4. Activate cold pump and pump molten glass into the hot tank through the tube

furnace.5. Charge for 6 hours at 5 kWt.6. Monitor heat input to verify adequate furnace performance.7. Hold glass at 1200 °C in hot tank for 12 hours. Monitor heat losses.8. Activate hot pump and pump molten glass into the cold tank through the heat

exchanger. 9. Discharge for 6 hours at 5 kWt.



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10.Monitor heat output to verify adequate heat exchanger performance.

The complete system prototype will function as a flexible platform for subsequent testing and development, including startup/shutdown procedures, freeze recovery techniques, materials compatibility studies, heat transfer coefficient measurement of molten glass, and many other possible tests. This in-depth testing is beyond the scope of the proposed 24 month project but will be pursued in future development efforts leading to commercialization.

Key risks and recovery plan: The major risk for the final task is a failure of component integration to achieve full system operation. We will attempt to fully validate each subsystem as a fallback. For example, if there in an issue with controlling the cold pump and the tube furnace simultaneously, we will validate each component separately to show charging capability, then use the hot pump and heat sink simultaneously to show integrated discharge capability. The system as a whole can be run as two independent subsystems: the charging subsystem (cold tank, cold pump, tube furnace) and the discharging subsystem (hot tank, hot pump, heat exchanger). This modularity allows flexibility in system control and validation testing.

Task 15: Technology transfer and outreachThe overall goal of the proposed program is to develop a commercially viable thermal energy storage system. In order to accomplish this goal we will focus on engaging target customers, suppliers, and the general public in addition to the technical tasks of the program. The project team will attend relevant industry trade shows and conferences, discussion panels, and symposia. We will visit key customers and partners. We will purchase market reports and publications in order to stay abreast of our technology developments.

Our efforts will be structured around a comprehensive outreach program: “The Promise of Thermal Storage,” focused on educating stakeholders (utilities, customers, and the general public) on the value of our proposed technology. Activities under this program will include workshops, discussion panels, blogs, interviews with the media, and appearances at local governing body meetings.

Significance to FOA TargetsPrimary Technical Targets

ID Number Category Program Desired Value

Halotechnics End of Project Target

1.1.1 Temperature for power generation in the down-stream power cycle ≥ 600 °C 1200 °C

1.1.2 Exergetic efficiency ≥ 95% 98%

1.1.3 Charging time for storage ≤ 6 hours for full charge

6 hours for full charge

1.1.4 Stored energy for technology demonstration ≥ 30 kWht 30 kWht

1.1.5 Technology demonstration (peak delivered thermal power from storage) ≥ 5 kWt 5 kWt



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Secondary Technical Targets

ID Number Category Program Desired Value

Halotechnics End of Project Target

1.2.1 Cost of storage system including charging and discharging devices ≤ $15/kWht $12/kWht a

1.2.2 Volumetric energy density ≥ 25 kWht/m3 170 kWht/m3

1.2.3 Operational lifetime 20+ years, 10,000+ cycles 10,000 cycles b

a Projected cost at commercial scale. Cost for developing first of a kind prototype will be higher.b Estimate from measured corrosion rate (TBD) of refractory tank lining.

We estimate capital costs of storage by first assuming we can develop an advanced molten glass that costs $500/ton (50% less than currently used molten salts). We estimate capital costs for the tank and balance of plant by scaling to 1/8th in volume (vs. Andasol) but 50% higher unit costs due to more expensive construction materials. This estimate results in $12/kWht, a 10X reduction in costs vs. today’s technology.

We estimate approximately 88 kg of molten glass to achieve 30 kWht of energy storage with our prototype. Assuming a low density for glass (2 kg/L) and allowing for generous insulation and pump volumes results in a volumetric energy density of 170 kWht/m3.

Performance Team: Halotechnics has assembled a multidisciplinary team of experts from the glass industry, physical chemists, and thermal/fluids engineers with direct experience in the critical areas of the proposed thermal storage system. The diverse background and experience of the team members will let us address head on the challenges and risks presented by the proposed project.

Team Member Title ExpertiseDr. Justin Raade CEO and Founder (PI) Expert in applied thermodynamicsMichael McDowell Project Manager (Pratt &

Whitney Rocketdyne)35 years of experience in engineering for severe environments

Leo Finkelstein Senior Staff Scientist 17 years of experience in developing low melting point glass materials

Scott Whiting Director of Engineering 15 years of experience in chemical reactor design and automation

Grady Hannah Director of Business Development

Leads customer-facing messaging and business strategy at Halotechnics

Dr. David Padowitz Consultant, Materials Science

Expert in materials science and combinatorial chemistry

Dr. Robert Bradshaw Consultant, Corrosion Chemistry

Recognized as the leading expert in high temperature fluids chemistry and corrosion

Dr. Adam Bruckner Consultant, Heat Exchanger Design

One of the original inventors of the liquid droplet heat exchanger

Dr. Michael Tenhover Consultant, Glass Technology

Has extensive experience in glass production technology and the chemicals industry

Dr. David Kearney Consultant, CSP Industry Widely regarded as an international expert in CSP technology



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Statement of Project Objectives (1 page)Objectives:Halotechnics proposes to develop a thermal storage system utilizing a low melting point molten glass as the heat transfer and thermal storage material. An advanced glass

represents a potential breakthrough in a low cost, earth abundant, and stable thermal storage material. This novel material will enable unprecedented efficiency with thermal energy storage exploiting sensible heat. We will develop a two-tank thermal storage system operating at a hot temperature of 1200 °C and a cold temperature of 400 °C. This project will leverage technology used in the modern glass industry, with decades of experience in handling high temperature viscous materials. Halotechnics will combine its proven expertise in combinatorial chemistry with advanced techniques for handling molten glass. The molten glass thermal storage system has the potential to reduce thermal

storage costs by a factor of ten once developed and deployed at commercial scale. Thermal storage at the target temperature can be integrated with existing high temperature gas turbines that significantly increase efficiencies over today’s steam turbine technology.

Scope of Work: Halotechnics has formed a project team with Pratt & Whitney Rocketdyne, a world leading engineering firm with experience in aerospace and power generation. We propose to design and build a complete lab scale prototype of an advanced sensible heat thermal storage system. Phase 1 of the program will focus on validating the critical components of the system at a prototype level. We will optimize the glass material and develop a pump, tank design, and heat exchanger capable of performing under aggressive thermal environments. Phase 2 will focus on integrating each component into a complete thermal storage system capable of pumping, heating, storing, and discharging the advanced molten glass.

If successful this project will be both transformative and disruptive. We propose to translate technology developed by the glass industry and use it to transform a new sector – to develop cheap thermal energy storage for concentrating solar power (CSP).


molten glass 1200 °C


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Technical Milestones and Deliverables (5 pages)The advanced molten glass thermal storage system is currently at TRL 3. We have a proof of concept glass material and conceptual designs for critical components of the system. At the conclusion of Phase 1 of the project (months 0-12) we will have progressed the technology to TRL 4. The glass material will be optimized; the glass pump will be built and a viscous fluid will be pumped, other critical components will be identified and engineering specifications developed. At the conclusion of Phase 2 of this project (months 13-24) we will have advanced the technology to TRL 5. We will integrate all the critical components and build a high-fidelity laboratory prototype that operates at full temperature.

Phase 1 Milestones and Deliverables:Phase 1 is focused on developing and verifying the performance of critical components in the thermal storage system (glass material, piping material, pumps, tanks, heat exchanger, and furnace).

Q1:

1. Glass screening method complete. Demonstrate throughput of 50 samples/day.2. Complete model of tank, pump, and heat exchanger performance.

Q2:

1. Complete Materials Survey Report for candidate alloys compatible with glass. Select alloys for corrosion testing.

2. Complete corrosion testing system development. Demonstrate crucible furnace operation at 1200 °C.

3. Complete model of furnace performance.4. Complete development of pump alpha prototype. Demonstrate performance with

proxy fluid at ambient temperature.

Q3:

1. Complete development of heat exchanger alpha prototype. Demonstrate performance with proxy fluid at ambient temperature.

2. Provide data of hot pump operating at 1200 °C with 5 kWt flow rate while pumping molten glass (4 kWt acceptable as fall back).

3. Provide data of cold pump operating at 400 °C with 5 kWt flow rate while pumping molten glass (4 kWt acceptable as fall back).

4. Provide data of hot tank test showing less than 10 °C heat loss over a 12 hour storage period (50 °C acceptable as fall back).

5. Provide data of cold tank test showing less than 3 °C heat loss over a 12 hour storage period (50 °C acceptable as fall back).

Note: Achieving the target heat loss values is an aggressive goal due to the small tank volume, multiple tank piercings due to extensive instrumentation, and experimental designs. We have provided a fall back scenario with greater heat losses that will still successfully prove the concept even if we do not meet the aggressive primary targets.

Q4:



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1. Provide 100 g sample of optimized 1st generation glass material. Provide physical property datasheet.

2. Provide data from first round of corrosion testing.3. Provide data of 5 kWt of heat flow out of flowing glass from heat exchanger (4

kWt acceptable as fall back).4. Provide data of 5 kWt of heat flow from tube furnace into flowing glass (4 kWt

acceptable as fall back).

Phase 1 Go/No-Go: Demonstrate functionality of critical components (TRL 4)

Phase 2 Milestones and Deliverables:Phase 2 is focused on integrating the critical components developed in Phase 1 and testing the complete thermal storage system.

Q1:

1. Begin developing 2nd generation glass material.2. Complete development of instrumentation for system testing (temperature,

pressure, flow sensors).

Q2:

1. Complete full system design. Provide details on complete system characteristics.2. Assemble complete system.

Q3:

1. Provide data from preliminary system test at reduced maximum temperature (700 °C) and reduced flow rates (3 kWt).

Q4:

1. Provide data from system testing at 1200 °C, verifying capability to charge, store, and discharge 30 kWht over a 24 hour period (20 kWht acceptable as fall back). Charge for 6 hours, store for 12 hours, discharge for 6 hours.

Phase 2 Go/No-Go: Demonstrate functionality of complete system (TRL 5)



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No. Task Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q41 Glass screening workflow development2 Optimize glass material

3 Piping material selection4 Corrosion testing

5 Tank modeling6 Tank design and testing

7 Pump modeling8 Pump design and testing

9 Heat exchanger modeling10 Heat exchanger design and testing

11 Furnace modeling12 Furnace testingG1 Go/No-Go 1: Achieve TRL 4

13 Full system design and assembly14 System testing15 Technology transfer and outreachG2 Go/No-Go 2: Achieve TRL 5

Phase 1 Phase 2

Table 3: Overall project timeline by task.



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Literature Citations (no limit)

[1] S. Relloso and E. Delgado, "Experience with molten salt thermal storage," in SolarPACES, Berlin, 2009.

[2] J. Stekli, "Thermal Energy Storage Research," in ARPA-E Thermal Storage Workshop, Washington, D.C., 2011.

[3] B. Kelly and D. Kearney, "Thermal Storage Commercial Plant Design," NREL/SR-550-40166, Golden, CO, 2006.

[4] "Concentrating Solar Power Projects: Andasol-1," NREL, Golden, CO, 2011.

[5] J. DiMartino, Corrosion Science, vol. 46, p. 1865–1881, 2004.

[6] T. H. Jensen, "Glass forehearth having a viscosity pump". U.S. Patent 4,083,711, April 1978.

[7] A. P. Bruckner, "Heat transfer and storage system". U.S. Patent 4,727,930, 1988.

[8] J. W. Raade and D. Padowitz, "Development of molten salt heat transfer fluid with low melting point and high thermal stability," Journal of Solar Energy Engineering, vol. in press, 2011.

[9] E. M. Levin, C. R. Robbins and H. F. McMurdie, Phase Diagrams for Ceramists, Columbus, OH: American Ceramic Society/NIST, 1964.

[10] A. Fluegel, European Journal of Glass Science and Technology Part A, vol. 48, no. 1, 2007.

[11] P. F. Green, Kinetics, Transport, and Structure in Hard and Soft Materials, London: Taylor and Francis Group, 2005.

[12] C. A. Angell, "Glass-Formers and Viscous Liquid Slowdown since David Turnbull," MRS Bulletin, vol. 33, p. 544, 2008.

[13] R. Gabrielli and C. Zamparelli, Journal of Solar Energy Engineering, vol. 131, 2009.

[14] A. P. Bruckner and A. T. Mattick, "High effectiveness liquid droplet/gas heat exchanger for space power applications," Acta Astronautica, vol. 11, no. 7-8, pp. 519-526, 1984.

[15] P. Sabharwall, "Molten salts for high temperature reactors: University of Wisconsin Molten Salt Flow Loop Experiments INL/EXT-10-18090," Idaho National Laboratory, Idaho Falls, Idaho, 2010.



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Qualifications, Experience, and Capabilities (3 pages each)Dr. Justin W. Raade (PI)

PROFESSIONAL PROFILEI am an engineer and entrepreneur with a passion for commercializing high impact R&D. I have ten years of experience in cleantech R&D with a focus on applied thermodynamics. To pursue this research I have secured government grants and private investment, and have founded a company to commercialize the results of the work. My business sense and management skills have been honed by real-world entrepreneurship in building a technology company from scratch. My current focus is on developing and commercializing technology that will make solar power cheaper than fossil fuels and able to provide electricity day and night.

PROFESSIONAL EXPERIENCEHalotechnics, Inc. Emeryville, CaliforniaCEO and Founder 2009 – presentI founded Halotechnics and built a multidisciplinary team to perform high-value research and development on breakthrough materials for solar power applications.

Began research with eutectic molten salt materials at Symyx Technologies in 2007. Screened 5000 unique mixtures and discovered breakthrough properties.

Founded Halotechnics in 2009 to develop and commercialize the advanced molten salt materials for heat transfer and thermal storage applications in concentrating solar power (CSP).

Negotiated spin-out from Symyx. Raised $2 million for Halotechnics in government R&D grants (from NSF SBIR and DOE) as well as private angel investment.

Hired a team of experts in chemistry, engineering, and business development and located new company in Emeryville, California.

Currently using combinatorial chemistry techniques to develop molten salt materials with low cost and unprecedented operating range (low melting point, high maximum temperature).

Symyx Technologies Santa Clara, CaliforniaPrincipal Investigator and Staff Scientist 2006 – 2009At Symyx I led multiple teams investigating various alternative energy technologies, including concentrating solar power, fuel cell reformers, and advanced industrial lubricants. I was hired as a mechanical engineer and quickly expanded the scope of my work through independent investigation.

Initiated and led program to develop advanced heat transfer fluids and thermal storage media for concentrating solar power. Program focused on deep eutectic salt formulations. Secured external funding for program with Department of Energy grant (Award DE-FG36-08GO18144).

Investigated on-board reforming of ethanol for mobile fuel cell applications. Led multidisciplinary R&D program to develop experimental methodologies for

evaluating new blends of synthetic automotive motor oils and industrial oils.



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Designed automated combinatorial chemical reactors to facilitate high-throughput experimentation with synthetic lubricants.

University of California, BerkeleyGraduate Student Researcher 2001 – 2005Robotics and Human Engineering LaboratoryAt UC Berkeley I focused my research primarily on applied thermodynamics for advanced energy storage technologies. Developed method for creating Ragone plots and optimal design of hybrid power systems.

Battery systems: Implemented 15 W solar panel to charge lithium polymer batteries for human exoskeleton application.

Hydrogen fuel cells: Designed fuel cell power systems (1.5 kW and 20 W) for human exoskeleton. Created hybrid power system with fuel cell and lithium polymer batteries.

Hydrogen peroxide: Developed free piston hydraulic pump powered by hydrogen peroxide. Constructed and tested prototype.

EDUCATIONUniversity of California, Berkeley Berkeley, CaliforniaPh.D. Mechanical Engineering, 2006Focus: Design, Thermodynamics Advisor: H. KazerooniThesis: “Graphical analysis of power systems for mobile robotics”

University of California, Berkeley Berkeley, CaliforniaM.S. Mechanical Engineering, 2003Thesis: “Design and testing of a monopropellant powered free piston hydraulic pump”Massachusetts Institute of Technology Cambridge, Massachusetts

B.S. Mechanical Engineering, 2001Thesis: “Design of multiplexing gearbox and zero-backlash flexure clutch for application in automobile seats”

GRANT AWARDS1. “Advanced molten salt heat transfer and thermal storage material for central receiver

solar thermal power generation,” Award IIP-1047450, National Science Foundation Phase 1 SBIR grant, $150,000, 2011.

2. “Deep eutectic salt formulations suitable as advanced heat transfer fluids,” Award DE-FG36-08GO18144, Department of Energy Solar Energy Technologies Program, $1.5 million, 2009 – 2012.

3. National Science Foundation Graduate Research Fellowship, $105,000, 2002 – 2005.

RELEVANT PATENTS1. J. W. Raade , B. Elkin, and J. Vaughn, “Thermal energy storage system with novel

molten salt,” U.S. provisional patent application 61/494,272, June 7, 2011.



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2. J. W. Raade , M. Tenhover, and J. Vaughn, U.S. provisional patent application, May 13, 2011.

3. J. W. Raade , G. Hannah, T. Roark, and J. Vaughn, “Molten salt material for heat transfer and thermal energy storage,” U.S. provisional patent application 61/485,491, May 12, 2011.

4. J. W. Raade and D. Padowitz, “Inorganic salt heat transfer fluid,” U.S. patent application 13/088,605, April 18, 2011.

JOURNAL PUBLICATIONS1. J. W. Raade and D. Padowitz, “Development of molten salt heat transfer fluid with

low melting point and high thermal stability,” Journal of Solar Energy Engineering, accepted for publication.

2. J. W. Raade and H. Kazerooni, “Analysis and design of a novel hydraulic power source for mobile robots,” IEEE Transactions on Automation Science and Engineering, vol. 2, no. 3, pp. 226-232, July 2005.

3. T. G. McGee, J. W. Raade, and H. Kazerooni, “Monopropellant-driven free piston hydraulic pump for mobile robotic systems,” ASME Journal of Dynamic Systems, Measurement, and Control, vol. 126, pp. 75–81, March 2004.

PEER REVIEWED CONFERENCE PUBLICATONS1. J. W. Raade and D. Padowitz, “Low melting point molten salt heat transfer fluid with

reduced cost,” submitted to 17th SolarPACES conference, accepted for publication.

2. J. W. Raade and D. Padowitz, “Development of molten salt heat transfer fluid with low melting point and high thermal stability,” proc. 16th SolarPACES conference, Perpignan, France, 2010.

3. J. W. Raade , K. R. Amundson, and H. Kazerooni, “Development of hydraulic-electric power units for mobile robots,” proc. ASME International Mechanical Engineering Congress and Exposition, Orlando, Florida, 2005.

4. J. W. Raade , H. Kazerooni, and T. G. McGee, “Analysis and design of a novel power supply for mobile robots,” proc. IEEE International Conference on Robotics & Automation, New Orleans, Louisiana, 2004.

5. J. W. Raade , T. G. McGee, and H. Kazerooni, “Design, construction, and experimental evaluation of a monopropellant powered free piston hydraulic pump,” proc. ASME International Mechanical Engineering Congress and Exposition, vol. 2, 2003.



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Leo FinkelsteinSummary Bilingual engineer and innovator with experience of the discovery of several patents in the area of materials and process development as it applies to microelectronic packaging and device encapsulation using ceramic, glass, solder and polymers.

Professional ProfileMr. Finkelstein was involved with InfoTurn Corp. as co-founder from 2004 till 2006. Prior to that he played major role as technical liaison between York Corp.(USA) and Byelorussneft (Byelorussia) to design, build, install and commissioned two complete propane turbocompressor units . He was a cofounder of VLSI Packaging Materials Corp. in 1988. Initially involved in all phases of the operation his major function was that of research and development of new low temperature sealing materials in conjunction with prototype development and the following technology transfer to the pilot line production. He also was involved in market research for new product ideas. His technical abilities range from his expertise, experience and knowledge in glass and ceramic materials, polymers, ceramic-metal and ceramic-glass interaction to microcircuit packages and advanced measuring instrumentation for the laboratory and mass production environment,

Mr. Finkelstein received an MS degree in Ceramics Engineering from St. Petersburg Chemical University in Russia. He completed PhD coursework just before emigrating to the U.S. in 1980. He has authored 6 patents and 5 publications.

Work ExperienceHalotechnics, Inc. - Consultant San Francisco, CA 2011

Involved in development of low temperature materials suitable for solar energy storage and heat transfer at high efficiency and low cost.

Infoturn Corporation - Founder/Director of Engineering San Francisco, CA 2002-2006

- Hired technical and management team

- Developed proposal for platform technology for re-configurable and re-programmable optical components that offered 5X price/performance advantages over existing solutions. Allowed creation of Application Specific Optical Processors (ASOP) and Field Programmable Optical Arrays (FPOA) that simplified and reduced costs for next generation optical systems. The technology used Electro-Static methods to generate and reconfigure photonic band-gap nano-structures in EO material.

LF Engineering - Consultant San Francisco, CA 1993 – 2002

Amrutech Corp. – Assisted in negotiating and securing $4 million contract between York Corp in US and Byelorussneft in Byelorussia to design, build and deliver two gas compressors. Technical liaison between the two companies.

- Developed and evaluated various glass film compositions doped with rare earth elements for eye-safe laser materials to improve thermo-mechanical characteristics.



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- Assisted in the development and evaluation of low temperature (below 300 °C) bonding materials for ceramic, glass and low TCE metal substrates.

- Provided technical assistance in development and evaluation of the super low temperature silver-glass die attach paste for temperature sensitive semiconductor devices.

- Conducted failure analysis for microelectronic hermetic ceramic packages after MIL spec testing, and recommended changes in design and material processes to overcome failures

VLSI Packaging Materials Co-founder & CTO Sunnyvale, CA 1988-1993

- Raised start-up capital of $2 million

- Lead research and development team in new product development

- Drove successful technology transfer from lab to high volume production of low cost ceramic lids and sealing process that were used in the assembly line of 486 microprocessors by a major semiconductor company.

- Conducted market research for new product concepts

- Developed and established innovative manufacturing process for low temperature hermetic sealing for electronic and hybrid devices that met US Department of Defense MIL specs.

- Conducted pilot assembly line and reliability testing to meet MIL specs.

-Developed and Licensed innovative low temperature silver glass die attach paste to a leading semiconductor packaging material development company.

- Worked closely with the international vendors and customers to introduce new product to the market

- Brought production yield from 50% to 98-99%.

TKG Partnership - Partner (Material development) Los Altos, CA 1985-1988

- Invented low temperature sealing material for ceramic microelectronic packaging.

Demetron Inc./Technology Glass Inc., Subsidiary of Degussa Corp. Senior R&D Engineer

Union City/Sunnyvale, CA 1980-1985

- Created and directed program to develop new gold dotting ink and ceramic metallization process for die attach application resulting in savings of half a million dollars annually and increased metallization yield from 75% to 99%.

- Developed moisture monitoring technique for glass/ceramic substrates used for assembly of hermetically packaged electronic devices

- Developed Ultra Dry Cerdip

- Developed a chip resistant, low -emission alumina substrate.



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R&D Institute of Abrasive Materials Senior R&D Engineer Leningrad, Russia 1977-1980

- Developed special glass film coating to improve adhesion of abrasive media to aluminum substrate and its thermo-mechanical performance

R&D Institute of Fused Quartz Senior R&D Engineer Leningrad, Russia 1971-1977

- Developed the CVD, PVD and HTHD processes for the SiO2 glass film doped with TiO2, and rare earth element oxides to modify spectrum characteristics and strengthen optical substrates for use in construction of spacecraft portholes.

- Developed super strong bulb as a high intensive source of light to provide energy to a solid-state laser by using a layer of glass film coating on silica glass surface.

EducationM.S. Ceramic Engineering, St. Petersburg Chemical University, Russia. Graduated with Honors

Completed all courses required for PhD in Ceramic Engineering, Leningrad

LanguagesEnglish, Russian

Relevant publicationsFive issued patents in the field of low temperature glass materials for microelectronic devices and glass film development to improve the thermo-mechanical and spectral characteristics of fused quartz.

1. Sealing glass compositionsLeo Finkelstein, Maurice E. Dumesnil, Richard R. TetschlagUS Pat. 5,013,360 - Issued 7 May 1991 - VLSI Packaging Materials, Inc.

2. Low melting glass composition Maurice E. Dumesnil, Leo FinkelsteinUS Pat. 4,743,302 - Issued 10 May 1988 - VLSI Packaging Materials, Inc.

3. Silver phosphate glass die-attach composition Maurice E. Dumesnil, Leo FinkelsteinUS Pat. 4,997,718 - Issued 5 Mar 1991 - VLSI Packaging Materials, Inc.

4. Low temperature sealing glass compositions Maurice E. Dumesnil, Leo FinkelsteinUS Pat. 5,188,990 - Issued 23 Feb 1993 - VLSI Packaging Materials, Inc.

5. Low temperature sealing glass composition Maurice E. Dumesnil, Leo FinkelsteinUS Pat. 5,281,561 - Issued 25 Jan 1994



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Michael W. McDowell (Pratt & Whitney Rocketdyne)Program Manager, CSP Advanced Technology Program

Professional ExperienceMr. McDowell has 35 years of comprehensive experience with high temperature fluid systems including:

modeling and analysis; design of test systems; and leading thermo-hydraulic designs for large and medium sized centrifugal and

electromagnetic pumps.

He has also overseen numerous system tests and high temperature fluid technology programs. These tests and programs required his oversight for; the design and construction of facility modifications, pump assembly, test operations, test reporting, and technical assistance to customers for resolution of test anomalies. While Chief Engineer of the Energy Technology Engineering Center (ETEC), McDowell was the program manager for the large Annular Linear Induction Pump (ALIP) sodium pump at the ETEC Sodium Pump Test Facility, which successfully concluded in 2001. He has been involved with the investigation and resolution of related electromagnetic pump operating problems; leading thermo-hydraulic designs for a large sodium centrifugal pumps’ test system and a smaller sodium test loop for testing a Flat Linear Induction Pump (FLIP). Currently, he is a program manager in Energy Systems for a variety of high temperature fluid applications, including solar power tower systems and component development.

Education M.S. in Nuclear Engineering, University of Illinois, 1975

B.S. in Mechanical Engineering, Stanford University, 1974



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Scott WhitingInnovative Mechanical Engineer with 15 years industry experience focused on delivering exceptional results in a highly competitive environment. Diverse background includes design of high throughput automation for technology companies, semi-conductor test and measurement instruments, water purification equipment and desalination plant systems, and development of automated high-pressure, high-temperature reactor platforms used for parallel synthesis and polymerization studies. Areas of expertise in:

Mechanical design – plant and factory systems to precision electro-mechanical instrumentation

Electrical – motion control, AC/DC power distribution, serial and network communication, heater controllers, analog/digital signal conversion

Project management – coordinated engineering projects in foreign and domestic environments

Analytical skills – problem resolution through fully- developed solutions addressing root-cause issues

Materials – extensive research of polymers and metal alloys to address complex mechanical requirements and project specifications

Machining and fabrication – extensive experience with mills, lathes, CNC, welding, forming, cutting

EDUCATIONUniversity of California, Berkeley Berkeley, California

B.S., Mechanical Engineering, mechanical design, MEMS, and composite materials emphasis. 2001

ITT Technical Institute Portland, Oregon

B.A.S., Automated Manufacturing Technology, highest honors, perfect attendance award. 1995

A.A.S., Electronics Engineering Technology, graduated with honors and awards. 1994

PROFESSIONAL EXPERIENCEHalotechnics, Inc. Emeryville, CA Director of Engineering 2011

Direct the growth and task load of the core engineering team responsible for developing prototype thermal energy storage systems.

Develop critical components and test fixtures necessary to validate scalable thermal energy storage concepts. Critical components include: internally insulated storage tank, piping, furnace, heat exchanger, high-temperature pump, and associated control devices.

Freeslate (formerly Symyx), Santa Clara, CA Senior Mechanical Engineer 2010-2011Engineering Lead on production design projects involving multi-channel reactor workflows. Accountable for all design aspects including:



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Mechanical – create and document all mechanical parts and assemblies including: electronics packaging, pneumatic actuation, fluid & gas control, pressure control, and safety devices.

Power distribution - utilize 5-wire 3-phase AC voltage for use as various single-phase AC single voltage levels while balancing phase loads and supporting DC voltage requirements.

Machine communication - design all internal and external machine serial communication architecture including: RS-232, RS-485, CANopen, UART, and Ethernet.

Pressure vessel design optimization – use FEA and performance testing to achieve a balanced design between pressure and temperature requirements, thermal mass, as well as special features such as magnetically coupled in situ stirring and sample injection and aspiration.

Machine control – stepper and servo motion controllers, encoders, and non-contact position sensors.

Heater control – custom multi-channel heater and over-temp controller utilizing TC and RTD inputs.

Symyx Technologies, Santa Clara, CA Senior Mechanical Engineer, Project Manager 2005-2010

Developed R&D proof-of-concept (POC) workflows for use in high throughput material research and combinatorial chemistry automation tools.

Designed automatic loading and substrate masking mechanism for use within a vacuum chamber to rapidly prepare libraries of transparent conductive oxides on glass substrates.

Created POC automated microcavity battery preparation workflow featuring precision robotic powder handling, weighing, packing, electrode build-up, and parallel electrical testing for up to 96 cells.

Royce Instruments, Napa, CA Senior Mechanical Engineer, Project Manager 2004-2005

Designed and developed automated laser diode manufacturing equipment and high-precision force measurement instruments for testing strength of bonded wire, die, and solder balls.

Managed project to develop a new universal force measurement machine for use in the semiconductor industry.

Manage project task assignments associated with all engineering groups and marketing.

Create and maintain project schedules and cost estimates. Report progress to CEO.

Responsible for design of precision electro-mechanical positioning and force sensing systems.

Designed complete line of five precision force measurement modules. Design achievements include capability of testing samples as small as 15 microns, repeatable mechanical positioning to 0.1 micron, force measurement resolution to 1 part per 10000, and load capacity up to 200 kg.

Designed machine enclosures incorporating advanced sheet-metal, aluminum casting, and plastic forming techniques.



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Provided mechanical engineering and integration expertise to successfully develop pick and place machine capable of stacking and placing die as small as 200 microns square. Featured 15 servo drive axes, three inspection cameras, and three machine control vision cameras.

Aquafects, Campbell, CA Company Founder 2003-2005 Founded California-based manufacturing company specializing in designing

innovative residential water purification systems.

Severn Trent Services, Torrance, CA Mechanical Engineer 2001-2003 Managed redesign of existing product line of turn-key automated bottling

equipment, emphasizing DFM and value-engineering techniques resulting in a typical manufacturing cost reduction of 20%. Designed and directed fabrication of prototype automated production and test systems.

Developed municipal-scale reverse osmosis filtration and water treatment systems.

Hewlett Packard, Vancouver, WA Design Engineer, Contract Manufacturing 1995-1998 Designed and implemented PLC-based control systems for automated Inkjet

printer manufacturing. Systems operated over ten-month period with zero downtime during production shifts.

Oversaw implementation of two high-volume production lines in both California and Mexico.

Improved $20M manufacturing process by focusing on the redesign and improvement of new automation that failed to meet factory capacities. Followed project through manufacturing release. Designed and improved fixtures and tooling - machined new parts to specification.

Optimized equipment to meet cycle time requirements - average cycle time decrease of 16.3%. Worked with process control software including: Eclipse, Adept Motionware, Visionware.

Porter Yett Co., Portland, OR

Diesel & Hydraulics Mechanic, Tool Fabricator 1992-1995

PATENTS AND PUBLICATIONS“Understanding the Complexities of Solder Ball Pull Testing on BGAs,” March 2005, Advanced Packaging Magazine.

“Apparatus and Method for Actuating a Syringe,” US Patent Application Number 2009/0004,063



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Grady Hannah

Professional Profile:Grady has been in cutting edge Sales and Business Development for 12 years. Getting his start in the Linux and Open Source software market, Grady made the switch to the video games market 6 years ago. Grady has held positions at top video game middleware startups including Intrinsic Graphics, AGEIA, and Replay Solutions, where his sales led directly to a $10M B Round of investment.

Currently at Halotechnics, the world leader in CSP thermal storage, Grady is in charge of WW Business Development for Halotechnics Saltstream products. With the Halotechnics team, Grady has brought Saltstream to project developers worldwide, and is helping to commercialize the Saltstream products.

Work experience:Director of Business Development, Halotechnics, Inc. Emeryville, CA 3/10 – present

Manage worldwide business activities for Halotechnics Saltstream business. Maintain contact and business discussions with worldwide CSP solar providers and EPC contractors. Price and bid Saltstream for deals and provide strategic advice to CEO.

Responsible for defining and executing Halotechnics mid-term marketing and sales initiatives for Saltstream 500 and Saltstream 700 products. Responsible for securing lighthouse accounts for Saltstream products, and building revenue and account plans.

Participate in investment discussions, advise CEO on how to best bring Halotechnics products to market. Product Manage, and engage partners to move forward with joint research.

Director of Business Development, Darkworks S.A. Paris, France – 1/09 – 1/11

Responsible for bringing TriOviz Stereoscopic 3D product to console video games.

Priced the product, defined feature set, and submitted budgets for sales and marketing activities. Advised the CEO and President on approaching the North American market. Sold TriOviz into top console games publishers and demonstrated to no less than 25. Brought forward lighthouse accounts and drove all sales activities. Revenue projection over 12 months of $1.8M.

Account Executive, Replay Solutions Mountain View, CA 12/06 – 12/08

Marketed and sold Replay QA playback solution for console games into top worldwide publishers: EA, MSFT, 2K Games, and Eidos among others. I set the price of the product, lead all sales in the gaming industry, and closed or partnered to close every deal the company made from the time I arrived. Signed worldwide deal with EA and brought forward Intel among other top partners.



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These sales activities lead to a $10M B round of financing for Replay.

Account Manager, AGEIA, Inc. 10/04 to 10/06

Responsible for SDK licensing and content acquisition in support of the AGEIA PhysX processor. Responsible for all North American activities, including licensing relationships with EA, Epic Games, Gearbox Software, 2K Games, and more.

Education:Macalester College, Saint Paul, MN – Bachelor of Arts, 1997



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Dr. David F. Padowitz

EDUCATIONPh.D. PHYSICAL CHEMISTRY, THE UNIVERSITY OF CHICAGO, December 1989.

Thesis: "Molecular beam and laser studies of the dynamics of gas-surface interactions." Advisor: Steven J. Sibener

B.S. CHEMISTRY, MICHIGAN STATE UNIVERSITY, East Lansing MI, June 1979.

Additional work in control systems theory and chemical engineering process design

PROFESSIONAL EXPERIENCEDIRECTOR OF DEVICE ENGINEERING, PRECURSOR ENERGETICS, 2010 - present

Responsible for research, production, and analysis of solar cells made with a new chemistry for printable electronic materials.

SENIOR STAFF SCIENTIST, SYMYX TECHNOLOGIES, 2001 - 2010

Member of R&D and Systems Engineering Staff. Designed and developed tools and workflows for high-throughput materials discovery.

Planned and executed research collaborations with partners in the energy, chemical, consumer, and life sciences industries.

Discovery and testing of high-temperature heat transfer materials for concentrating solar power in a DOE funded program.

Assessed technologies and markets for utility-scale electrical energy storage for a prominent VC firm.

Designed and managed transparent conductive oxide project for a major international partner.

Led a joint team transferring technology from NREL during incubation of a dominant start-up.

Project Lead on an $8M catalyst testing reactor for a leading energy company. Business development in electronic materials and clean tech

ASSISTANT PROFESSOR OF CHEMISTRY, AMHERST COLLEGE, 1994 - 2001

Research: Materials Science with expertise in Scanning Probe Microscopy (STM and AFM).

Teaching: General and Physical Chemistry, Themodynamics, Quantum Mechanics and Spectroscopy.

HONORARY FELLOW, UNIVERSITY OF WISCONSIN - MADISON, 1997-1998

VISITING ASSISTANT PROFESSOR, UNIVERSITY OF MIAMI, 1993-1994

Created graduate course in Instrumental Analysis



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RESEARCH ASSOCIATE, U. C. BERKELEY AND LAWRENCE BERKELEY NATIONAL LABORATORY, 1989-93.

Ultra-fast laser probes of electron dynamics with Charles B. Harris

ANALYTICAL CHEMIST, ENVIRONMENTAL CONTROL TECHNOLOGY INC., Ann Arbor, MI, 1981-82.

REGIONAL SERVICE MANAGER, PLAYBACK INC., Lansing, MI, 1979-81.

PUBLICATIONS in peer-reviewed journals (broad field - chemical physics of surfaces and interfaces):

1. "Molecular Tracer Dynamics in Crystalline Organic Films at the Solid-Liquid Interface." D. F. Padowitz, D. M. Sada, E. L. Kemer, M. L. Dougan, and W. A. Xue, J. Phys. Chem. B 106, 593-598 (2002).

2. "STM Observations of Exchange Dynamics at the Solid-Liquid Interface Using a Molecular Tracer." D. F. Padowitz and B. W. Messmore, J. Phys. Chem. B 104, 9943 (2000).

3. “Cycloaddition Chemistry of Organic Molecules with Semiconductor Surfaces” R. J. Hamers, S. K. Coulter, M. D. Ellison, J. S. Hovis, D. F. Padowitz, M. P. Schwartz , C. M. Greenlief, and J. N. Russell, Jr., Acc. Chem. Rsh. 33, 617 (2000).

4. "Two-Dimensional Localization of Electrons at Interfaces” R. L. Lingle, Jr., D. F. Padowitz, R. E. Jordan, J. D. McNeill, and C. B. Harris, Phys. Rev. Lett., 72, 2243 (1994).

5. "Two-Photon Photoemission as a Probe of Electron Interactions with Atomically Thin Dielectric Films on Metal Surfaces” D. F. Padowitz, W. R. Merry, R. E. Jordan, and C. B. Harris, Phys. Rev. Lett. 69, 3583 (1992).

6. "New Modulated Molecular Beam Scattering Methods for Probing Nonlinear and Coverage Dependent Reaction Kinetics at Surfaces” D. F. Padowitz, K. Peterlinz, and S. J. Sibener, Langmuir 7, 2566 (1991).

BOOK CHAPTERS AND CONFERENCE PROCEEDINGS:1. "Methods of Tunneling Spectroscopy with the STM” R. J. Hamers and D. F.

Padowitz, in Scanning Tunneling Microscopy: Theory, Techniques, and Applications, 2nd ed., Dawn A. Bonnell, editor (Wiley-VCH, New York, 2001).

2. "Two-Photon Photoemission and the Dynamics of Electrons at Interfaces" D. F. Padowitz, C. B. Harris, R. E. Jordan, R. L. Lingle, Jr., J. D. McNeill, and W. R. Merry, SPIE Proceedings, Vol. 2125, Laser Techniques for Surface Science, (January 1994).



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3. "Localization of Electrons at Interfaces” R. L. Lingle, Jr., D. F. Padowitz, R. E. Jordan, J. D. McNeill, and C.B. Harris, in Reaction Dynamics in Clusters and Condensed Phases, J. Jortner and B. Pullman, eds. (Kluwer Academic Publishers, Dordrecht, The Netherlands, 1994).

PATENTS AND PUBLISHED PATENT APPLICATIONS1. US 7603889 System for Monitoring and Controlling Unit Operations

2. US 7254990 Machine Fluid Sensor

3. US 7210332 Mechanical Resonator

4. US 7043969 Machine Fluid Sensor and Method

5. WO 2004/086027 A2 Mechanical Resonator

6. EP 1644717 Mechanical Resonator

FUNDING AND AWARDSMax and Etta Lazerowitz Lectureship, Amherst College, 1999-2000.

Petroleum Research Foundation Type GB Grant 1997-2001.

Research Corporation Cottrell College Science Award 1997-2000.

Xerox Corporation-James Franck Institute Fellowship, University of Chicago, 1985.

PROFESSIONAL ASSOCIATIONSAmerican Chemical Society

American Physical Society

Materials Research Society



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Dr. Robert W. BradshawI was a Principal Member of the Technical Staff (Chemical Engineering) at Sandia National Laboratories in Livermore, CA until retiring in 2010. My technical work has involved a broad range of areas related to high temperature materials and chemistry and corrosion of metals (both high temperature and aqueous environments). I have conducted studies of gaseous reactions of bromine to produce hydrobromic acid at elevated temperatures and the equilibrium behavior of the Iodine-HI-H2O system. I have developed modified Fe-Cr-Mo steel compositions that demonstrated superior corrosion resistance in molten salt environments compared to the standard alloy. I developed high-temperature alloys for coal gasification applications and conducted experimental evaluations of their sulfidation resistance in laboratory tests at high pressure and temperature to simulate coal gasification environments.

My other recent R&D work involved materials and process chemistry issues related to chemical munitions disposal and a novel freeze desalination method that was awarded a patent. I have conducted experimental studies the oxidation reactivity of hydrides for hydrogen storage media and evaluated novel bench-scale reactors for reforming hydrocarbons. I have conducted materials compatibility studies in a variety of environments related to Sandia’s defense projects and

My molten salt research has spanned several decades at Sandia beginning with the initial development of solar central receiver technology in the 1980's. I was generally responsible for establishing Sandia’s molten salt research program which supported the Laboratory’s development of advanced concentrating solar power (CSP) technology. I developed innovative methods to expand the working temperature range of molten nitrate salts for the primary solar thermal energy collection systems (towers and troughs) and thermal energy storage. These approaches enabled reducing the freezing point of molten salts (simplifying system operation) or increasing the maximum operating temperature (raising system efficiency). Two patents were awarded for these low-freezing molten salt formulations. I determined experimentally the chemical stability limits (equilibrium chemistry properties) of various molten salt mixtures and measured their physical properties, viscosity and density. I designed corrosion experiments to evaluate the compatibility of engineering alloys and other materials under conditions that prevail in CSP systems and conducted the metallurgical evaluation of the alloys. These studies qualified materials that were subsequently used to construct CSP demonstration systems and operating plants. I developed and demonstrated a technique to reduce the cost of phase-change thermal energy storage.

EducationPh.D. Chemical Engineering, Stanford University, 1976.

M.S. Chemical Engineering, Rutgers University, 1968.

B.S. Chemical Engineering, Rutgers University, 1967.



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Professional ExperienceSandia National Laboratories, Materials Chemistry Department, Livermore, CA

Principle Member of the Technical Staff, 1975 – 2010; (retired Dec. 2010)

Electronic Associates, Inc., Princeton, NJ

Applications Engineer, Hybrid Computing and Process Simulation, 1968-1969

Selected PublicationsA list of publications (those publicly accessible) is available upon request.

Publications specifically related to proposed project:

1. R. W. Bradshaw and N. P. Siegel, Development of Molten Nitrate Salt Mixtures for Concentrating Solar Power Systems, Proceedings SolarPACES 2009, Berlin, Germany, Sept. 15-18, 2009.

2. R. W. Bradshaw and D. A. Brosseau, Improved Molten Salt Formulations for Heat Transfer Fluids in Parabolic Trough Solar Power Systems, Proceedings SolarPACES 2008, Las Vegas, NV, Mar. 4-7, 2008.

3. R. W. Bradshaw and S. H. Goods, Corrosion of Alloys and Metals by Molten Nitrates, Invited book chapter, High Temperature Corrosion in Molten Salts, C. A. C. Sequiera, Editor, Trans Tech Publications, Zurich, Switzerland, ISBN 0-87849-917-2, 2003.

4. B. P. Somerday, K. T. Wiggans and R. W. Bradshaw, Environment-assisted failure of alloy C-276 burst disks in a batch supercritical water oxidation reactor, Engineering Failure Analysis, 13, 80-95 (2006).

5. D. E. Dedrick, R. Behrens, R. W. Bradshaw, and W. M. Clift, Material Safety Studies at Sandia National Laboratories, IEA Task 17 Workshop: Safety Session, Manchester, UK, May 2, 2006.

6. B. P. Somerday, R. W. Bradshaw and K. T. Wiggans, Stress Corrosion Cracking of Ni-Based Alloys in Batch Supercritical Water Oxidation Environments, Proceedings CORROSION 2004 (NACE), paper #04564 , New Orleans, Mar. 2004.

7. S. H. Goods and R. W. Bradshaw, Corrosion of Stainless and Carbon Steels in Molten Mixtures of Industrial Nitrates, J. Mater. Engg. Performance, 13 (1), 78 (2004).

8. R. W. Bradshaw and A. S. Nagelberg, Chemical Characterization of Complex Oxide Products on Titanium-Enriched 310SS, Journal of the Electrochemical Society, V 128 , N12 , P 2655, 1981.

9. R. W. Bradshaw and A. S. Nagelberg, Influence of Titanium Alloying Additions on Chromium-Oxide Scales Formed in Coal-Gasification Atmospheres, Journal of the Electrochemical Society, V 126 , N8 , P C331, 1979.



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Publications demonstrating capabilities in the broad field:

1. R. W. Bradshaw and R. S. Larson, Formation of Hydrogen Bromide from Methane and Bromine at Elevated Temperature, Proceedings of the National Hydrogen Assoc. 14th Annual Meeting, Washington, DC, Mar. 3-6, 2003.

2. R. W. Bradshaw, R. S. Larson, A. E. Lutz, Vapor-Liquid Phase Behavior of the Iodine-Sulfur Water-Splitting Process, Sandia National Labs, SAND2004-8014, Jan. 2004.

3. R. W. Bradshaw, B. A. Simmons, E. H. Majzoub , W. M. Clift and D. E. Dedrick, Clathrate Hydrates for Production of Potable Water (Invited Presentation), MRS Spring Meeting, Materials Science for Water Purification, Session JJ, April 18, 2006, San Francisco, CA.

4. T. Weiss, J. Didlake, T. Shepodd and R. Bradshaw, Processing of Lewisite in the Explosive Destruction System, 8th International Chemical Weapons Demilitarisation Conference, Edinburgh, Scotland, UK, April 12-14, 2005.

5. A.E. Lutz, R. W. Bradshaw, L. Bromberg, A. Rabinovich, Thermodynamic Analysis of Hydrogen Production by Partial Oxidation Reforming, International Journal of Hydrogen Energy, 29 (8), p.809-16 (2004).

6. A. E. Lutz, R. W. Bradshaw, J. O. Keller and D. Witmer, Thermodynamic Analysis of Hydrogen Production by Steam Reforming , Intl. J. Hydrogen Energy, 28, 159 (2003).



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Dr. Adam P. BrucknerProfessor, Department of Aeronautics and AstronauticsUniversity of Washington, Seattle, WA

EducationPh.D.: Princeton University, 1972 M.A.: Princeton University, 1968B.Engr.: McGill University, 1966

Positions HeldProfessor: Sept. 1991-presentDepartment Chair: July 1998-June 2010Research Professor: July 1988 - Sept. 1991Research Associate Professor: July 1978 – July 1988Research Assistant Professor: July 1975 – July 1978Research Associate: June 1972 – July 1975

Honors and AwardsFellow, American Institute of Aeronautics and Astronautics (AIAA), 1997Certificate of Appreciation, Universities Space Research Association (USRA), 1994Professor of the Year, AA Dept. (Co-recipient) 1994AIAA Certificate of Recognition, 1992; Certificate Appreciation, 1991AIAA Associate Fellow, 1989

Peer-Reviewed Publications Specifically Related to the Proposed RD&D Project1. Bruckner, A.P., Trueblood, B., and Pressentin, R., “Multimegawatt Nuclear Power

System for Lunar Base Applications,” in Space Nuclear Power Systems 1987, El-Genk, M.S. and Hoover, M.D., eds., Orbit Book Co., Malabar, FL, pp. 565-74, 1988.

2. Bruckner, A.P., Hedges, D.E., and Yungster, S., “Liquid Droplet Heat Exchanger Studies,” in Space Nuclear Power Systems 1986, El-Genk, M.S. and Hoover, M.D., eds., Orbit Book Co., Malabar, FL, pp. 151-59, 1987.

3. Bruckner, A.P., and Shariatmadar, A., “Heat Transfer and Flow Studies of the Liquid Droplet Heat Exchanger,” Space Nuclear Power Systems 1985, El-Genk, M.S. and Hoover, M.D., eds., Orbit Book Co., Malabar, FL, pp. 119-29, 1986.

4. Bruckner, A.P., “Continuous Duty Solar Coal Gasification Using Molten Slag and Direct-Contact Heat Exchange,” Solar Energy 34:239 (1985).

5. Bruckner, A.P., and Mattick, A.T., “High Effectiveness Liquid Droplet/Gas Heat Exchanger for Space Power Applications,” Acta Astronautica 11:519 (1984).

Peer-Reviewed Publications Demonstrating Capabilities in the Broad Field 1. Bruckner, A.P., and Knowlen, C., “Ram Accelerator,” in Encyclopedia of Aerospace

Engineering, Blockey, R., and Shyy, W. (eds.), John Wiley & Sons Ltd, Chichester,



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UK, pp. 1063-1074, 2011. (Invited)

2. Bauer, P., Knowlen, C., and Bruckner, A.P., “Modeling Acceleration Effects on Ram Accelerator Thrust at High Pressure,” J. Propulsion and Power, 21: 955-957, 2005.

3. Bundy, C., Knowlen, C., and Bruckner, A.P., “Unsteady Effects on Ram Accelerator Operation at Elevated Fill Pressures,” J. Propulsion and Power 20: 801-810, 2004.

4. Schultz, E., Knowlen, C., and Bruckner, A.P., “Starting Envelope of the Ram Accelerator,” J. Prop. and Power, 16:1040-1052, 2000.

5. Schultz, E., Knowlen, C. and Bruckner, A.P., “Obturator and Detonation Experiments in the Subdetonative Ram Accelerator,” Shock Waves, 9:181-191, 1999.

6. Higgins A.J., Knowlen, C., and Bruckner, A.P., “Ram Accelerator Operating Limits, Part 1: Identification of Limits,”J. Propulsion and Power, 14:951-958, 1998; Part 2: Nature of Observed Limits,” J. Propulsion and Power, 14:959-966, 1998.

7. Bruckner, A.P., “The Ram Accelerator: Overview and State of the Art,” in Ram Accelerator, Takayama, K., and Sasoh, A., eds., Springer-Verlag, Berlin, 1998, pp. 3-23.

8. Coons, S., Williams, J., and Bruckner, A.P., “Design of a Water Vapor Adsorption Reactor for Martian In Situ Resource Utilization,” J. British Interplanetary Soc., 48: 347, 1995. (Invited).

9. Jardin, M., and Bruckner, A.P., “A Fedback Controlled Gas Mixing System for the Ram Accelerator,” J. Propulsion and Power 11: 1291, 1995.

10.Hertzberg, A., Bruckner, A.P., and Bogdanoff, D.W., “Ram Accelerator: A New Chemical Method for Accelerating Projectiles to Ultrahigh Velocities,” AIAA J. 26:195 (1988).

Non-Peer Reviewed Publications and Patents Demonstrating Capabilities in the Broad Field1. Knowlen, C., Higgins, A.J., Harris, P., and Bruckner, A.P., “Hypersonic Shock-

Induced Combustion Propulsion,” Paper AIAA-2009-0715, 47th Aerospace Sciences Meeting and Exhibit, Orlando, FL, Jan. 5-8, 2009.

2. Schneider, M.A., and Bruckner, A.P., “Extraction of Water from the Martian Atmosphere,” Space Technology & Applications International Forum – STAIF-2003, M.S. El-Genk, ed., Am. Inst. Phys. Conf. Proc. Vol. 654, pp. 1124-1132, Feb 2003.

3. Bruckner, A.P., and Hertzberg, A., “Direct Contact Droplet Heat Exchangers for Thermal Management in Space,” Proc. 17th Intersociety Energy Conversion Engineering Conf., pp. 107-12, Los Angeles, CA, Aug. 8-13, 1982.

4. Bruckner, A.P., and Hertzberg, A., “A New Method for High Temperature Solar Thermal Energy Conversion and Storage,” Proc. Annual Meeting of Solar Thermal Test Facilities Users Association, STTFUA/81-13, Pasadena, CA, April 21-24, 1981, pp. 186-97.

5. Shaw, D.J., Hertzberg, A., and Bruckner, A.P., “A New Method of Efficient Heat Transfer and Storage at Very High Temperatures,” Proc. 15th Intersociety Energy Conversion Engineering Conf., pp. 125-32, Seattle, WA, Aug. 18-22, 1980.



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Patents1. U.S. Patent No. 5,927,653, “Two-Stage Reusable Earth-to-Orbit Aerospace Vehicle

and Transport System,” Mueller, , G.E., Kistler, W.P., Johnson, T.G., Pohl, H.O., McLain, C., Hill, A.S., Andrews, J.E., Taylor, T.C., Cohen, A., Myers, D., Bruckner, A.P., Knowles, S.C., and Warwick, R., July 27, 1999.

2. U.S. Patent No. 5,097,743, “A Method and Apparatus for Zero-Velocity Start of Ram Accelerator Projectiles,” Hertzberg, A., Bruckner, A.P., Knowlen, C., and McFall, K., March 24, 1992.

3. U.S. Patent No. 4,982,647, “A Method and Apparatus for Initiating the Stable Operation of a Ram Accelerator,” Hertzberg, A., Bruckner, A.P., Bogdanoff, D.W., and Knowlen, C., January 8, 1991.

4. U.S. Patent No. 4,938,112, “Apparatus and Method for the Acceleration of Projectiles to Hypervelocities,” Hertzberg, A., Bruckner, A.P., and Bogdanoff, D.W., July 3, 1990.

5. U.S. Patent No. 4,727,930, “Heat Transfer and Storage System,” Bruckner, A.P., Hertzberg, A., and Shaw, D.J., March 1, 1988.

Selected Professional Service Member, Museum of Flight Pathfinder Award Selection Committee, 2008-present

AIAA Space Resources Technical Committee, 2007-2011

Co-Director (founding), Global Integrated Systems Engineering (GISE) Program, University of Washington, 2006-2007

NASA/USRA RASC-AL Program Steering Committee, 2003-2008

Session Co-Chair, “Space Resource Utilization on Mars,” Space Technology and Applications International Forum (STAIF), 2004 -2007

AIAA Space Colonization Technical Committee, 2003-2011

Member, Local Organizing Committee, 18th International Colloquium on Dynamics of Explosions and Reactive Systems (ICDERS), Seattle, WA, July 29-August 3, 2001

AIAA Pacific Northwest Section Council Member, 1998-2000



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Dr. Michael Tenhover

Education:Ph.D. Applied Physics 1981 - California Institute of Technology

B.S. in Physics 1977- University of Cincinnati

Employment:Current Position: President of Tenhover Consultants (2003 to present).

Active in Energy, Chemical, Materials, and Petroleum Technologies.

Previous Positions:Chief Technology Officer 5 years with Hosokawa Micron (World leading company for process equipment) Osaka, Japan.

Responsible for 5 Global R&D Centers (staff of 100) focused on the development of new products/processes for the company.

Chief Scientist for Advanced Materials 15 years with Standard Oil/British Petroleum/Carborundum, Niagara Falls Technology Center, NYChief Scientist and Director of the Carborundum Technology Center Carborundum

Headed group of 63 Scientists and Engineers involved with high temperature ceramics: bonded refractories (CarbofraxTM), fused cast refractories (MonofraxTM), high temperature insulation (FiberfraxTM), Silicon Carbide (HexaloyTM), carbon-carbon fiber composites (HITCO), SiC-SiC fiber composites, and Boron Nitride ceramics.

The major customers for these materials were the Glass, Steel, Aerospace, and Automotive markets. Some of the customers included Corning Glass Works, PPG, General Electric, Allied-Signal (Honeywell), DuPont, Audi, BMW, and TRW.

Background/Experience: Materials Processing and Equipment- liquid/solid separation, particle technology,

thin film deposition, coating technology, powder classification and agglomeration, glass containment technology, high temperature insulation and corrosion.

Solar Photovoltaic, Solar Thermal, Geothermal: technology, scale-up, economics, and manufacturing.

Energy Storage- Double Layer Capacitors, rechargeable batteries, flow batteries, non-oxide ceramics

Oil Exploration and Production technology, Crude Oil refining, Ammoxidation Catalysis, Enhanced Oil Recovery

Mining- precious metals and coal. Extensive Project and Management Experience



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US Patents: 36 issued US Patents

Publications: Over 85 publications in refereed journals.

Books: Four Review Chapters in Technical Books

Presentations: Numerous presentations at conferences and technical organizations

Awards:T. L. Steele Award- undergraduate Award in Physics University of Cincinnati 1975

IBM T. J. Watson Fellowship California Institute of Technology 1980

Carborundum Company Award -Most significant new product of year 1989

BP Inventors Hall of Fame - 25 issued US Patents 1992

President’s Award -Most significant commercialization effort of the year

The Carborundum Company 1993

Relevant Patents:Coated reinforcements for high temperature composites and composites made therefrom, United States Patent 5,273,833

Multi-layer coatings for reinforcements in high temperature composites, United States Patent 5,156,912

Hybrid reinforcements for high temperature composites and composites made therefrom, United States Patent 5,270,112

Silicon based intermetallic coatings for reinforcements, United States Patent 5,114,785



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Dr. David Kearney President, Kearney & Associates

Dr. Kearney is President and principal member of Kearney & Associates, specializing in trough technology and electric solar power plant development. Dr. Kearney provides consultation in the commercial development and project implementation of solar thermal systems, largely but not limited to solar electric power plants and R&D projects to advance the technology. His experience spans both US and European activities in the field. K&A is widely regarded as a recognized international expert in trough technology. Dr. Kearney has more than forty years mechanical engineering experience in the fields of thermal and power engineering, with over 25 years specialization in solar and other renewable and energy-efficient thermal energy systems.

In 2005, he was appointed to the Solar Task Force assembled by the Western Governors Association in the western states of the U.S., contributing to the findings on central solar thermal electric power options. In 2006 he was selected to be a Fellow in the American Solar Energy Society. As a member of Luz International Ltd. in the 1980’s and since that time, he has evaluated and projected solar thermal electric plant feasibility, costs and O&M requirements, including requirements for staffing, equipment and structure.

EXPERIENCE

1991 - Present President, Kearney & Associates, Vashon, Washington

Develops or participates in U.S. and international projects, with emphasis on technical evaluations, feasibility studies and other assessments in renewable energy, particularly solar thermal electric technology. Clients include utilities, government agencies, industrial users/manufacturers, EPC and consulting firms.

Selected projects include:

2009-present Leading NREL project on development of guidelines for large commercial solar system acceptance testing for use by stakeholders in solar power plant development.

2010-present Providing support to IFC (part of the World Bank group) on CSP technology issues and evaluations

2007-present Provides support in technology and project development for solar electric parabolic trough plants in the Southwest to leading industry stakeholders, including key technology providers.

2004-present Provides R&D support to thermal storage development and other technology issues for CSP technology under contract to the National Renewable Energy Laboratory, Golden, Colorado.

2006 Evaluated potential solar site on behalf of CFE (the national utility of Mexico) for their upcoming World Bank/GEF project.

2005 Participated in team evaluation for the U.S. State of New Mexico focusing on the feasibility of a 50 MWe solar thermal electric plant with thermal storage.



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2003-2004 Key member of team assessing parabolic trough solar electric plants for municipal utilities in California sponsored by the San Francisco Public Utility Commission and the California Energy Commission.

2001 Participated as expert consultant to Sargent & Lundy LLC in their assessment of trough technology for NREL and the U.S. National Research Council.

1998 Carried out assessment of private power sector interest in participating in a GEF solar thermal electric project in Egypt. Primary purpose of this assessment was to determine the level of interest of the private sector in developing a solar thermal project in Egypt. The contact group included 11 solar equipment suppliers, 5 construction and/or architect-engineer firms, and 16 power system suppliers or IPP developers

1990s. As a consultant to Pilkington Solar International in the mid-1990’s, K&A was a key member of a EU-sponsored evaluation on a solar thermal electric feasibility evaluations for Spain, the Canary Islands, Morocco and Crete.

1991 Performed solar thermal electric feasibility study for the islands of Hawaii, funded by the State of Hawaii.

1985-1991 Luz International Ltd., Los Angeles, Calif.Vice President-Advanced TechnologyDeveloped and managed U.S. research and development activities of the Luz International Ltd. companies. Provided expertise on SEGS performance, Luz solar technology, costing and SEGS plant systems in support of SEGS development activities, including project marketing, financial closings, and CEC permitting.

1983-1991 Kearney & Associates, Del Mar, CaliforniaPresidentEngineering consulting and project management in energy systems. Special expertise and recognition in parabolic trough solar electric technology. Technical evaluation and design support in recent years to SEGS projects, with special focus on system design and performance, thermal storage and technology design improvements.

1981-1983 Insights West, Inc., Los Angeles, CaliforniaVice PresidentDeveloped and directed technical projects in support of engineering consulting on advanced energy systems. Technical focus on cogeneration, solar technology, thermal energy storage and industrial heat pumps. Served U.S. utilities and architect/engineering firms.

1978-1981 Solar Energy Research Institute (SERI), Golden, CODivision Manager, Solar Thermal, Ocean and WindAdvanced from senior staff position to lead 150-man Division staff in research and development programs in solar thermal, ocean and wind technologies. Technical emphasis and leadership in solar industrial process heat program and parabolic trough solar collector systems.

1970-1978 General Atomic Co., San Diego, CaliforniaBranch ManagerLed two technical branches in Fusion and High Temperature Gas-Cooled Reactor areas. Conducted and directed engineering analyses and methods development in heat



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transfer and fluid mechanics. Led conceptual design team on 300 MWe demonstration fusion power reactor project.

1966-1970 Mechanical Engineering Dept., Stanford UniversityGraduate Student and Research AssistantEarned Ph.D. under Professors Moffat, Kays and London. Theses included heat transfer experiments in highly accelerated turbulent boundary layers with transpiration, and engineering tradeoff study on turbocharged diesel engine aftercooling.

1962-1966 General Electric R&D Center, Schenectady, New YorkThermal EngineerCarried out thermal engineering studies and tests on jet engine components, heat exchangers and other thermal equipment.

1959-1962 United States Navy, USS Orleck (destroyer)Engineering Officer and Lieutenant J.G.Led Engineering Department responsible for main propulsion equipment (steam turbines) and all auxiliary energy and service systems.

EDUCATIONPhD Mechanical Engineering, Stanford University (1970)

MS Mechanical Engineering, Union College (1966)

BS Mechanical Engineering, Univ. of Rochester (1959)

P.E. California (1972) (expired)

PUBLICATIONS/PRESENTATIONS

Over 75 published papers and meeting presentations in fields of energy technology, energy systems and heat transfer. In recent years, papers have focused on design and performance of the solar thermal electric SEGS plants and parabolic trough technology. Details furnished upon request. Several examples are:

1. Book Chapter: Kearney, D., Price, H., "Advances in Parabolic Trough Solar Power Technology," Advances in Solar Energy, V16, 2004, publ. by ASES, Boulder, CO.

2. Lead Author of CSP Section for Report of Western Governors Association Solar Task Force (January 2006)

3. “Recent Advances In Parabolic Trough Solar Power Plant Technology”, D. Kearney and H. Price, J. of Solar Engineering, 2006.

4. D. Kearney , U. Herrmann, P. Nava, B. Kelly, R. Mahoney J. Pacheco, R. Cable, N. Potrovitza, D. Blake, H. Price, “Assessment of a Molten Salt Heat Transfer Fluid in a Parabolic Trough Solar Field”, J. of Solar Energy Engineering, ASME, Vol. 125, No. 2, May 2003, pp 170-176.

5. D. Kearney , B. Kelly, U. Herrmann, R. Cable, J. Pacheco, R. Mahoney, H. Price, D. Blake, P. Nava, and N. Potrovitza, 2004, “Engineering Aspects of a Molten Salt Heat Transfer Fluid in a Trough Solar Field”, Journal Energy, Volume 29, Issues 5-6, Pages 861-870 (April - May 2004).



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Participating Organizations (1 page)The capabilities of the proposed project partners – Halotechnics and Pratt & Whitney Rocketdyne – are complementary and result in a strengthened team. Halotechnics has expertise in materials science, chemistry, and thermal systems engineering. Its strength is in novel discovery and design at a laboratory scale. PWR is a leader in advanced engineering and design for extreme environments in the aerospace and power generation industry. By leveraging each party’s strengths we propose to design a thermal energy storage prototype with maximum commercial relevance. The proposed prototype will be designed with an eye toward scaling to full commercial size, using relevant component designs, alloys, and other materials that are commercially available at a large scale.

About Halotechnics: Founded in 2009 by Dr. Justin Raade as a spin-out from pioneer Symyx Technologies, Halotechnics draws upon a rich heritage in combinatorial chemistry extending back to 1996. The innovation proposed here fits squarely into our company mission: to develop and commercialize advanced thermal energy storage systems enabled by our proprietary materials. Receiving the ARPA-E award would be instrumental in making our vision a reality, since the project’s risk cannot justify venture investment or traditional corporate R&D funds. We must prove that the system works before securing traditional funding to scale it up for commercial deployment.

Halotechnics has a proven track record of early stage product development and is currently commercializing the results of R&D. Our core expertise leverages high throughput materials discovery methods to rapidly develop novel materials. We have developed powerful software tools and experimental apparatus for synthesizing and characterizing materials. Halotechnics has the chemistry and materials science expertise to synthesize and screen thousands of candidate materials for desirable properties and low cost. We have the informatics know-how to design, analyze, and store the data resulting from our materials screening. We have the engineering expertise to take the hits from our materials screening and build them into advanced thermal energy storage systems, validating their performance under realistic operating conditions at the laboratory scale and larger.

About Pratt & Whitney Rocketdyne (PWR): Located in Canoga Park, PWR is a global engineering leader that designs and produces some of the world's most sophisticated hardware. Our emphasis on high power density energy conversion brings knowledge of extreme operating conditions (cryogenic to 3300 °C, vacuum to 9,000 psi), cutting-edge material developments and objective application of engineering and scientific methods. We have five decades of rocket engine experience covering safety, conduits, mixing, combustion, pumping, and storage in liquid and gaseous states. We use a multi-disciplined, systems approach to assure a comprehensive result.

PWR has unique abilities and experience that make it qualified for the alternative energy industry and in particular the solar energy industry. PWR has the infrastructure and resources consisting of processes and personnel to develop and advance energy technologies. In addition, PWR’s experience with liquid metals and molten salts from its heritage nuclear programs at Atomics International and the Energy Technology Engineering Center (ETEC) is invaluable in understanding materials compatibility.



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PWR has been involved in solar power programs since the 1980s. PWR has experience in molten salt receiver systems stemming back to the Solar Two pilot plant project in the 1990s, which was an extension of the work done before on the Solar One project. PWR has extensive experience in many technologies relevant to CSP systems including solar power tower designs and technologies extensible to thermal storage systems adapted for solar trough plants.

Prior Collaboration (1 page)

None.



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Management Plan (1 page)Roles of Project Team Members: Halotechnics will lead the development of the advanced molten glass and the critical components of the thermal energy storage system (pumps, tanks, and heat exchanger design). PWR will be responsible for surveying feasible alloys and joining techniques that may be compatible with the molten glass. PWR’s contribution will be embodied in the Materials Survey Report deliverable (Phase 1). PWR will also provide input during review meetings of corrosion testing data (Phase 2).

The main objectives of the procedures presented in this section are:

To establish clear organizational structure and working procedures, which will ensure smooth flow of the work and seamless interfaces between PWR and Halotechnics.

To allow effective control of the work process and to supply measures that will assure the required quality.

To ensure that the work will be documented, distributed and filed properly, during and as well as at the end of the development project.

To allow remedial actions to be performed professionally and swiftly.

Meetings: Internal meetings will be held within each company as required or directed by the project manager. Regular teleconferences will be scheduled between Halotechnics and PWR as necessary in order to stay on schedule and meet milestones. Face to face meetings will take place periodically; transportation is readily available between Halotechnics in the San Francisco Bay Area and PWR in southern California.

Any meeting, discussion or telephone conversation which has record value will be recorded and summarized in minutes that will be distributed to meeting participants. It is the responsibility of meetings participants to agree at the start of each meeting on the person assuming the task of summarizing and distributing the meeting notes.

The minutes contents will note, at least, the following items:

Place and date of meeting Meeting participants Meeting aim Issues discussed according the meeting agenda Meeting conclusions Actions to carry out including execution dates and the people in charge of them

Schedules & Follow-up: Halotechnics and PWR will prepare an overall and detailed project schedule identifying critical path, priority activities, target dates for milestones completion and material flow, along with required resources to accomplish the work. The schedule will be reviewed with both companies management and finalized per their inputs. Schedule will be updated periodically according to the actual work performed and actual progress done.

Periodical review meetings with project member management will be scheduled in order to follow up on project progress, pin-point outstanding problems and decide on remedy actions.



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Multi-Investigator Projects (2 pages)Dr. Justin Raade will oversee the program as Principal Investigator.

Michael McDowell will oversee the work performed at PWR as subcontractor.

Each critical component will have a subsystem lead who will be responsible for its development. This structure promotes accountability and ensures that development proceeds on schedule. See the organizational chart below. Scott Whiting will manage the engineering team and will act as thermal system integrator. Leo Finkelstein will manage the scientific team and coordinate the development of the novel glass material.

The following is a brief description of the current business agreements between Halotechnics and each Key Participant, as well as a description of their role in the project.

Dr. Justin W. Raade | full time employeeDr. Raade will oversee the program as Principal Investigator. He has experience in leading multidisciplinary R&D teams and in commercializing the results of high-impact research. His doctoral research, funded by an NSF Graduate Research Fellowship, was focused on energy storage using hybrid systems with fuel cells and lithium polymer batteries.

Leo Finkelstein | part time consultant, prospective full time employee if selected for the proposed award

Mr. Finkelstein has 17 years of experience in developing low melting point glass materials. He is named on multiple patents for such materials for applications in semiconductor packaging. He will lead the development of the advanced glass formulation.

Scott Whiting | part time consultant, prospective full time employee if selected for the proposed awardMr. Whiting has 15 years of experience in chemical reactor design and automation. At Halotechnics he leads the team developing high temperature scientific apparatus for



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characterizing thermal fluids. He has a background in thermal systems engineering and robotics.

Grady Hannah | part time consultantMr. Hannah has 10 years of experience in Silicon Valley technology companies. He sold enterprise Linux solutions and Open Source cluster technology and later transitioned into the video game software market. Later his sales led directly to a $10 million B Round while he was at Replay Solutions. Mr. Hannah leads customer-facing messaging and strategy at Halotechnics and will be involved with Technology Transfer and Outreach.

Dr. David Padowitz | informal advisor, prospective part time consultantDr. Padowitz is an expert in materials science and combinatorial chemistry. He has held senior positions in academia as well as in Silicon Valley advanced materials companies. Dr. Padowitz will develop rapid materials screening protocols and design experiments for candidate glass formulation development and testing.

Dr. Robert Bradshaw | part time consultantDr. Bradshaw is recognized as the leading expert in high temperature fluids chemistry and corrosion. He was Principal Member of Technical Staff at Sandia National Laboratories. Dr. Bradshaw has authored many peer reviewed articles and holds several patents on molten salt science and technology. He oversees work with corrosion and high temperature viscosity of molten salt at Halotechnics.

Dr. Adam Bruckner | informal advisor, prospective part time consultantDr. Bruckner is an inventor on the original patent for the liquid droplet heat exchanger, and has authored many publications on aspects of high temperature fluid heat exchange. He will consult o heat exchanger modeling.

Dr. Michael Tenhover | advisor, prospective part time consultantDr. Tenhover performs analytical research on the economics and operational aspects of a wide array of chemical processes. He has extensive experience in glass technology and the chemicals industry including senior management positions at Hosokawa Micron (CTO) and British Petroleum/Carborundum (Chief Scientist for Advanced Materials). He will lead the modeling and development of the viscosity pump.

Dr. David Kearney | advisor, prospective part time consultantDr. Kearney is widely regarded as an international expert in CSP technology and maintains consulting relationships with many industry leaders. He was VP of Advanced Technology at Luz Intl. where he played a key role in building the Solar Electric Generating System (SEGS). He will be involved with Technology Transfer and Outreach activities.



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Budget Summary (2 pages)Overall budget:

CATEGORY Year 1 Year 2 Year 3 Total Costs

a. Personnel $876,260 $876,260 $0 $1,752,520b. Fringe Benefits $0 $0 $0 $0c. Travel $19,200 $19,200 $0 $38,400d. Equipment $64,967 $64,967 $0 $129,933e. Supplies $272,400 $66,000 $0 $338,400f. Contractual

Sub-recipient $50,000 $50,000 $0 $100,000FFRDC $0 $0 $0 $0Vendor $151,000 $141,000 $0 $292,000

Total Contractual $201,000 $191,000 $0 $392,000g. Construction $0 $0 $0 $0h. Other Direct Costs $94,600 $79,600 $0 $174,200i. Indirect Charges $701,008 $701,008 $0 $1,402,016Total Project Costs $2,229,434 $1,998,034 $0 $4,227,469

Budget by task: The table below breaks down the budget timeline by task. Direct labor costs are shown, numbers to not include contractual, other direct cost, or indirect costs. See the Technical Milestones and Deliverables section for more detail on the tasks and timeline.

Task Cost by task1. Glass screening workflow development $113,7472. Optimize glass material $528,7493. Piping material selection $14,9994. Corrosion testing $56,9185. Tank modeling $25,0026. Tank design and testing $105,0047. Pump modeling $25,0028. Pump design and testing $95,0049. Heat exchanger modeling $25,00210. Heat exchanger design and testing $95,00411. Furnace modeling $29,99912. Furnace testing $39,99813. Full system design and assembly $287,79614. System testing $287,79615. Technology transfer and outreach $22,500

Total personnel costs $1,752,520

Table 4: Budgeted cost by task.

Equipment purchases:



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The table below shows equipment purchases budgeted for the project. The useful life of the equipment will exceed the 24 month proposed project duration. Therefore only applicable depreciation expense will be allocated to the project costs (see Budget Justification for details).

Equipment Cost Description Disposition after projectDifferential scanning calorimeter

$107,300

Discovery DSC by TA Instruments (New Castle, DE). Rapid screening of melting point of glass mixtures.

Retained by Halotechnics. Depreciation expense during project performance.

Glass viscometer $57,600

RSV-1600 by Orton (Westerville, OH). Measures viscosity of full operating range of molten glass.


Tube furnace (1500 °C) $18,000

Blue M tube furnace by Lindberg/MPH (Riverside, MI). To be used as heat input to molten glass.


Table 5: Major equipment purchases.

Manufacturing costs:

The advanced glass developed by this project will be manufactured at large scale using well-established techniques practiced by the modern glass industry. Glass raw materials are first crushed and mixed in the desired proportions, heated in large refractory lined furnaces until a homogeneous mixture is reached, and then formed into the desired shape. Commercial glass furnaces typically produce 400 tons per day or more.

The glass developed by this project will be formed into fine pellets or a powder for distribution to customer’s solar plants. The glass will be melted and loaded into the customer’s storage tanks on site.

We are targeting a cost less than $500/ton for the raw materials and production cost of our advanced molten glass (50% less than currently used molten salts). The earth abundant components are intend to use in our glass are commonly available for $80-$500/ton, produced in quantities of millions of tons worldwide. Glass containers and flat glass with traditional compositions are commonly produced today for costs near $100/ton.

We estimate capital costs for the tank and balance of plant by scaling to 1/8 th in volume (vs. Andasol) but 50% higher unit costs due to more expensive construction materials. This estimate results in $12/kWht, a 10x reduction in costs vs. today’s technology.



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Transition/Commercialization Strategy (2 pages)Halotechnics is developing the most advanced heat transfer fluids in the world for high temperature industrial processes. We have secured government research funds from DOE and NSF and are currently in the process of commercializing the advanced molten salt products resulting from those projects. We believe that the sun is the ultimate energy source. By leveraging government funds for high risk, high reward R&D, followed by private investment directed toward commercialization, we aim to make the biggest commercial impact possible in order to achieve the vision of the SunShot Initiative and reduce the nation’s dependence on imported energy.

As a first mover in the field of molten glass heat transfer and thermal energy storage, Halotechnics stands poised to capture a significant portion of this emerging market. Our strategy is to gain first-mover advantage, build a name for the company by establishing a presence at industry conferences and trade shows, and to get out in front and keep innovating.

Business Model and CustomersHalotechnics is the architect of thermal storage. Our thermal energy storage systems will achieve market-leading low installation cost due to our advanced designs enabled by proprietary storage materials. We are the world expert in molten salt – its chemistry and how it behaves, how to procure it, how to manufacture it, and how to use it in full-scale plants. CSP plants are typically built by EPC (Engineering, Procurement, and Construction) firms. Halotechnics provides Engineering services for the thermal energy storage system to project developers. We do the detailed engineering design of the thermal energy storage system – the pumps, pipes, tank design, materials selection, and preferred suppliers. This is the ‘E’ in EPC.

For the molten salt, our area of expertise, we provide the complete engineering, procurement, construction, and management solution to our customers. We leverage our relationships with salt suppliers to procure the lowest cost components. We understand the chemistry of our proprietary salt products and know how they behave at large scale during long term operation. We coordinate the logistics to deliver the raw material components to the customer’s site. We set up mobile manufacturing facilities to crush, mix, melt, and install our products into the thermal storage tanks of the customer’s plant. And finally we offer complete maintenance, diagnostic, and repair services for the molten salt inventory.

Ours is a capital efficient business model since our main product is the know-how for building a competitive thermal energy storage system. The manufacturing equipment necessary for the installation of the molten salt inventory is readily available and can be set up under tents in temporary facilities at each plant site. The U.S. based plants we design will be built with U.S. labor and will typically source a majority of the components from domestic sources.

We see an opportunity to take a leading position in high temperature thermal energy storage at operating temperatures greater than 565 °C. Halotechnics has invented breakthrough heat transfer fluid enabling operation at 700 °C. The proposed project would allow us to expand our expertise to include molten glass in addition to molten salt, for applications up to 1200 °C. There are currently no commercially available



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components for pumping, storing, and controlling the flow of storage fluids at these temperatures. Receiving the proposed award would provide a jump-start on developing our advanced prototype systems.

The concentrating solar power industry is constrained by the requirements of project finance; every aspect of a $1-2 billion plant must have a 20 year track record of proven performance, or have the guarantee of a company with a big balance sheet willing to back the technology. Halotechnics will form strategic alliances with leading EPC firms in order to achieve bankability with our technology. We will build a pilot scale thermal energy storage system with our partner firm to build confidence in the performance of our products. We will then do the detailed engineering for a full scale commercial plant. We must establish a strong relationship with our EPC partner and they will then provide a guarantee on the performance of our designs. In this manner Halotechnics will provide the ‘E’ and our partner firm will provide the ‘PC.’ We have a goal to achieve bankability (technology capable of securing project finance) with our products by 2013. Potential EPC partners include Bechtel, Fluor, Sener, Abener, and other who are active in CSP project development.

Post Award Activities Leading to CommercializationOur strategy with the proposed project will be to eliminate the science risk associated with our advanced molten glass thermal storage concept. We will obtain data validating the performance of the novel material and thermal storage system by successfully completing the project. At the conclusion of the ARPA-E project we will seek venture funding to build a pilot scale system and develop the full-scale engineering design for deployment at commercial CSP facilities. After proving the technology at pilot scale we will enter the full scale commercial market as a thermal storage system technology provider. We intend to become a reliable partner for CSP project developers seeking to build low-cost, high temperature plants. We will partner with large companies in order to make our technology bankable.

If we are successful in the proposed project for a 1200 °C thermal energy storage system we will seek to scale up the prototype to a pilot scale system built with additional grant funds and private capital. This pilot system will include a molten salt inventory of approximately 1,000 tons and will cost $8-10 million. Halotechnics will seek private investment from venture capital firms or strategic partners in order to leverage any federal funds provided for pilot scale development. We are projecting a total venture investment of $12-15 million in order to build out our sales and business teams, expand our engineering and services capability, and provide for materials and construction costs of pilot scale plants. After securing this investment and successfully completing a pilot project we anticipate that we will have sufficient data and proven performance with our system designs that we will be able to secure an EPC partner and a bankable guarantee for our designs. At this point we anticipate receiving an increasing number of contracts to sell our guaranteed designs to project developers who are building advanced CSP plants with thermal energy storage. We will be cash flow positive and profitable due to our capital efficient business model. Our most likely exit scenario would be acquisition in 5-6 years by a large EPC firm or solar technology firm who wishes to gain exclusive access to our must-have thermal energy storage technology.



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Intellectual Property Strategy (no limit)Halotechnics has filed one provisional patent relevant to the proposed project: “Molten glass for heat transfer and thermal energy storage,” U.S. provisional patent application No. 61/486,046. Additional patent applications will be filed to protect the technology proposed in this document. Expected patents fall in the following general categories:

Composition of matter. These patent claims cover the proportion of each oxide or other constituent in the preferred mixtures; the formula.

Synthesis process. These patent claims will specify the temperature, duration, and other steps and techniques for synthesizing the proprietary glass materials.

Novel use. It may be possible to develop an existing material for a novel use, analogous to a pharmaceutical firm patenting a previously known chemical compound to treat a disease.

Related equipment. We will expand our IP portfolio to include related technology for wetted components in the plant: coatings, pumps, tanks, system design.

As of the date of this submission there has not yet been a memorandum of understanding signed between team members. Intellectual property will prospectively be allocated as follows:

Materials for heat transfer and thermal storage (Halotechnics) Component and system design (Halotechnics) Techniques and apparatus for synthesizing and screening materials

(Halotechnics) Pre-existing IP related to alloys and joining techniques (PWR)

SaltstreamTM Product LineHalotechnics is developing a suite of branded molten salt products for heat transfer and thermal energy storage in applications ranging from 500 °C to 1200 °C.

Saltstream 500 is a mixture of nitrate salts designed for next generation trough CSP plants operating at 500 °C. Previously available molten salt mixtures melt at 140 °C or higher, but Saltstream 500 melts at 65 °C.

Saltstream 565 is a drop-in replacement for central receiver CSP plants operating at 565 °C. It has similar physical properties as previous molten salt materials but 20% lower cost due to our use of earth abundant components.

Saltstream 700 is designed for next generation central receiver CSP plants. It consists of chloride salts stable to 700 °C and has an unprecedented low melting point near 250 °C.

GT 1200 is the prospective trade name for the material to be developed by the proposed project. It is a tailor-made fluid for the requirements of commercially available gas turbine combined cycle power blocks. It is a novel earth abundant material suitable for pumped heat transfer and thermal energy storage applications at extremely high temperatures up to 1200 °C.



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We have patents pending on each of the proprietary materials described above. We intend to use this IP protection to give us a competitive advantage in achieving high performance thermal energy storage systems that cannot be duplicated by any competitor.



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Additionality and Risk (2 pages)We believe our proposed thermal storage system represents a challenging project with significant technical risk. We have constructed a reasonable approach to tackle the design problems step-by-step. And if we are successful in demonstrating our prototype we will make today’s thermal storage technology obsolete. We are driven by the promise of an earth abundant thermal storage material and system that couples directly to high performance gas turbine combined cycle power blocks. The reward of developing such a technology would be electricity from the sun, day and night, at a cost cheaper than fossil fuels.

At the current level of technology readiness, the technology for thermal energy storage at high temperature is too risky for traditional venture capital investment or corporate R&D budgets. ARPA-E provides a crucial role in funding high impact R&D at this stage. Thermal storage at 565 °C is established technology. However thermal storage at 1200 °C represents a significant risk to project developers. There are no commercially available pumps, pipes, storage vessels, or heat transfer fluids that can reach this operating temperature. Even if isolated components were available there has never been a demonstration of a heat transfer and thermal storage system operating anywhere close to this temperature. For this reason solar companies cannot justify their R&D investments to invent this technology from scratch. Leading central receiver developers are looking to 700 °C for their next generation plants. Going to 1200 °C would leapfrog the intermediate temperature entirely.

The proposed technology must overcome significant market risk. Venture capital investors typically do not fund R&D. They fund commercialization. If we are successful in demonstrating at a lab scale a breakthrough fluid with compelling heat transfer properties and dirt cheap cost, as well as the system to pump and store that novel fluid, this is the natural entry point for venture capital. Halotechnics intends to raise venture capital once we have developed the technology and removed the science risk. The analogy venture capitalists like to say goes as follows: “Bring us your magic fluid in a vial. We’ll invest and turn that vial into thousands of tons.” ARPA-E funding would allow us to develop that vial and subsequently begin the process of scaling to full commercial deployment. The proposed market for our technology, concentrating solar power, represents large growth potential but today is still relatively small. Investors will come to the market once scale takes hold and a positive feedback loops occurs – more people, including the public and politicians, seeing CSP plants under construction and operating, delivering the goods of clean reliable electricity.

We believe that the heat transfer fluid and thermal storage system is the key enabling technology that will open up a new field for concentrating solar power and set us on the path toward achieving the SunShot goals by 2020. However, after a successful R&D program focused on thermal storage, additional challenges will remain. The receiver design capable of operating at 1200 °C represents a significant challenge. We will lay the groundwork for this subsequent development effort by working with PWR on material selection and joining technology for pipes compatible with molten glass. However the detailed design and demonstration of such a receiver will require future R&D. The next step after the successful development of a thermal storage system and prototype receiver operating at 1200 °C would be the development of a pilot scale plant



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that integrates these two crucial subsystems. A project such as this would also require the integration of a commercially available gas turbine. Such turbines are available in a wide variety of sizes from 5 MW up to 500 MW, but all are design to burn fuel internally with a combustor. The plant envisioned by this proposal would require a turbine to be modified to accept heat from an external source. By focusing first on thermal storage, then on receiver design, and finally on pilot scale system integration, we believe that the goals of the SunShot Initiative are within reach.

The proposed project will enhance economic security by promoting domestic mining and manufacturing. The raw materials and components we propose to use in our prototype could come primarily from domestic sources and therefore enhance domestic economic productivity. The U.S. glass industry would benefit by an injection of new technology and access to a new growth market – concentrating solar power – with significant social and economic benefits.



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Cost Share Verification (no limit)The cost share source will be primarily Halotechnics funds. Some cost share will be in cash in the form of unrecovered indirect costs, cost share patent costs, and other allowable costs ($840,000). Additional cost share will come from in-kind contributions from consultants working on the project objectives ($83,750). Total cost share is budgeted at 21.9% of total project costs.

See the following tables for details.



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Table 6: Cost share summary from Budget Justification.

Requested Federal Funding Cost Share (3) (4)

$1,752,520 $0 $1,752,520

$0 $0 $0

$38,400 $0 $38,400

$129,933 $0 $129,933

$338,400 $0 $338,400

$338,000 $54,000 $392,000

$0 $0 $0

$144,450 $29,750 $174,200

$2,741,703 $83,750 $0 $0 $2,825,453

$562,016 $840,000 $1,402,016

$3,303,719 $923,750 $0 $0 $4,227,469k. Totals (sum of 6i-6j)

j. Indirect Charges

i. Total Direct Charges (sum of 6a-6h)

Grant Program, Function or ActivityObject Class Categories

h. Other (TT&O)

a. Personnel

b. Fringe Benefits

c. Travel

d. Equipment

6. Total (5)

f. Contractual

g. Construction

Section B - Budget Categories

e. Supplies

Table 7: Cost share summary from SF-424A.



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Other Sources of Funding (no limit)Dr. Justin Raade (PI)

Financial assistance that is currently being received from U.S. Government agency:

Dr. Raade receives financial support from Halotechnics via two current U.S. Government grants, both focused on developing advanced molten salt heat transfer fluids.

Molten salt heat transfer fluids at 500 °C and 565 °Ci. Government entity

U.S. Department of Energy

ii. Title of project

Deep Eutectic Salt Formulations Suitable as Advanced Heat Transfer Fluids

iii. Funding amount

$1.5 million

iv. Beginning and end dates

September 30, 2008 to June 30, 2012

v. Abstract of project

Halotechnics is conducting a high-throughput combinatorial research and development program focusing on deep eutectic salt formulations. Molten salts exhibit many desirable heat transfer qualities within the range of the project objectives but typically have high freezing points. Halotechnics is investigating complex mixtures of inorganic salts to discover deep eutectic or low freezing point formulations suitable as advanced heat transfer fluids. In order to effectively map out the phase space in a reasonable amount of time, Halotechnics is combining the power of high throughput combinatorial discovery tools (for fast materials synthesis and characterization) with an efficient methodology for the design of experiments (to eliminate redundant or infeasible zones of the design space). Approximately 10,000 candidate formulations have been screened to date. The discovery program will focus on experimental methods to acquire data on the behavior of salt formulations and will utilize theoretical modeling techniques where advantageous. The final HTF candidates will be submitted for scale-up field testing at Sandia National Laboratories which will serve to validate their performance under pilot scale CSP plant conditions.

vi. Specific aims

The aim of this project is to develop advanced heat transfer fluids for applications in solar thermal power generation. Halotechnics is targeting two materials under this program. 1) A low melting point nitrate/nitrite based fluid stable to 500 °C. This fluid is



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designed for advanced parabolic trough plants. 2) a low cost nitrate based molten salt stable to 565 °C. This fluid is designed for central receiver power plants.

vii. Federal program manager contact information

Brian HunterU.S. Department of Energy, Golden Field Office1617 Cole Blvd.Golden, CO 80401303.275.4934303.275.4753 [email protected]

Molten salt heat transfer fluids at 700 °Ci. Government entity

National Science Foundation


Advanced Molten Salt Heat Transfer and Thermal Storage Material for Central Receiver Solar Thermal Power Generation

iii. Funding amount

$150,000 (SBIR Phase 1)


January 1, 2011 to June 30, 2011


Intellectual Merit: This Small Business Innovation Research Phase 1 project proposes developing a novel molten salt heat transfer and thermal storage material for central receiver solar thermal power generation. Solar thermal technology developers are pushing to increase the operating temperature of their systems, thereby lowering their levelized cost of electricity and reducing the cost of storage. Known salt mixtures considered for heat transfer fluids have high melting points typically over 300 °C or insufficient thermal stability. Halotechnics will conduct a high throughput materials discovery program to rapidly screen over 2000 unique mixtures of inorganic salts and to discover a novel eutectic mixture with a low melting point of 200 °C and a high maximum temperature of 700 °C. This broad operating range is currently unavailable with any commercially feasible material in the marketplace. Discovering new eutectic mixtures is a combinatorial problem, since the number of possible mixtures increases exponentially with the number of components. We will apply combinatorial chemistry techniques, originally developed for pharmaceutical applications, to a new field: solar thermal materials. Halotechnics will combine the power of high throughput discovery



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tools (for fast materials synthesis and characterization) with an optimized methodology for experiment design (to efficiently constrain the design space).

Broader Impacts: It is imperative that we reduce our usage of fossil fuels (oil, natural gas, and especially coal) to address pressing societal concerns – climate change and environmental degradation, energy security, and price volatility. Solar thermal power, a compelling source of renewable electricity at large scale, represents a possible solution to fossil fuel use. However, electricity from solar thermal power currently costs too much to be directly competitive with fossil fuels. Furthermore, although solar thermal plants have the capability of storing heat in order to produce power after sundown, this represents a significant capital cost to plant developers. In order to achieve large scale deployment and to compete with fossil fuels, there is a crucial need across the solar thermal industry to lower costs and develop viable thermal storage. At the heart of these plants is the heat transfer fluid and thermal storage material. The market for this crucial component is projected to reach $5.5 billion by 2020. The development of the proposed innovation would both reduce the cost of solar thermal power and enable economic thermal storage, bringing the nation significantly closer to eliminating the use of coal. The goal is to enable cheap power from the sun day and night.

vi. Specific aims

The aim of this project is to develop advanced heat transfer fluids for applications in solar thermal power generation. Halotechnics is targeting a molten salt fluid with a melting point at 200 °C and stable to 700 °C. Candidate materials include novel mixtures of chloride, carbonate, and sulfate salts. This fluid is designed for next generation central receiver power plants.


Ben Schrag, PhDNational Science Foundation4201 Wilson BoulevardArlington, VA 22230(703) 292-8323(703) 292-9057 [email protected]

Pending financial assistance from U.S. Government agencies:

Thermal storage system operating at 700 °Ci. Government entity

National Renewable Energy Laboratory, SunShot Incubator


Advanced Thermal Energy Storage System with SaltstreamTM Molten Salt



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iii. Requested funding amount

$1 million

iv. Proposed beginning and end dates

November 1, 2011 to October 31, 2012


Halotechnics proposes to develop a thermal storage system utilizing a high stability, low melting point molten salt as the heat transfer and thermal storage material – SaltstreamTM 700. This advanced molten salt stable to 700 °C represents a potential breakthrough in a high performance thermal storage material for applications in concentrating solar power (CSP). This novel material will enable unprecedented efficiency with thermal energy storage exploiting sensible heat. This project will leverage technology used in the metal heat treating industry, with decades of experience in handling high temperature molten salt. We will develop a two-tank thermal storage system operating at a hot temperature of 700 °C and a cold temperature of 300 °C. The proposed project scope includes the development of the system to pump, heat, and store the novel material. Halotechnics will combine its proven expertise in combinatorial chemistry with advanced engineering designs for handling molten salt. The molten salt thermal storage system has the potential to reduce thermal storage costs by a factor of five once developed and deployed at commercial scale.

Halotechnics has formed a project team with BrightSource Energy, the nation’s leading developer of utility-scale solar power. BrightSource will develop the system architecture of an advanced CSP plant operating at supercritical steam conditions approaching 700 °C. The proposed thermal storage system will be designed to fit directly into the plant envisioned by BrightSource. By leveraging the strengths of each project participant we intend to maximize the commercial impact of this technology and accelerate its deployment at full scale.

vi. Specific aims

We propose to build a miniature CSP plant at a laboratory scale, with each critical component designed with an eye toward scalability to commercial size. This systematic approach will eliminate the greatest amount of risk from critical components of the molten salt thermal storage system. We will use a pipe passing through a tube furnace to simulate the radiant heating environment of salt flowing through the tubes of a receiver. We will design the molten salt pump using a long-shaft design conceptually similar to commercial-size molten salt pumps. We will use relevant alloys for piping and tank construction, not specialty items available only for small scale niche applications. Our 700 °C tank will be internally insulated with ceramic materials available in bulk quantities; once proven at laboratory scale, this tank design will lend itself naturally to scaling up to storing thousands of tons of salt and eliminating the need to use expensive nickel alloy construction. Our 300 °C tank design will be scaled directly from the cold salt tank design used at today’s commercial CSP plants (such as Andasol and Gemasolar).



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vii. PI and contact info

Dr. Justin Raade 5980 Horton St. Suite 450Emeryville, CA 94608(510) 547-2634 office(510) 547-2624 [email protected]

Prior, current, or pending financial assistance supporting the proposed project from a government entity:

Halotechnics has two grant applications pending for developing thermal storage systems operating at 500 °C and 565 °C. The proposed work in these applications does not overlap in any way with the proposed ARPA-E project.

Thermal energy storage system operating at 500 °Ci. Government entity

The BIRD Foundation (Israel)


CSP Plants based on Specialized Parabolic Trough with SaltstreamTM Technologies


$500,000


October 1, 2011 to September 30, 2013

v. Description of project

The focus of this R&D program is to create an integrated solution by optimizing and demonstrating a system that includes Saltstream™ type heat transfer fluid with optimized critical solar components and overall Parabolic Trough Power Plants design. The demonstration plant will include a test loop with all of the critical components. The test loop will be used to optimize the characteristics of the components, examine their behavior across a range of operating conditions and develop an optimized configuration for the whole power plant.

Ener-t International – will complete the development of the specialized solar field and BOP’s components required for this application. Ener-t will build a molten salt flow loop for testing Saltstream and the specialized components that are necessary for the advanced parabolic trough power plant design.



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Halotechnics – will optimize Saltstream for the parabolic trough system. This will involve tuning the composition of the material for the optimum combination of melting point, maximum temperature, and cost. Halotechnics will provide a quantity of Saltstream for testing in the flow system.

Thermal energy storage system operating at 565 °Ci. Government entity

The Skolkovo Foundation (Russia)


Advanced Thermal Energy Storage with SaltstreamTM Molten Salt


$10 million


November 1, 2011 to October 31, 2014

v. Description of project

Halotechnics proposes to build a complete thermal energy storage system prototype using SaltstreamTM molten salt, operating up to 565 °C. We will design and build a scaled down concentrating solar power plant in our laboratory to validate the performance of our products. Concentrating solar power plants generate electricity by focusing sunlight using mirrors onto a receiver, then passing a fluid through the receiver to collect the heat, and finally using the heated fluid to boil water and drive a steam turbine generator. Our prototype system will use radiative heaters to simulate the solar receiver and a heat sink to simulate the steam generator in a full size plant. This prototype is crucial to generate realistic operating data on our materials and designs. We are in discussions with five leading customers who are currently building molten salt concentrating solar power plants, but they must see real data of successful prototype operation in order to have confidence that our products will function as expected at large scale. Once successful at lab scale we will begin design and construction of a pilot scale system before full scale commercial deployment of our products.

Prior, current, or pending financial assistance supporting the proposed project from a private entity

None.



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The information below describes other sources of funding for Key Participants in the proposed project.

Financial assistance that is currently being received from U.S. Government agency:

Dr. David Kearney:

i. Government entity

Alliance for Sustainable Energy LLC, Management and Operating Contractor for the National Renewable Energy Laboratory


Acceptance Testing and Support for NREL's CSP Program

iii. Funding amount

$132,493


27 May 2011 to 27 May 2012

v. Abstract of the project

NREL is actively involved in CSP system-level and component-level support for the development of codes and standards for CSP technologies. Market acceptance of CSP plants depends to a great degree on developers, utilities, and investors having a common understanding of the performance metrics of planned and operating facilities. To assist with this mission, NREL requires assistance to develop performance acceptance test guidelines for the solar block of CSP trough plants. It is envisioned that this work will also provide a basis for the acceptance protocols for other CSP technologies. It is planned that field tests of guidelines developed in this project will be used to validate methods and practicality.

vi. Specific aims

Task 1 – Continued development of NREL guidelines on acceptance testing

Task 2 – Field validation of acceptance test guidelines

Task 3 – Support on the development of ASME PTC 52

Task 4 – Technical support on commercial projects


Mark Mehos, NREL1617 Cole Blvd.Golden CO, [email protected]



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Pending financial assistance from U.S. Government agencies:Dr. Adam Bruckner:

Proposal Title Agency Principal Investigator Co-Investigators Funding Requested

Microphysics of heat and mass transfer in dry-to-icy lunar regolith: Interdependence on physical properties, cohesive forces, and volatile content

NASA Stephen E. Wood,(Univ. of Washington, Seattle, WA)

Adam Bruckner (Univ. of Washington, Seattle, WA)

Carl Knowlen (Univ. of Washington, Seattle, WA)

Howard Perko (Colorado State Univ. /Magnum Geo-Solutions, Ft. Collins, CO)

$825,000

9/1/2011 - 8/31/2015

(Submitted Feb. 2011)

Eight Types of Water in the Martian Tropics: Theoretical, Experimental, and In Situ Investigations in Support of the Mars Science Laboratory Mission



$535,000

9/1/2011 – 1/11/2015

(Submitted March 2011)

Carbon Dioxide Ice on Mars: Laboratory Simulation and Investigation of its Radiative and Physical Properties and Behavior


Gary Hansen (Univ. of Washington, Seattle, WA)

Adam Bruckner (Univ. of Washington, Seattle, WA)Carl Knowlen (Univ. of Washington, Seattle, WA)

$400,000

1/1/12 – 12/31/14

(Submitted July 2011)

Ram Accelerator High Velocity Launch System

(Subcontract proposal for DARPA SBIR proposal)

Systima Technologies, Inc., Bothell, WA

Carl Knowlen (Univ. of Washington, Seattle, WA)


$33,000

11/1/2011 – 5/31/2012

(Submitted June 2011)



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No other applicable sources of funding for Key Participants.



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Conflicts of Interest within Project Team (no limit)None

Ineligibility Criteria (no limit)None


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