Lessons learnt during the design, construction and start-up phase of a molten salt testing facility

In 2010, CIEMAT (Centro de investigaciones energéticas medioambientales y tecnológicas) signed a turn-key contract to have an experimental plant for thermal storage using molten salts at its PSA (Plataforma Solar de Almeria) facilities. This plant was designed to evaluate components, instrumentation and operation strategies and to give support to the industry in the qualification and evaluation of components. During the design, construction and start-up phases of this plant, many different aspects regarding design, construction and commissioning have been learnt and these will contribute to the improvement of other plants. Among other tips explained in the paper, we recommend the use of venting valves to eliminate the water present in the system after the pressure test or released by the salts during the first melting. The selection of instrumentation with no electronic components near a heat source, thus preventing them from overheating, is also advisable. The heat exchanger design and dimensioning should take into account not only the thermal losses to the atmosphere and through pipes and supports, but any possible reduction in the heat exchange surface that could have detrimental consequences in the thermal performance. Special attention must be paid when dimensioning and installing the EHT and insulation because both components are decisive in the avoidance of plug formation. Its correct installation in valves and supports and the proper positioning of the temperature control sensors, i.e. where no other heat source can distort the readings, are crucial. Recommendations and strategies for the operation and shutdown of this experimental plant are being gathered for a future paper. -- Highlights: • Description of the experimental molten salt storage system built at CIEMAT. • Design technical considerations for an experimental molten salt storage plant. • Hints for piping and heat exchangers design and thermal losses calculation. • Recommendations for selecting instrumentation and elements with electronic parts. • Installation remarks for insulation and heating elements