# US 12,760,665 B2 · Thermal energy storage systems for use in material processing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,760,665 B2 - Document ID: US12760665B2 - Status: Granted - Kind: B2 - Application number: 19/410,588 - Filed: 2025-12-05 - Published: 2026-04-02 - Granted: 2026-10-13 - Earliest claimed: 2020-11-30 - Assignees: Rondo Energy, Inc. - Applicants: Rondo Energy, Inc. - Inventors: John Setel O'Donnell; Yusef Desjardins Ferhani; Peter Emery Von Behrens; Matthieu Jonemann - Web page: https://patentgrep.com/patent/US12760665B2 ## CPC - F01K 3/02: Use of accumulators and specific engine types; Control thereof - B63H 11/00: Marine propulsion by water jets - F01K 3/08: Use of accumulators and the plant being specially adapted for a specific use - F01K 3/186: {using electric heat} - F01K 13/02: Controlling, e.g. stopping or starting - F01K 15/00: Adaptations of plants for special use {(F01K7/02 takes precedence)} - F03G 6/071: {with energy storage devices} - F22B 29/06: of once-through type, i.e. built-up from tubes receiving water at one end and delivering superheated steam at the other end of the tubes (combined low- and high-pressure boilers of forced-flow type F22B33/16) - F22B 35/10: of once-through type - F28D 20/00: Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00 - H01M 8/04014: Heat exchange using gaseous fluids; Heat exchange by combustion of reactants - H01M 8/04029: Heat exchange using liquids - H01M 8/04037: {Electrical heating} - H01M 8/04052: {Storage of heat in the fuel cell system} - H01M 8/04074: {Heat exchange unit structures specially adapted for fuel cell} - H02J 1/102: being switching converters (H02J1/108, H02J1/12 take precedence) - H02J 3/00: Circuit arrangements for AC mains or AC distribution networks - H02J 3/04: Arrangements for connecting networks of the same frequency but supplied from different sources - H02M 1/0003: {Details of control, feedback or regulation circuits} - H02M 1/007: {Plural converter units in cascade (push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826)} - B63H 1/12: with rotation axis substantially in propulsive direction - B63H 11/12: the propulsive medium being steam or other gas - B63H 11/14: the gas being produced by combustion - B63H 11/16: the gas being produced by other chemical processes - F01K 11/02: the engines being turbines - F01K 19/04: in combination with cooling or heating - F03D 9/18: storing heat - F28D 2020/0004: {Particular heat storage apparatus} - Y02E 60/14: Thermal energy storage - F01K: STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES (gas-turbine or jet-propulsion plants F02; nuclear power plants, engine arrangements therein G21D) - B63H: MARINE PROPULSION OR STEERING (propulsion of air-cushion vehicles B60V1/14; specially adapted for submarines, other than nuclear propulsion, B63G; specially adapted for torpedoes F42B19/00) - F03G: SPRING, WEIGHT, INERTIA OR LIKE MOTORS; MECHANICAL-POWER PRODUCING DEVICES OR MECHANISMS, NOT OTHERWISE PROVIDED FOR OR USING ENERGY SOURCES NOT OTHERWISE PROVIDED FOR (arrangements in connection with power supply in vehicles from force of nature B60K16/00; electric propulsion with power supply in vehicles from force of nature B60L8/00) - F22B: METHODS OF STEAM GENERATION; STEAM BOILERS - F28D: HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT (fluid heaters having heat generating means and heat transferring means F24H; furnaces F27; details of heat-exchange apparatus of general) - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY - H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P) - F03D: WIND MOTORS - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract An energy storage system (TES) converts variable renewable electricity (VRE) to continuous heat at over 900° C. Intermittent electrical energy heats a solid medium. Heat from the solid medium is delivered continuously on demand. Heat delivery via flowing gas establishes a thermocline which maintains high outlet temperature throughout discharge. The delivered heat which may be used for processes including power generation and cogeneration. In one application, thermal energy storage systems are used to improve efficiency and reduce carbon emissions associated with processing materials or other industrial applications. ## Claims ### Claim 1 A material processing system for use with a process gas including: a reformer configured to receive heat and a feedstock to produce the process gas; a thermal energy storage (TES) unit configured to store thermal energy generated from an electric heater, wherein the TES unit is configured to provide the heat to the reformer using stored thermal energy; and a material processing reactor configured to receive the process gas and perform a process on a material in the reactor; wherein the TES unit is configured to output stored thermal energy at a rate that maintains a predetermined process condition in the reactor. ### Claim 2 (depends on 1) The system of claim 1, wherein the reformer includes one or more reactor tubes. ### Claim 3 (depends on 2) The system of claim 2, wherein the TES unit further includes a fluid movement system configured to direct a working fluid to convectively heat the reactor tubes in order to drive at least a portion of a reaction in the reformer. ### Claim 4 (depends on 2) The system of claim 2, wherein the reactor tubes are configured to be exposed to radiant heat transfer from the TES unit in order to drive at least a portion of a reaction in the reformer and a fluid movement system configured to direct a reformer feedstock through the reactor tubes. ### Claim 5 (depends on 4) The system of claim 4, wherein the reformer feedstock includes one or more of the following: steam, a hydrocarbon, a carbon oxide, or any combination thereof. ### Claim 6 (depends on 1) The system of claim 1, wherein the process gas includes one or more of the following: hydrogen, carbon monoxide, or any combination thereof. ### Claim 7 (depends on 1) The system of claim 1, wherein the reformer is also configured to receive heat from a combustion process. ### Claim 8 (depends on 7) The system of claim 7, wherein the combustion process uses waste gas from the material processing reactor as at least a portion of fuel input. ### Claim 9 (depends on 8) The system of claim 8, further including a post carbon capture combustion plant configured such that a product of combustion in the reformer is directed to at least one heat exchanger that generates steam and at least a portion of the cooled products of combustion are directed to a sorption carbon capture process, wherein the steam generated is used at least in part to power the carbon capture process. ### Claim 10 (depends on 9) The system of claim 9, where the steam passes through a non-condensing turbine to produce steam and electricity to drive the carbon capture process. ### Claim 11 (depends on 1) The system of claim 1, further including a high-pressure vessel configured to enclose the TES unit. ### Claim 12 (depends on 1) The system of claim 1, wherein the reactor is configured to perform an endothermic reaction. ### Claim 13 (depends on 1) The system of claim 1, wherein the reactor is configured to perform a direct reduction process on the material. ### Claim 14 (depends on 1) The system of claim 1, A material processing system for use with a process gas including: a reformer configured to receive heat and a feedstock to produce the process gas; a thermal energy storage (TES) unit configured to store thermal energy generated from an electric heater, wherein the TES unit is configured to provide the heat to the reformer using stored thermal energy; and a material processing reactor configured to receive the process gas and perform a process on a material in the reactor; wherein the TES unit is configured to output stored thermal energy at a rate that maintains a predetermined process condition in the reactor; wherein the reactor is configured to perform a direct reduced iron reaction. ### Claim 15 A method of material processing using a process gas, including: receiving, at a reformer, heat and a feedstock to produce the process gas; storing, in a thermal energy storage (TES) unit, thermal energy generated from an electric heater; providing, from the TES unit, the heat to the reformer using the stored thermal energy; receiving, at a material processing reactor, the process gas; and performing a process on a material in the reactor; wherein the TES unit outputs stored thermal energy at a rate that maintains a predetermined process condition in the reactor. ### Claim 16 (depends on 15) The method of claim 15, wherein the reformer includes one or more reactor tubes. ### Claim 17 (depends on 16) The method of claim 16, further including: using a fluid movement system to direct a working fluid to convectively heat the reactor tubes in order to drive at least a portion of a reaction in the reformer. ### Claim 18 (depends on 16) The method of claim 16, further including: exposing the reactor tubes to radiant heat transfer from the TES unit in order to drive at least a portion of a reaction in the reformer; and using a fluid movement system to direct a reformer feedstock through the reactor tubes. ### Claim 19 (depends on 18) The method of claim 18, wherein the reformer feedstock includes one or more of the following: steam, a hydrocarbon, a carbon oxide, or any combination thereof. ### Claim 20 (depends on 15) The method of claim 15, wherein the process gas includes one or more of the following: hydrogen, carbon monoxide, or any combination thereof. ### Claim 21 (depends on 15) The method of claim 15, further including: receiving, at the reformer, heat from a combustion process. ### Claim 22 (depends on 21) The method of claim 21, further including: using waste gas from the material processing reactor as at least a portion of fuel input to the combustion process. ### Claim 23 (depends on 22) The method of claim 22, further including: directing a product of combustion in the reformer to at least one heat exchanger to generate steam; directing at least a portion of cooled products of combustion to a sorption carbon capture process; and using the generated steam at least in part to power the carbon capture process. ### Claim 24 (depends on 23) The method of claim 23, further including: passing the steam through a non-condensing turbine to produce steam and electricity to drive the carbon capture process. ### Claim 25 (depends on 15) The method of claim 15, further including: enclosing the TES unit within a high-pressure vessel. ### Claim 26 (depends on 15) The method of claim 15, wherein performing the process on the material in the reactor includes performing an endothermic reaction. ### Claim 27 (depends on 15) The method of claim 15, wherein performing the process on the material in the reactor includes performing a direct reduction process on the material. ### Claim 28 (depends on 15) The method of claim 15, wherein performing the process on the material in the reactor includes performing a direct reduced iron reaction.