How It Works TESS vs BESS Applications Sustainability How We Work Contact
Thermocline Energy Storage

Store Heat.
Dispatch
On Demand.

ThermoVault designs, engineers, and supplies packed-bed thermocline thermal energy storage systems — low-cost, long-duration, built for power grids, industry, and renewables.

Thermocline Cycle — Charge → Store → Discharge
CHARGE DISCHARGE HOT 600°C FRONT COLD 25°C Charge: 6h Discharge: 18h Output: 600°C for ~14h flat RTE: 74.7%
36MWh
Capacity
74.7%
RTE
18h
Discharge
Built for
☀️ CSP & Solar-Thermal
💨 Wind & Renewable IPPs
🏭 Industrial Heat Users
⚡ Grid & Utility Operators
How It Works

Simple physics.
Powerful storage.

A packed bed of ceramic balls absorbs heat when energy is available and releases it on demand — using nothing more than airflow and gravity.

System Overview — Charge · Store · Discharge
ENERGY SOURCE Solar / Wind / Grid HOT FLUID CHARGE ↓ ThermoVault PACKED BED Ceramic Balls HOT AIR DISCHARGE ↓ HEAT OUTPUT Steam / Air / Process INDUSTRIAL FACILITY 24 hr / day WHEN ENERGY IS CHEAP ENERGY STORED AS HEAT HEAT DISPATCHED ON DEMAND
01
Low-cost energy turns into heat.

When renewable electricity is cheap and abundant — while the sun is shining or the wind is blowing — ThermoVault charges its packed bed. Hot fluid flows through the bed, transferring heat into thousands of ceramic balls.

  • Charges in 4–8 hours from solar, wind, or the grid
  • Works with any high-temperature heat source
  • Electrical heaters or direct solar thermal input
WIND SOLAR GRID CHARGING Ceramic Balls
02
Ceramic balls hold the heat.

The packed bed of ceramic balls — made from abundant, locally available materials — stores the thermal energy with less than 15 kW standby heat loss. No exotic chemicals. No high-pressure containment. No degradation over decades.

  • Ceramic balls made from abundant natural materials
  • Single-tank design — far simpler than two-tank molten salt
  • Negligible standby losses — refractory insulation holds the heat
  • No degradation — the same balls work for 30,000+ cycles
HOT ZONE 600°C THERMOCLINE FRONT COLD ZONE 25°C
03
Heat is dispatched on demand.

When heat is needed, cold air enters from the bottom and exits superheated from the top — delivering 600°C for up to 14 hours flat before tapering. A full charge gives up to 18 hours of useful discharge. Output connects directly to your end application.

  • 600°C outlet temperature held flat for ~14 hours per cycle
  • Up to 18 hours total discharge per charge cycle
  • Output rate controlled by air flow — instantly adjustable
  • Hot air output feeds directly into: steam boiler, industrial process, or steam turbine for grid power
COLD AIR IN DISCHARGE HOT AIR HEAT EXCH. STEAM INDUSTRIAL PROCESSES
ThermoVault charges in 6 hours and discharges at 600°C for up to 14 hours flat — delivering stored heat directly as hot air, steam, or grid electricity via a steam turbine.
70%
Cost Reduction
vs. conventional two-tank molten salt TES
900°C
Max Temperature
Full industrial heat range — from renewables to heavy industry
GWh+
Scalable
From 10 MWh pilots to multi-GWh grid-scale installations
30yr
System Lifetime
Ceramic storage media lasts the life of your plant
TESS vs BESS

25× cheaper than
lithium-ion.

Thermal energy storage isn't competing with batteries — it's replacing them for long-duration, high-temperature applications where batteries simply cannot go.

CAPEX per kWh Stored — Technology Comparison
ThermoVault TES
₹925/kWh
CAES
₹5,010/kWh
Pumped Hydro
₹12,525/kWh
Li-ion BESS
₹23,380/kWh
Vanadium Flow
₹29,225/kWh
Parameter
ThermoVault TES
Li-ion BESS
CAPEX per kWh
₹925/kWh
₹23,380/kWh
Round-trip Efficiency
74.7%
85–92% (electrical only)
Cycle Life
30,000+ cycles — no degradation
3,000–6,000 cycles, 2%/yr degradation
Max Temperature
600–900°C
Fails above 45°C
Discharge Duration
Up to 18 hours per cycle
2–4 hours (economical limit)
Storage Medium
Ceramic balls — abundant, local
Lithium, cobalt, nickel — imported
Fire / Safety Risk
None — inert ceramic + air
Thermal runaway risk
Replacement Cycle
None — 30+ year system life
Full replacement at ~year 10
Li-ion is ideal for short-duration, electricity-to-electricity storage. ThermoVault is built for long-duration, high-temperature applications where batteries cannot operate — and at a fraction of the cost.
Key Benefits

Why thermocline
storage wins.

Zero-Carbon Heat & Power
ThermoVault stores renewable energy as heat and dispatches it continuously — decoupling generation from consumption. Industrial facilities can eliminate fossil fuel combustion without changing their existing heat infrastructure.
Lowest Cost
A single-tank packed-bed design using ceramic balls made from abundant materials is inherently low-cost — no expensive fluids, no complex vessel pairs, no degrading chemicals. Capital cost is up to 70% lower than two-tank molten salt systems at equivalent capacity.
18-Hour Discharge. On Your Schedule.
Charge in 6 hours when energy is cheap. Discharge at 600°C for up to 14 hours flat — then up to 18 hours total per cycle. ThermoVault dispatches heat when you need it, independent of whether the sun is shining or the wind is blowing.
Reliable — No Degradation
ThermoVault achieves 74.7% round-trip efficiency. Unlike batteries, ceramic storage media does not degrade with cycling — no electrolytes, no membranes, no moving parts in the storage core. A system commissioned today performs identically after 30,000 cycles.
Modular & Scalable
ThermoVault systems are sized precisely to your project — from 10 MWh demonstration units to GWh-scale grid storage. Multiple vessels can be arranged in parallel to serve very large heat loads without engineering complexity.
Proven Materials
Ceramic packed beds have stored high-temperature heat in steel mills and industrial regenerators for over a century. Sintered at 2000°C, the ceramic balls are chemically inert and thermally stable — rated for 30,000+ cycles. ThermoVault uses this proven material science in a new, optimised configuration.
How We Work

Two models.
One technology.

ThermoVault works with clients in two ways — we can supply a fully engineered system for you to own and operate, or we can build and operate the system ourselves so you simply pay for the energy you use.

Model 01
System Supply
We design, engineer, and supply a complete thermocline TES system. You own the asset, operate it on your terms, and capture the full value of long-duration thermal storage.
What's included
  • — Full system design & simulation
  • — Engineering & fabrication to specification
  • — Delivery & on-site commissioning
  • — Performance validation & handover
  • — Optional ongoing technical support
You own & operate the asset
Model 02
Build & Operate
ThermoVault builds, owns, and operates the thermocline system at your site. You pay only for the heat or energy you use — no upfront capital, no operational complexity.
What's included
  • — No upfront capital required
  • — ThermoVault finances, builds & operates the system
  • — You pay per MWh of heat or power delivered
  • — Fixed or index-linked energy price
  • — Long-term project partnership
Energy-as-a-Service
Both models use the same proven thermocline technology — the difference is who owns the asset and how you pay. Talk to our team and we'll recommend the right structure for your project.
Our Process

From requirements
to a working system.

01
Requirements & Site Assessment
We gather your energy capacity, power levels, temperature range, and site constraints to define the full system specification.
02
Design & Simulation
We simulate the full thermocline system — materials, bed geometry, flow rates, and transient performance — before a single component is ordered.
03
Engineering & Fabrication
We engineer structural, thermal, and fluid systems. Components are fabricated and quality-checked to our exacting specifications.
04
Delivery & Commissioning
We deliver the complete TES unit, support installation, and commission the system to verify performance against design targets.
Markets We Serve

Every application
that needs heat.

Our systems are engineered for the specific demands of each sector — from grid-scale renewable integration to high-temperature industrial processes.

☀️
Solar Energy Producers
Store excess thermal output from concentrated solar or solar-thermal hybrids. Discharge overnight or during peak demand to increase plant revenue and grid value.
300–600°C
⚡
Power Grid Operators
Deploy long-duration thermocline TES alongside grid infrastructure. Provide dispatchable thermal capacity to balance variable renewable generation at scale.
Grid Scale · MWh–GWh
🏭
Industrial Facilities
Capture and store high-temperature process heat from cement, steel, glass, and chemical plants. Re-use stored energy to cut fuel costs and carbon emissions.
200–900°C
💨
Renewable Developers
Add dispatchable thermal storage to wind or solar projects. Improve economics, reduce curtailment, and meet round-the-clock energy supply commitments.
Power-to-Heat-to-Power
Applications

One system.
Three outputs.

ThermoVault delivers high-temperature heat in three configurations — direct hot air for industrial processes, steam for power or process heat, and combined heat and power via a steam turbine.

Direct Hot Air for Industrial Processes

ThermoVault can directly deliver superheated air at high temperatures to replace fossil fuels in direct- and indirect-fired industrial processes — no heat exchanger required, minimal equipment changes.

  • Drop-in replacement for gas-fired burners and furnaces
  • Direct air supply to kilns, dryers, and calcination processes
  • Suitable for cement, ceramics, glass, and food processing
  • Output temperature controllable via air flow rate
  • Zero combustion emissions at the point of use
200–900°C · Direct Air Output
ENERGY INPUT Solar / Wind / Grid ThermoVault HOT AIR INDUSTRIAL PROCESSES
Energy → ThermoVault → Hot Air → Industrial Process
ThermoVault delivers hot air directly into kilns, furnaces, and dryers — replacing fossil fuel combustion with zero-carbon stored heat, without changing the underlying industrial process.
Steam for Industrial Processes

ThermoVault can deliver dispatchable saturated or superheated steam that matches existing boiler infrastructure — a drop-in replacement for fossil-fired steam generation with no process changes required.

  • Saturated or superheated steam at process specification
  • Drop-in replacement for existing fossil-fired boilers
  • Compatible with food, chemical, pharmaceutical, and textile industries
  • Continuous 24/7 steam supply from intermittent renewable input
  • Eliminates Scope 1 emissions from steam generation
Steam · Drop-in Compatible
ENERGY INPUT Solar / Wind / Grid ThermoVault + WATER BOILER STEAM INDUSTRIAL PROCESSES
Energy → ThermoVault → Boiler → Steam → Industrial Process
ThermoVault delivers dispatchable saturated or superheated steam that matches existing boiler infrastructure — a drop-in replacement for fossil-fired steam generation, 24 hours a day.
Grid Electricity via Steam Turbine

ThermoVault's hot air output drives a boiler to produce high-pressure steam, which then powers a steam turbine to generate grid electricity. This configuration delivers either heat or electricity — not both simultaneously — depending on your project's commercial structure.

  • Hot air → boiler → high-pressure steam → steam turbine → grid electricity
  • Converts stored thermal energy into dispatchable baseload power
  • Charges during cheap renewable hours, generates during peak grid demand
  • Grid arbitrage: charge at ₹1–2/kWh, dispatch at ₹8–12/kWh peak rates
  • 74.7% round-trip efficiency from charge to electrical output
  • No battery degradation — same efficiency after 30,000 cycles
Grid Power · Steam Turbine · Arbitrage
ENERGY INPUT Solar/Wind/Grid ThermoVault BOILER HI-P STEAM TURBINE ELECTRICITY TO GRID LO-P STEAM PROCESS HEAT
Energy → ThermoVault → Boiler → Turbine → Grid Electricity + Process Steam
ThermoVault charges during cheap solar hours and dispatches grid electricity at peak demand — turning a ₹1–2/kWh input into ₹8–12/kWh output, with a 4.4-year payback on a 36 MWh unit.
Get In Touch

Tell us about
your project.

Share your energy storage requirements and our engineers will respond with an initial assessment.

Energy Storage Projects
Tell us your MWh capacity, power rating, temperature range, and site location. We'll design a system around your needs.
Partnerships & Investment
Interested in partnering with or investing in ThermoVault? We'd love to hear from strategic partners and early-stage investors.
Email Us
info@thermovault.in
Location
Chennai, Tamil Nadu, India
Global Reach
We work with clients across Europe, MENA, South Asia, and Southeast Asia.
Sustainability

The formula for
industrial decarbonisation.

Renewable electricity + thermal energy storage. Industry accounts for nearly a third of global emissions — and heat is the hardest part to clean up. ThermoVault is part of the solution.

50%
of global energy use
is heat — the largest single energy end-use on the planet
74%
of industrial energy
is used as heat — almost entirely supplied by fossil fuels today
10%
from renewables today
only 10% of industrial heat currently comes from renewable sources
🌱
Eliminate Fossil Fuel Combustion
ThermoVault replaces gas-fired boilers and fossil fuel furnaces with stored renewable heat — eliminating Scope 1 emissions at the point of industrial use, with no changes to the underlying process.
☀️
Unlock More Renewable Generation
Renewable curtailment — energy wasted because the grid cannot absorb it — is a growing problem. ThermoVault absorbs surplus solar and wind power at the moment of generation, storing it as heat for later use and making more renewables economically viable.
♻️
Recover Industrial Waste Heat
Foundries, cement plants, glass furnaces, and chemical facilities vent high-temperature exhaust every day. ThermoVault captures this waste heat and stores it for re-use — turning a liability into a zero-carbon energy asset.
⚡
Stabilise the Grid
By decoupling renewable generation from energy consumption, ThermoVault reduces peak demand stress on the grid, absorbs excess supply during low-demand periods, and dispatches clean energy when the grid needs it most.
🏭
Decarbonise Hard-to-Abate Industries
Cement, steel, glass, and ceramics need heat at temperatures that batteries and heat pumps cannot reach. ThermoVault operates at up to 900°C — making it one of the only technologies that can decarbonise these sectors cost-effectively.
🌍
Zero Critical Material Dependency
No lithium, cobalt, or vanadium. ThermoVault's ceramic storage medium is made from abundant, locally sourced materials — with no supply chain tied to geopolitically sensitive mining regions. A genuinely clean technology at every stage of its lifecycle.
McKinsey / LDES Council
"Thermal energy storage has the potential to greatly contribute to decarbonising global heat and power, while helping to ensure the energy system operates affordably, reliably, and efficiently."
20%
of global CO₂ footprint addressable by TES

Ready to store your energy?

Tell us your requirements and we'll design a thermocline vault built precisely for your project.