An approach for intensifying the thermal response of phase-change materials (PCMs) in the shell-and-tube containment system via applying fin-assisted foam strips was proposed in this paper. The thermal response of these materials to energy storage and recovery duties is inherently limited due to their high thermal resistance. To support better thermal communication between the tube carrying the heat-transfer fluid and PCM in charge, this study suggests applying a fin array with foam strips. The use of foam strips rather than full foam was suggested since they require less material and can achieve better enhancement rate as they can operate in a more convection-friendly environment. The proposed approach was successfully tested and verified by comparing the enhanced melting and solidification rates between four different enhancement additives within the same volume limitations. These additives were: foam alone, fins alone, even fins with foam strips, and uneven fins with foam strips. A computational model that took into account the impact of the convective flow of PCM and the non-Darcy flow in foam strips was applied and validated via previous research. The results revealed that the uneven fins with foam strips had the best enhancement potential when compared to other additives in use. It was found that the melting rate could be enhanced up to 58 % and the corresponding solidification rate could be enhanced up to 42 % depending on the type and volume fraction of the enhancement additive used. 

Intensifying the thermal response of PCM via fin-assisted foam strips in the shell-and-tube heat storage system

Inherent fluctuations in the availability of energy from renewables, particularly solar, remain a substantial impediment to their widespread deployment worldwide. Employing phase-change materials (PCMs) as media, saving energy for later consumption, offers a promising solution for overcoming the problem. However, the heat conductivities of most PCMs are limited, which severely limits the energy storage potential of these materials. This study suggests employing circular fins with staggered distribution to achieve improved thermal response rates of PCM in a vertical triple-tube heat exchanger involving two opposite flow streams of the heat-transfer fluid (HTF). Since heat diffusion is not the same at various portions of the PCM unit, different fin configurations, fin dimensions and HTF flow boundary conditions were explored using computational studies of melting in the PCM triple-tube system. Staggered configuration of fin distribution resulted in significant increases in the rates of PCM melting. The results indicate that the melting rate and heat charging rate could be increased by 37.2 and 59.1%, respectively, in the case of staggered distribution. Furthermore, the use of lengthy fins with smaller thickness in the vertical direction of the storage unit resulted in a better positive role of natural convection; thus, faster melting rates were achieved. With fin dimensions of 0.666 mm × 15 mm, the melting rate was found to be increased by 23.6%, when compared to the base case of 2 mm × 5 mm. Finally, it was confirmed that the values of the Reynolds number and inlet temperatures of the HTF had a significant impact on melting time savings when circular fins of staggered distribution were included.

Investigation of Heat Transfer Enhancement in a Triple Tube Latent Heat Storage System Using Circular Fins with Inline and Staggered Arrangements.

Employing phase-change materials (PCM) is considered a very efficient and cost-effective option for addressing the mismatch between the energy supply and the demand. The high storage density, little temperature degradation, and ease of material processing register the PCM as a key candidate for the thermal energy storage system. However, the sluggish response rates during their melting and solidification processes limit their applications and consequently require the inclusion of heat transfer enhancers. This research aims to investigate the potential enhancement of circular fins on intensifying the PCM thermal response in a vertical triple-tube casing. Fin arrays of non-uniform dimensions and distinct distribution patterns were designed and investigated to determine the impact of modifying the fin geometric characteristics and distribution patterns in various spatial zones of the heat exchanger. Parametric analysis on the various fin structures under consideration was carried out to determine the most optimal fin structure from the perspective of the transient melting evolution and heat storage rates while maintaining the same design limitations of fin material and volume usage. The results revealed that changing the fin dimensions with the heat-flow direction results in a faster charging rate, a higher storage rate, and a more uniform temperature distribution when compared to a uniform fin size. The time required to fully charge the storage system (fully melting of the PCM) was found to be reduced by up to 10.4%, and the heat storage rate can be improved by up to 9.3% compared to the reference case of uniform fin sizes within the same fin volume limitations.

/pdf/improved-melting-of-latent-heat-storage-using-fin-arrays-1eoru16y.pdf

Improved Melting of Latent Heat Storage Using Fin Arrays with Non-Uniform Dimensions and Distinct Patterns

Due to the potential cost saving and minimal temperature stratification, the energy storage based on phase-change materials (PCMs) can be a reliable approach for decoupling energy demand from immediate supply availability. However, due to their high heat resistance, these materials necessitate the introduction of enhancing additives, such as expanded surfaces and fins, to enable their deployment in more widespread thermal and energy storage applications. This study reports on how circular fins with staggered distribution and variable orientations can be employed for addressing the low thermal response rates in a PCM (Paraffin RT-35) triple-tube heat exchanger consisting of two heat-transfer fluids flow in opposites directions through the inner and the outer tubes. Various configurations, dimensions, and orientations of the circular fins at different flow conditions of the heat-transfer fluid were numerically examined and optimized using an experimentally validated computational fluid-dynamic model. The results show that the melting rate, compared with the base case of finless, can be improved by 88% and the heat charging rate by 34%, when the fin orientation is downward–upward along the left side and the right side of the PCM shell. The results also show that there is a benefit if longer fins with smaller thicknesses are adopted in the vertical direction of the storage unit. This benefit helps natural convection to play a greater role, resulting in higher melting rates. Changing the fins’ dimensions from (thickness × length) 2 × 7.071 mm2 to 0.55 × 25.76 mm2 decreases the melting time by 22% and increases the heat charging rate by 9.6%. This study has also confirmed the importance of selecting the suitable values of Reynolds numbers and the inlet temperatures of the heat-transfer fluid for optimizing the melting enhancement potential of circular fins with downward–upward fin orientations.

Melting Enhancement in a Triple-Tube Latent Heat Storage System with Sloped Fins.

This work evaluates the influence of combining twisted fins in a triple-tube heat exchanger utilised for latent heat thermal energy storage (LHTES) in three-dimensional numerical simulation and comparing the outcome with the cases of the straight fins and no fins. The phase change material (PCM) is in the annulus between the inner and the outer tube, these tubes include a cold fluid that flows in the counter current path, to solidify the PCM and release the heat storage energy. The performance of the unit was assessed based on the liquid fraction and temperature profiles as well as solidification and the energy storage rate. This study aims to find suitable and efficient fins number and the optimum values of the Re and the inlet temperature of the heat transfer fluid. The outcomes stated the benefits of using twisted fins related to those cases of straight fins and the no-fins. The impact of multi-twisted fins was also considered to detect their influences on the solidification process. The outcomes reveal that the operation of four twisted fins decreased the solidification time by 12.7% and 22.9% compared with four straight fins and the no-fins cases, respectively. Four twisted fins improved the discharging rate by 12.4% and 22.8% compared with the cases of four straight fins and no-fins, respectively. Besides, by reducing the fins’ number from six to four and two, the solidification time reduces by 11.9% and 25.6%, respectively. The current work shows the impacts of innovative designs of fins in the LHTES to produce novel inventions for commercialisation, besides saving the power grid.

/pdf/solidification-enhancement-in-a-triple-tube-latent-heat-26tic4sbwj.pdf

Solidification Enhancement in a Triple-Tube Latent Heat Energy Storage System Using Twisted Fins

This study aims to assess the effect of adding twisted fins in a triple-tube heat exchanger used for latent heat storage compared with using straight fins and no fins. In the proposed heat exchanger, phase change material (PCM) is placed between the middle annulus while hot water is passed in the inner tube and outer annulus in a counter-current direction, as a superior method to melt the PCM and store the thermal energy. The behavior of the system was assessed regarding the liquid fraction and temperature distributions as well as charging time and energy storage rate. The results indicate the advantages of adding twisted fins compared with those of using straight fins. The effect of several twisted fins was also studied to discover its effectiveness on the melting rate. The results demonstrate that deployment of four twisted fins reduced the melting time by 18% compared with using the same number of straight fins, and 25% compared with the no-fins case considering a similar PCM mass. Moreover, the melting time for the case of using four straight fins was 8.3% lower than that compared with the no-fins case. By raising the fins’ number from two to four and six, the heat storage rate rose 14.2% and 25.4%, respectively. This study presents the effects of novel configurations of fins in PCM-based thermal energy storage to deliver innovative products toward commercialization, which can be manufactured with additive manufacturing.

https://www.mdpi.com/2071-1050/13/5/2685/pdf

Amirhossein Shafaghat

Papers

Effect of Twisted Fin Array in a Triple-Tube Latent Heat Storage System during the Charging Mode

Solidification of a nano-enhanced phase change material (NePCM) in a double elliptical latent heat storage unit with wavy inner tubes