Experimental Analysis of Encapsulated

Phase Change Material Based Thermal

Energy Storage

Nadir Abbas 14-ME-23

Arslan Ameen 14-ME-28
Khalid Rafique 14-ME-29
Ahmad Raza Tahir 14-ME-30
Marya Saeed 14-ME-184

Advisor
Engr.Najam ul Hassan Shah
Lecturer

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF MECHANICAL & AERONAUTICAL
ENGINEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY

TAXILA
May, 2018

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 Experimental Analysis of Encapsulated
Phase Change Material Based Thermal
Energy Storage

Nadir Abbas 14-ME-23

Arslan Ameen 14-ME-28
Khalid Rafique 14-ME-29
Ahmad Raza Tahir 14-ME-30
Marya Saeed 14-ME-184

A Final year project submitted in partial fulfillment of the requirements for the degree of

B.Sc. Mechanical Engineering

Project Advisor:

Engr. Najam ul Hassan Shah

Lecturer

Neutral Examiner Signature:_____________________________________________

Project Advisor Signature: _____________________________________________

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF MECHANICAL & AERONAUTICAL ENGINEERING
UNIVERSITY OF ENGINEERING AND TECHNOLOGY TAXILA
May, 2018
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 ABSTRACT

Thermal energy storages (TESs) are essential in concentrated solar power (CSP) plants to ensure

energy availability during night and cloudy periods. The purpose of this work is to perform

experimentation to analyze performance of an encapsulated phase change material (EPCM) based

TES. The experimental setup developed for this purpose consist of ten stain-less-steel capsules

filled with a commercial PCM with 50-50% composition of NaNO 3-KNO3, melting point 220oC.

The capsules are arranged in a vertically inline position in a rectangular stain-less-steel chamber.

A centrifugal pump and storage tank support flow of fluid through the TES chamber, while

electric heaters are used to simulate conditions of heat absorbed by solar flux. In addition,

thermocouples are used to get temperature values through data acquisition system to support

proper measurement and analysis. The experimentation shall be performed for complete charging

and discharging cycles with varying flow rates (0.01, 0.02, 0.03 kg/s) and inlet temperature

(250oC and 280oC) conditions of heat transfer fluid. The readings shall be processed to get refined

results in terms of energy stored, heat transfer rate, energy density, Heat losses etc. To

consequence the experimentation, numerical simulations shall be performed to validate the

results, using an already developed model. The results of this work shall help in developing

energy solutions for our growing population. The profited applications may include CSP as well

as solar refrigeration technologies.

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 UNDERTAKING

The substance of this dissertation is original work of the author. Due references and

acknowledgements have been made, where necessary, to the work of others. No part of

this report has already been accepted for any degree, and it is not being currently

submitted in candidature of any degree.

Nadir Abbas 14-ME-23 ________________

Arslan Ameen 14-ME-28 ________________
Khalid Rafique 14-ME-29 ________________
Ahmad Raza Tahir 14-ME-30 ________________
Marya Saeed 14-ME-184 ________________

7
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 ACKNOWLEDGEMENT

Starting with the name of our Creator and Well-wisher the most Merciful and Generous. I

am thankful to our Care Taker, Who provided me the opportunity to get knowledge with

good health and well-functioning body. He guided me throughout my academic career; it

is because of His countless blessings that I have achieved all the goals that I have ever set

in my life. I am also thankful to our Prophet (S.A.W.W) Who guided us to live our lives

in a good manner and opened the doors of knowledge for us. It is the result of His

teachings that I am able to reach at this stage.

My supervisor Engr. Najam ul Hassan Shah helped and encouraged me in any sense I

consulted him. I am thankful to him for his support and help. I was motivated by our

respected teachers Dr. Muzaffar Ali, Dr. Tanzeel-ur-Rashid, Dr. Nazeer Ahmad Anjum,

and Dr. Masood Ur Rehman Shah. Dr. Nadeem Ahmed Sheikh from Capital University of

Science and Technology (CUST) Islamabad and Dr. Maher Ghazal from GIKI Institute,

Tope, also played a pivotal role by their critical discussion on the topic, without which

the project could not have reached the current form. The personality that impressed me

the most is Engr. Najam ul Hassan Shah. He guided me in all kinds of matters related to

study and real life problems; he taught me many skills.

I am grateful to all my teachers for being nice to me and guiding me. I am thankful to

Engr. Muhammad Usman and all lab staff especially Mr. Muhammad Shafiq, Mr. Toqeer

and Mr. Aamir for facilitating me in the lab. I am thankful to my all family members

especially to my parents, for their patience and supporting through their motivating

words.

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 Table of Contents
ABSTRACT........................................................................................................................v

UNDERTAKING.............................................................................................................vii

ACKNOWLEDGEMENT...............................................................................................ix

LIST OF FIGURES........................................................................................................xiii

LIST OF EQUATIONS...................................................................................................xv

LIST OF TABLES.........................................................................................................xvii

CHAPTER 1: INTRODUCTION....................................................................................1

1.1 Background..........................................................................................................1

1.2 Problem Statement..............................................................................................3

1.3 Aims & Objectives..............................................................................................4

1.4 Literature Review................................................................................................4

1.4.1 Solar Thermal Technologies........................................................................4

1.4.2 Thermal Energy Storage.............................................................................5

1.4.3 Latent Heat Based Thermal Energy Storage............................................6

1.4.4 Sensible Heat Based Thermal Energy Storage..........................................6

1.4.5 Phase Change Material (PCM) Based Thermal Energy Storage............6

1.5 Literature Gap.....................................................................................................7

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 1.6 Utilization of Research Results..........................................................................7

CHAPTER.2: METHODOLOGY OF RESEARCH......................................................8

2.1 Research Methodology........................................................................................8

2.1.1 Experimental Analysis...............................................................................10

2.1.2 Comparative Analysis................................................................................12

2.2 Work Schedule Plan..........................................................................................13

2.3 Budget Description............................................................................................14

CHAPTER.3: MATHEMATICAL ANALYSIS............................................................15

3.1 Mathematical Model.........................................................................................15

3.2 Energy Balance Equations...............................................................................17

3.3 Simulation Results.............................................................................................22

CHAPTER.4: EXPERIMENTAL ANALYSIS..............................................................24

4.1 Calculations.......................................................................................................24

4.2 Annexures..........................................................................................................27

Conclusion........................................................................................................................34

Abbreviations...................................................................................................................35

References.........................................................................................................................36

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 LIST OF FIGURES

Figure 1 Flow Diagram of the Methodology.......................................................................9

Figure 2 Experimental Setup for Performance Analysis of Phase Change Material Based

Thermal Energy Storage System.......................................................................................11

Figure 3 DAQ 1.................................................................................................................12

Figure 4 DAQ 2.................................................................................................................12

Figure 5-Arrangement of Thermocouples in Storage Tank...............................................16

Figure 6-Schematic of Thermal Energy Storage for Mathematical Model (a) side view

showing EPCM capsules in Inline arrangement, (b) Front view.......................................17

Figure 7-Description of Energy Interactions between Components of TES Chamber in

One Section........................................................................................................................17

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14
 LIST OF EQUATIONS

Equation 1..........................................................................................................................18

Equation 2..........................................................................................................................18

Equation 3..........................................................................................................................18

Equation 4..........................................................................................................................18

Equation 5..........................................................................................................................19

Equation 6..........................................................................................................................19

Equation 7..........................................................................................................................19

Equation 8..........................................................................................................................20

Equation 9..........................................................................................................................20

Equation 10........................................................................................................................20

Equation 11........................................................................................................................20

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 LIST OF TABLES

Table 1-Basic Model of Thermal Energy Storage for Numerical Simulations..................23

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 CHAPTER 1: INTRODUCTION

1.1 Background
There are many conventional ways of storing and transducing energy in different forms

e.g. storing electrical energy in batteries and then utilizing it according to needs.

Similarly, elastic potential energy can be stored energy in springs and pressure energy in

accumulators but there was not a way to store heat energy in any device. Heat energy can

be stored into mechanical energy and then into electrical energy and electrical energy can

be stored in batteries but could not be stored in heat energy directly in any conventional

device. Most of the time heat is generated in any process as a result of friction or as a

byproduct and wasted to environment but one cannot utilize it or store it to extract some

useful work from it.

Every day sun rises and sets and there is a huge amount of heat energy associated with

sun which almost every day is wasted and causing global warming and we do not have

any device to store this huge amount of energy which can meet energy demands of whole

population.

Phase change material is a substance having capability to melt and solidified at certain

temperature and store large amount of energy when changing its phase[1] i.e. from solid

to liquid and vice versa. In this work PCM capsules have 76 mm diameter. PCM are

classified as organic PCM and inorganic PCM, Eutectic and hygroscopic PCM.[2]

Organic PCM are further classified into paraffin and non-paraffin PCM. Paraffin wax is

the common example of paraffin PCM. It’s made the straight chain n-alkanes (CH3–

(CH2)n–CH3). Non-paraffin PCM are fatty acids and glycol. Inorganic PCM are salts,

1
metals, alloys and salts hydrate. They include the sodium sulphate decahydrate and

calcium chloride hexa hydrate

A major drawback of solar energy is its temporal intermittency. To overcome this

problem, one solution is to use a backup system (energy hybridization) that burns fossil

fuel or biomass. A second solution is to use a thermal energy storage (TES) system to

store heat during sunshine periods and release it during the periods of weak or no solar

irradiation.

The development of an efficient and cost-effective TES system is crucial for the future of

CSP technologies [3]. Economically, TES allows an increase in the duration of electricity

production. Moreover, integrating a TES system in specific CSP configurations permits

optimization of electricity resale and the CSP electricity production [4]. Electricity prices

vary during a day depending on demand. The solar intensity's largest periods do not

correspond to the electricity's most expensive periods. Adding a TES allows heat storage

during high solar intensity periods and provides productions during high electricity cost

periods.

There are currently three kinds of TES systems available: sensible heat storage, latent

heat storage and thermo-chemical heat storage [5, 6]. Sensible heat storage systems are

the most mature. They are widely used in industrial plants, most notably in Spain. . Latent

heat storage allows large amounts of energy to be stored in relatively small volumes (high

energy density) and is cost competitive.

2
 1.2 Problem Statement
Now a day’s world is completely dependent on fossil fuel reservoirs to fulfill its energy

demands. The fact is that these reservoirs are rapidly consumed and will be unavailable

one day. Thus the idea to search and invent other renewable energy resources is basic

need of today, to accomplish world’s energy needs that is increasing with the passage of

time. Among all the renewable energy resources, the solar energy is most important one

because of its enrich supply everywhere on earth and it can be directly converted to the

electricity by the help of solar cell that are also available in the form of solar panels now

a days. The main challenge with solar energy is its availability only with sun light and

consequently the mechanism for its storage. The commercial progress for storage systems

for sensible heat energy is more than for latent heat energy and storage of energy based

on phase change materials that is viable because variations of temperature are small, less

capital investment is required and can store energy on large scales.

This study will evaluate the actual performance of phase change material H220 having

phase change temperature 220 ˚C. To find the effectiveness of PCM material for thermal

energy storage the system is tested In terms of time charging/discharging cycles, energy

storage density and fraction of latent energy stored. An overall analysis will be performed

on this system during different charging and discharging cycles and its ability to store

thermal energy will be evaluated. This study will help to improve the effectiveness of

PCM based thermal energy storage systems for R&AC lab.

3
 1.3 Aims & Objectives
Aim of the study is to evaluate the performance of EPCM based Thermal Energy Storage

System and to interpret the experimental results by varying the temperatures, direction of

flow, during different charging/discharging cycles for concentrated solar thermal

applications and to compare the results with the mathematical model.

Following are the objectives of the research:

i. To maintain the apparatus for effective experimental results.

ii. To predict performance of an EPCM-TES.
iii. To investigate effect of changing flow direction during discharging phase on

performance of EPCM-TES.
iv. To perform calculations on readings taken by apparatus.
v. To investigate effect of input parameters like HTF temperature and mass flow

rate on performance of EPCM-TES.

vi. To perform the First Law Analysis to use the stored energy in project of Solar

Refrigeration and Solar Power Generation.

1.4 Literature Review
1.4.1 Solar Thermal Technologies

Thermal Energy can be stored by different methods and technologies. By the specific

technology excess amount of thermal energy can be stored and be utilized later ranging

from small to large scales.[7] Examples of the thermal energy storage include storing the

energy from summer heat to use in winter or winter cold to use in summer as air

conditioning. Different types of the storage media can be used for the thermal energy

storage such as water, eutectic solutions and phase change materials. Now a days there

are many methods that can store the thermal energy that can be used from few days to

years. Both types of heat, latent heat and the sensible heat are used for thermal energy

storage with high temperature. Eutectic solutions of the different metals such as

4
Aluminum and Silicon (AlSi12) are used for the thermal energy storage. Renewable

energy can be utilized in major different areas such as water and air cooling and heating

and rural services. Renewable energy can be achieved from the natural process in various

forms. It can be obtained from sun or the waste materials dumped in the earth. Renewable

energy resources are the solar heat from the sun, waste materials, biofuels, biomass, wind

and oceans.[8] Solar energy, solar radiations and heat from sun is utilize by using

different methods and technologies such as photovoltaic cells and concentrated solar

power (CSP). Energy from the solar radiation can be utilized in two ways:

i. By changing the electromagnetic radiation directly into current and voltage by

using the photovoltaic cells.

ii. By absorbing the radiations in form of thermal energy storage which can be

utilized for cooling, heating, power generation and many other applications.
1.4.2 Thermal Energy Storage

One of the major part of the energy storage is the Thermal Energy Storage

(TES).Thermal energy storage systems use the different methods and technologies to

store the energy in the form of heat, electricity and other forms of energy. There are the

three methods used to store the thermal energy that are mostly used now a days. These

methods are: Latent heat based energy storage method, sensible heat based energy storage

method and the phase change material based energy storage method. In this project

Encapsulated Phase Change Material (EPCM) Based thermal energy storage method will

be used to store the thermal energy. The selection of the energy storage method depends

upon the temperature of the storage media. Thermal energy can be stored at both low

temperature and high temperature. In our work we will use the temperature range of 220

℃ , 235 ℃ , 250 ℃ , 265 ℃ and 280 ℃ .

5
 1.4.3 Latent Heat Based Thermal Energy Storage

Latent heat is the form of thermal energy which released or absorbed during a constant

temperature process. Latent heat is released or absorbed when changing the state of the

substance without changing the temperature.[9, 10] Thermal energy can be stored when

the substance reaches a temperature at which it change its phase usually from solid to

liquid.[11] At the phase change temperature material absorb a large amount of heat which

is known as latent heat of fusion.

1.4.4 Sensible Heat Based Thermal Energy Storage

The heat exchanged by a thermodynamic system or a body in which heat exchange the

temperature of the system or body is called sensible heat[12-14] Sensible heat based

thermal energy can be stored by changing the temperature of the storage media. The

storage media used for the sensible heat based energy storage are water, clay and earth. In

this system the storage medium does not change its phase by varying the temperature

range.[15] The materials that we use in this category for the high temperature are ceramic

materials, concrete and molten salts. Molten salts can be used for the thermal applications

but they have high freezing point about 100 0C.

1.4.5 Phase Change Material (PCM) Based Thermal Energy Storage

Phase change material is a substance having capability to melt and solidified at certain

temperature and store large amount of energy when changing its phase[1] i.e. from solid

to liquid and vice versa. In this work PCM capsules have 76 mm diameter. PCM are

classified as organic PCM and inorganic PCM, Eutectic and hygroscopic PCM.[2, 16]

Organic PCM are further classified into paraffin and non-paraffin PCM. Paraffin wax is

6
the common example of paraffin PCM. It’s made the straight chain n-alkanes (CH3–

(CH2)n–CH3). Non-paraffin PCM are fatty acids and glycol. Inorganic PCM are salts,

metals, alloys and salts hydrate. They include the sodium sulphate decahydrate and

calcium chloride hexa hydrate[17].

1.5 Literature Gap

Latent Heat based Energy Storage method is of great focus now a days. Reason behind is

it is more economical than other energy storage methods. A lot of research has been done

on Latent Heat Based Energy Storage method. Previous work was done on lower

temperatures ranges (150 ℃ -170 ℃ ). There was need to experiment the Latent

Heat of Energy method for higher temperature ranges. In this work experimentation was

done on higher temperature ranges (220 ℃ , 235 ℃ , 250 ℃ , 265 ℃ , 280

℃ )

1.6 Utilization of Research Results

Results obtained from experimentation EPCM-TES will be used to analyze the

experimental setup for utilization of Solar Refrigeration/AC and power generation

systems using First law analysis.

7
 CHAPTER.2: METHODOLOGY OF RESEARCH

2.1 Research Methodology

In this work experimental analysis of latent heat thermal energy storage will be done

using PCM products Limited’s H-220 (NaNO3-KNO3 in 50:50 composition) as phase

change material (PCM). The basic aim of this work is to establish utilization of EPCM

system for thermal energy storage to combine further with the Refrigeration, Air

conditioned and/or power generation systems of RERDC lab UET Taxila. This project is

continuity of three previous projects, two conducted at undergraduate and another at

Master’s level. Previous work has experimented a small scale thermal energy storage

system using Adipic acid (MP 150 C) as PCM. Master’s work established the current

system’s performance using mathematical modelling and simulation. While in third

project designing, fabrication and testing of apparatus was done. In this work first of all

apparatus was examined. It was founded that oil pump sealing’s were break downed. Two

solutions were suggested to solve this problem. First, oil pump may be replaced. Second

sealing’s may be replaced. Both solutions were approached. Replacement of sealing was

easy solution so it was adopted. For replacement of oil pump another oil pump was

purchased. Re-examination of apparatus was done and apparatus was brought to running

condition. For safely operate the project safety operating procedure (SOP) was

developed. Operating input temperatures were decided as 220 ℃ , 235 ℃ , 250

litr .
℃ , 265 ℃ , 280 ℃ . Operating input flow rates were decided as 4 , 3.33
min

litr . litr .
, and 2.67 , for 3000RPM, 2500RPM and 2000RPM respectively.
min min

8
Steps for executing the project are as under:

1) Install, examine and bring the apparatus to running condition

2) Develop SOP, and design of experiment
3) Conduct detailed experimentation under different flow rates and inlet

temperature conditions
4) Process the experimental data to obtain secondary results
5) Compare with theoretical simulation
6) Analyze EPCM-TES compatibility with Solar Refrigeration/AC and power

generation systems using First law analysis

Install and bring apparatus to running condition

Develop SOP and Design of Experimentation

Conduct Detailed Experimentation at varying

Temperatures and Flow-rates

Analyze experimental data and compare with

theoretical simulation

First Law Analysis for (i)Solar Refrigeration

(ii)Solar Thermal Power

Figure 1 Flow Diagram of the Methodology

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 2.1.1 Experimental Analysis

There are four main components of EPCM-TES.

 Control panel

 Oil storage tank

 Positive displacement pump

 Energy storage chamber

Control Panel

By control panel functionality of heaters installed in oil storage tank, flow rate of heat transfer

fluid, are being controlled.

Oil storage tank

Oil storage tank has three heaters installed in it which serve as solar energy source. Their

temperature can be controlled by temperature controller on control panel. Heaters installed in oil

storage tank are of 6 watt each providing cumulative power of 18 watt. Therefore to operate this

apparatus, power source of 18 watt and 3 phase supply is required. Oil stored in tank serves as

heat transfer fluid (HTF).

Positive Displacement Pump

Pump is used to circulate HTF to or from energy storage chamber. Direction of flow is controlled

by gate valves on piping system. Speed of pump can be controlled from control panel.

Energy Storage System

It has two chambers insulation chamber and energy storage chamber. Insulation chamber has 15

inch glass wool insulation. This insulation is provided to minimize heat losses from energy

11

Figure 2 Experimental Setup for Performance Analysis of Phase Change Material Based Thermal
Energy Storage System.
storage system. However a lot of heat is lost from energy storage chamber. To calculate

temperature, thermocouple are installed at different spots in insulation chamber.

Energy is stored in this chamber as latent heat. To store energy this chamber has 10 inline

vertically placed cylindrical shaped capsules. Capsules are filled 80% with H-220 (NaNO3-

KNO3) as phase change material and 20% void space. Capsules are made up of stainless steel of

grade 316. In charging cycle HTF moves from bottom to top while in discharging cycle HTF

moves from top to bottom in storage chamber. Thermocouples are installed inside the chamber to

get temperature readings. Further energy losses and energy stored is calculated by these

temperature values.

Heat exchanger is used to transfer heat from HTF in discharging cycle to determine how much

stored energy can be utilized. Temperature from thermocouples installed at different locations are

obtained on PC display using Data Acquisition System. LABVIEW software is used to display

temperature readings on display and it also communicates between DAQ and PC.

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 Figure 3 DAQ 1

Figure 4 DAQ 2
.1.2 Comparative Analysis

Obtained results from experimental analysis were compared with mathematical

simulation[18] performed earlier on this project.

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 2.2 Work Schedule Plan

Proposed work plan is described in the table below.

Se Oc No De Ja Fe March Ap Ma Jun

p t v c n b r y e

Topic Selection

Literature Review

Maintenance of
Apparatus

Experimentation

Semester Report
Preparation

Results

Thesis
Preparation

Journal Paper

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.3 Budget Description

Unit Quantit
Sr.no Apparatus Required Total Cost
Cost y

1 Gendorri Pump 5500 1 5500

2 Exhaust Fan 2500 2 5000

3 Shell S-2 Oil for Makeup 25litre 8000 1 8000

Manufacturing/ Maintenance
4 5000 1 5000
Cost

5 Total Cost 23500

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 CHAPTER.3: MATHEMATICAL ANALYSIS

.1 Mathematical Model

Thermal Energy storage is essential for CSP technologies (like parabolic trough or solar

power towers) to meet energy requirements during night and cloudy days. The thermal

energy storage under current investigation contains s 10 cylindrical EPCM capsules filled

with a suitable material, and placed inside a rectangular chamber, in inline arrangement.

Thermocouples are installed into capsules and on outside of capsules to calculate

temperatures.

Figure 5-Arrangement of Thermocouples in Storage

Tank

16
The hot fluid coming from CSP receiver, flows across the EPCMs transfer some of its

energy to PCM and moves out at a lower temperature. The temperature of PCM inside

capsules rises until it reaches phase change temperature, then the PCM starts melting,

the temperature of PCM continues to rise beyond phase change temperature if

sufficient time is allowed to continue heat transfer and fluid inlet temperature is

sufficiently higher than phase change temperature of PCM to allow effective heat

transfer. On the other hand, when thermal energy is required for any operation, cooler

fluid moves into the TES chamber, gets thermal energy from the PCM capsules and

moves out at an elevated temperature. This hotter fluid can then be utilized for steam

generation in a Steam turbine power plant, or any other application desired. For

comprehensive thermal analysis of this system a reasonable mathematical model for

simulation was developed to analyze effect of various parameters on the performance

of EPCM TES.

Figure 6-Schematic of Thermal Energy Storage for Mathematical Model (a) side view
showing EPCM capsules in Inline arrangement, (b) Front view

17
 Figure 7-Description of Energy Interactions between Components of TES Chamber in One
Section

.2 Energy Balance Equations

Consider for each section of the TES (Fig. 7), HTF enters at a temperature of 𝑇�, imparts

some of its energy to Capsule (𝑄𝑐𝑎𝑝𝑠𝑢𝑙�) and Chamber (𝑄𝑐ℎ𝑎𝑚𝑏��), and leaves at a

temperature of (𝑇�) to the next section immediately below this during a time step ∆�. The

exit temperature (𝑇�) can be expressed using explicit formulation as follows.

Equation 1

where �̇�� is the rate of Energy of HTF entering the section [�/𝑠], �̇𝑜𝑢� is the rate of

Energy of HTF leaving the section [�/𝑠], 𝑄𝑐𝑎𝑝𝑠𝑢𝑙� is the rate of heat transfer from

HTF to capsule shell [ ], 𝑄𝑐ℎ𝑎𝑚𝑏�� is the rate of heat transfer from HTF to the

stainless steel chamber of test section [ ], 𝑚̇ � is the mass flow rate of HTF, 𝐶𝑝𝑎𝑣� is

18
the specific heat of the HTF at average temperature of HTF 𝑇�𝑎𝑣� = (𝑇� + 𝑇�)/2 [ ]. It
Th
is important to note that all properties on the R.H.S of equation are calculated at

time step, while 𝑇� on the L.H.S of the equation is determined for � + 1th time step.

However formal symbols of time step on R.H.S are avoided to keep the expression

simple.

The values of �̇��, �̇𝑜𝑢�, 𝑄𝑐𝑎𝑝𝑠𝑢𝑙�, and 𝑄𝑐ℎ𝑎𝑚𝑏�� can be determined as follows:

Equation 2

-
Equation 3

Equation 4

Equation 5

Where ℎℎ (𝑇�) and ℎℎ (𝑇�) are specific enthalpy of HTF at inlet and exit of the

section respectively [�/𝑘�], ℎ𝑐𝑎𝑝−𝑠𝑢� and ℎ𝑐ℎ𝑎𝑚𝑏−𝑠𝑢� are convection heat transfer

coefficients at the capsules and chamber surfaces respectively [�/𝑚�], 𝐴𝑠𝑐𝑎𝑝 and

𝐴𝑠𝑐ℎ𝑎𝑚𝑏�� are the surface areas of capsules and chamber surface respectively [𝑚2], and

19
𝑇𝑐𝑎𝑝 and 𝑇𝑐ℎ𝑎𝑚𝑏 and temperatures of capsules and chamber surfaces respectively [ ].

The convection heat transfer coefficient for capsule surface is calculated using the

Zhukauskas correlation for the specified configuration of PCM capsules. The

convection heat transfer coefficient at the chamber surface is calculated assuming that

the flow of HTF at the chamber surface is similar to that across the PCM capsules.

The temperatures of Capsule shell, PCM, Chamber and insulation respectively can be

expressed as follows:

Equation 6

Equation 7

Equation 8

Equation 9

20
where 𝑄𝑃𝐶� is the rate of heat transfer from capsule shell to the PCM [ ], 𝑄��𝑠𝑢 is the

rate of heat transfer from stainless steel chamber to insulation [ ], 𝑚̇ 𝑐𝑎𝑝, 𝑚̇ 𝑃𝐶�, 𝑚̇

𝑐ℎ𝑎𝑚𝑏 and 𝑚̇ ��𝑠𝑢 are the masses of capsule shell, PCM, chamber and insulation in each

section respectively [𝑘�], 𝐶𝑝𝑐𝑎𝑝, 𝐶𝑝𝑃𝐶�, 𝐶𝑝𝑐ℎ𝑎𝑚𝑏, 𝐶𝑝��𝑠𝑢 are the specific heat capacities

of these components respectively [�/𝑘��], �𝑃𝐶� the latent heat capacity of the PCM

[�/𝑘�], and ∆∅𝑃𝐶� is the change in melt fraction of the PCM material during the time

step ∆�. Since, lumped model is assumed for PCM any amount of energy added or

removed at any temperature other than melting temperature will be in sensible form,

while heat addition or removal from PCM when it is at melting temperature will be

purely latent, causing the melt-fraction of PCM to change, until the PCM inside a

capsule changes phase completely.

The values of 𝑄𝑃𝐶� and 𝑄��𝑠𝑢 can be determined by using the following expressions:

Equation 10

Equation 11

Where 𝑘���𝑃𝐶� and 𝑘�����𝑠𝑢 are effective thermal conductivities for use with lumped

models of transient charging and discharging of PCM inside cylindrical EPCM and plane

insulation respectively [�/𝑚�], 𝐴𝑠𝑐𝑎𝑝 and 𝐴𝑠��𝑠𝑢 are surface areas of capsule surface and

insulation respectively.

21
 .3 Simulation Results
The current investigation utilizes the mathematical model developed in previous chapter

to perform parametric analysis to evaluate the thermal performance of an EPCM-TES.

The proposed TES chamber consists of 10 EPCM capsules (Table 5-1) filled with

inorganic PCM NaNO3-KNO3 (50:50) obtained from PCM Products Limited, UK with

the brand name of Plus ICE H-220. Shell S-2 is used as heat transfer fluid. Rectangular

test section containing cylindrical capsules arranged vertically in an in-line arrangement

is selected. This particular arrangement is selected because it is found suitable for such

type of application in recent studies.

The Performance of EPCM-TES is evaluated by varying the following parameters:

• Inlet temperature of HTF
• HTF Mass Flow Rate
• Size of PCM Capsule
• No. of Capsules
• Direction of Flow in Discharging phase

An in-depth analysis is performed to view the effect of variation in these parameters on

thermal performance of EPCM-TES system. The effect of varying these parameters on
performance of EPCM-TES is presented in terms of the following indicators.

• Temperature evolution of Capsules

• Outlet Fluid Temperature and Change in Temperature of HTF across TES

• Thermal Energy Storage

• Rate of Heat Transfer
• Evolution of Melt-Fraction over time
• Percentage of Energy from HTF stored in H-220 Capsules
• Maximum Energy Stored vs. Varying parameter

22
Phase Change Material Plus ICE H-220 PCM Melting Temp. 220 oC
Heat Transfer Fluid Shell S-2 Oil
Test Section
Height of TES chamber 1100 mm Chamber Wall Thickness 5 mm
Length of TES chamber 260 mm Chamber Material Stainless-
steel
Width of TES chamber 93 mm Insulation thickness 15 cm
Capsules
No. of Capsules 10 Shape Cylindrical
Capsule Size (Dia.) 76 mm Capsule length 256 mm
Distance between 16.6 mm Lateral pitch 16.6 mm
Wall Thickness 3.175 mm
PCM filling 80% Void 20%
HTF Flow Direction Bottom to Top
Table 1-Basic Model of Thermal Energy Storage for Numerical Simulations

The Energy stored in PCM capsules increase in time span of 1.7 hours. For a mass flow

of 0.01 kg/s, only 7.5 MJ energy could be stored. While for flow rate of 0.05 kg/s, and

energy as high as 10 MJ could be stored, an increase of 33%

23
 CHAPTER.4: EXPERIMENTAL ANALYSIS

.1 Calculations
Heat transfer fluid

Density

Density= 876 kg/m3 at 0oC

Density changes with a factor of 0.65/oC. So in general,

Density = 876 – (Temperature × 0.65)

Mass flow rate

Pump gives 4 ltr/3000rpm

2.67 ltr per 2000 rpm (Currently running rpms)

Mass flow rate = volume × density

Volume displaced = 2.67 ltr/ min= 2.67 × 10-3m3/ 60 sec

=0.00004445 m3/sec

So,

Mass flow rate = 0.00004445 × density

Specific Heat capacity Cp

Cp =1.809 kj/kg at 0oC

Value of Cp increases with factor of 0.0036 per oC

24
Cp = 1.809 + (0.0036 × average temperature)

Energy Transferred

Energy transferred = mass × Cp × temperature difference

Insulation

Outer volume = 0.367725 m3

Inner volume = 0.041937 m3

Insulation volume = Vouter – Vinner = 0.3258 m3

Density = 19 kg/ m3

Mass = density × volume = 0.3258 × 19

Mass = 6.1902 kg

Cp =0.67 kj / kg.k

Energy consumed = mass × Cp × ΔTaverage

Inner Chamber

Area = Height × Width = 1100 × 305 mm2 = 0.3355 m2

Volume = Area × Thickness = 0.3355 × 0.005 m3 = 0.001678 m3

(* Thickness= 5mm)

kg
Density = 7850
m3

Mass = Density × Volume = 7850 × 0.01678 = 13.16838 kg

25
 kj
Cp = 0.62
kg . k

Energy Transferred = Mass × Cp × ∆Tavg

Energy transferred in Capsules

Energy Transferred = Total Energy Transferred – (Energy consumed by Insulation +

Energy consumed by inner Chamber)

Dimensions

H1 =1397 mm, H2 =1100 mm

W1 = 609.6 mm, W2 = 305 mm

L1 = 431.8 mm, L2 = 125 mm

V1 = 0.367 m3, V2 = 0.041937 m3

Insulation Volume = 0.3258 m3

26
.2 Annexures

27
28
29
30
31
32
33
 Conclusion

The concern of present work is Experimental analysis of phase change material based

thermal energy storage system. Temperature range for experimentation was selected 220

℃ , 235 ℃ , 250 ℃ , 265 ℃ , 280 ℃ . Another input factor was flow rate

of HTF. Flow rates were decided as 3000RPM, 2500RPM and 2000RPM. This project is

continuity of three previous projects. Apparatus for experimentation was designed and

fabricated in last project. Diameter of PCM Capsule was selected 76 mm with 20%

empty space in it. Shell S-2 was selected as HTF. PCM products Limited’s H-220

(NaNO3-KNO3 in 50:50 composition) was selected.as phase change material (PCM). In

this work experiment was done for both charging and discharging cycles. Purpose was to

check the efficiency of apparatus for energy storage and its utilization.
By experimentation it is concluded that experimental setup can be used for Solar

Refrigeration/AC and power generation systems using First law analysis placed in R&AC

lab. Experimental calculation is compared with mathematical simulation results. It is

found that a lot of energy is lost during experimentation. Reason behind observed is that

lamination of Apparatus is not so good. If lamination of project is improved a lot of

energy can be saved from being lost. It is also observed that PCM used was not preferable

for high temperature ranges of the order of 300 ℃ and onward. So it is advice able if

apparatus is to be used for higher values of temperature one must change PCM material.

34
 Abbreviations

UET University of Engineering and Technology

CSP Concentrating Solar Power
PCM Phase Change Material
EPCM Encapsulate Phase Change Material
TES Thermal Energy Storage
HTF Heat Transfer Fluid
DAQ Data Acquisition System

AC Air Conditioning

SOP Standard Operating Procedure

R&AC Refrigeration and Air Conditioning

CUST Capital University of Science and Technology

GIKI Ghulam Ishaq Khan Institute

TC Thermocouples

35
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