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Heat Transfer Characteristics During Melting and Solidification of Phase Change Energy Storage Process
Heat Transfer Characteristics During Melting and Solidification of Phase Change Energy Storage Process
This study focuses on heat transfer characteristics of phase change material (PCM) during energy
storage and release in vertical double pipe configuration. Paraffin wax with an average melting
temperature of 52 °C is used as the energy storage material and water is used as the heat transfer
fluid (HTF). The heat transfer fluid flows in the inner tube and the wax is stored on the shell
side. Eighteen thermocouple wires are placed in the wax to provide a detailed measurement for
the temperature field during energy storage and release. Measurements are made as a function
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of the flow direction, flow rate, and inlet temperature of the heat transfer fluid. Results indicate
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that natural convection dominates the melting process for upward flow of the heat transfer fluid.
On the other hand, the solidification process is dominated by conduction. During melting and
upward flow of the HTF, the density difference of hotter and cooler molten wax layers initiates
natural convection cells. Further mixing within the melt is also caused by descent of the higher
density solid wax.
Introduction and release times upon storing the PCM on the shell
side. The study by Choi and Kim11 focused on heat
Endeavors of researchers to secure clean and envi- transfer by use of finned tubes. The results show 4-fold
ronmentally friendly energy sources include use of enhancement upon the use of finned tubes. This is
energy storage systems. These systems can be used to caused by the increase in the effective thermal conduc-
store energy for household and industrial applications. tivity of the phase change material due to high thermal
Also, energy storage units can be combined with non- conductivity of the metal fins. Plate heat exchangers
fossil and sustainable energy sources, such as solar, provide higher heat transfer coefficients than regular
ocean thermal, tidal, wind, and geothermal energies. shell and tube heat exchangers.12 This should reduce
Irrespective of the attractive features of the energy drastically the required system volume for the same
storage systems its use remains to be found on a very thermal capacity. Also, charge and release times are
limited scale. This is caused in part by the lower prices reduced considerably. However, use of plate heat ex-
of fossil fuels and the huge field of experience in design, changers remains to be found on a limited scale. This
construction, and operation of fossil fuel power plants. is because of the lack of field experience and industrial
Studies of energy storage systems were motivated in standards. Also, the number of manufacturers and
part by the rising energy costs during the second half selection choices are quite limited for the shell and tube
of the twentieth century and the need for these con- configuration. Use of spherical capsules to store the
figurations in space applications. Earlier studies focused PCM is motivated by the fact that spheres provide the
on development of full-scale household devices, i.e., solar highest specific surface area. Spherical shells are used
ovens,1 water heaters,2 etc. Results of these studies for ice formation in large tanks during off-peak load
indicated the need for better understanding of various hours.13 Ice melting during the daytime would provide
aspects of the melting and solidification through de- lower cost air conditioning and cooling applications.
tailed modeling and experimental investigations. Ex- Experimental evaluation of the natural convection role
amples for mathematical modeling and analysis include inside the spherical capsules14 show a stronger role
the studies by Sparrow et al.,3,4 Green et al.,5 Zhang et
during melting than solidification. Also, the natural
al.,6 and Chen.7 Results of these studies show a limited
convection role is enhanced by the increase in the
role of natural convection during the solidification
diameter of the spherical capsule.
process. On the other hand, natural convection is found
to drastically enhance the melting process.8,9 Experi- Use of paraffin wax as PCM has a major drawback of
mental investigations focused on development of the low thermal conductivity, which would increase the
heat exchange configuration. These developments in- melting and solidification times. This problem is ad-
cluded shell and tube,10 double pipe,11 plate,12 or spheri- dressed through the use of finned tubes15 as well as
cal shells.13,14 The study by Esen et al.10 was conducted metal fiber,16 metal matrix inserts,17 or metal beads and
for energy storage and release in shell and tube heat screens.18 These attempts resulted in higher effective
exchange units. Results indicate shorter energy storage thermal conductivity and heat transfer enhancement of
1- to 5-fold. This is achieved with replacement of less
than 5% in volume of the wax with the tube fins or
* To whom correspondence should be addressed. Tel.: various forms of metal structures.16-18
965-481-1188, ext. 5619. Fax: 965-483-9498. E-mail: hisham@
kuc01.kuniv.edu.kw. The focus of this study is to evaluate natural convec-
†
Kuwait University. tion effects during melting and solidification of paraffin
‡
Environment Public Authority. wax in double pipe heat exchange systems. The main
10.1021/ie030495b CCC: $27.50 © 2004 American Chemical Society
Published on Web 07/15/2004
Ind. Eng. Chem. Res., Vol. 43, No. 17, 2004 5351
(not applicable).
Fo ) aBibStc (1)
Figure 3. Transient temperature profiles in PCM, surrounding
where a, b, and c are fitting constants, and Fo, Bi, and
air, and HTF for downward HTF flow, TiH (hot) ) 85 °C, TiH (cold)
St are Fourier, Biot, and Stefan numbers, respectively. ) 15 °C, MH ) 0.303 kg/s.
It should be noted that (TP) in Stefan number is set
equal to the PCM melting temperature for melting, and for downward flow of the HTF. In presence of natural
for solidification (TP) is set equal to the PCM temper- convection, or upward flow of the HTF, the Nusselt
ature at the start of the solidification cycle. number correlation is expressed in terms of Rayleigh
Melting and Solidification Nusselt Number. The (Ra), Stefan (St), and Fourier (Fo) numbers
model equations for solidification are similar for those
of melting; however, the temperature differences in eqs
Nu ) aRabStcFod (7)
3 and 4 must be reversed for solidification to take into
consideration heat transfer from the PCM into the HTF.
Results and Discussion
The heat transfer coefficient of the PCM during melting/
solidification is obtained from the definition of the heat The experimental system is operated for the following
transfer resistance between the PCM and the HTF, set of conditions: (a) flow rates of HTF are 0.238-0.37
which is given by kg/s; (b) inlet temperatures of heating HTF are 65-85
°C; and (c) inlet temperatures of cooling HTF are 10-
1 20 °C.
hP ) (2)
1 DoHln(DoH/DiH) DoH In addition, the system is operated at the following
- - modes: (a) melting (energy storage) and solidification
U 2kw DiHhH (energy release); and (b) upward and downward HTF
flow.
The overall heat transfer coefficient (U) used in eq 2 The following points should be mentioned regarding
is obtained from the heat transfer rate equation for the the discussion and the developed correlations. The
energy storage system, which is given by correlations developed in the following sections are valid
for the above experimental ranges as well as the type
U ) MHCpH (TiH - ToH)/(AH × LMTD) (3) of PCM and HTF used in the measurements and the
geometry of the energy storage unit. A limited number
The logarithmic mean temperature difference for melt- of illustrations is given in the following sections. How-
ing, LMTD, is defined by ever, the discussion covers all experimental conditions
considered in the measurements.
(TiH - T1) - (ToH - T13) Transients of Axial and Radial Temperature
LMTD ) (4) Profiles. The measured data for the axial temperature
ln((TiH - T1)/(ToH - T13)) profiles at the outer surface of the HTF tube are shown
in Figure 3. The data set includes the melting and
In eq 4 T1 and T13 are the PCM temperatures at the solidification modes. Also, the temperature profiles for
same level of the inlet and outlet HTF, respectively. In the inlet and outlet HTF and the surrounding air are
eq 2, the heat transfer coefficient for the HTF is shown in the figure. Analysis of the measured axial
calculated from the Dittus and Boelter equation. temperature profiles shows the following: (a) The
temperature difference of the inlet and outlet HTF for
hH ) 0.023 Re0.8PrakH/DiH (5) cooling or heating vary over a range of 0.5-2 °C. (b)
Downward flow of the HTF results in a higher temper-
where a ) 0.3 (for cooling) and a ) 0.4 (for heating). Re ature for the PCM located at the top of the tube than
and Pr are the Reynolds and Prandtl numbers. The heat the PCM located at the bottom of the tube. This behavior
transfer coefficient for the PCM given by eq 2 is used remains unaltered throughout the experiment even
to obtain the Nusselt number correlation. For solidifica- after melting of the PCM. This is because the molten
tion the Nusselt number is found to have negligible wax has lower density than the solid wax. Also, the melt
dependence on natural convection. Therefore, the cor- density decreases with temperature increase. This
relation for Nuseelt number during solidification is implies that for downward HTF flow the system will be
defined in terms of the Stefan (St) and Fourier numbers, stable with no natural convection effects. (c) Upward
where flow of the HTF results in higher temperature for the
PCM located at the bottom of the tube. This behavior
Nu ) aStbFoc (6) is altered as the PCM starts to melt. This is because
the hotter melt with lower density moves to the top part
Equation 6 is valid for both cases of upward or down- of the tube. Consequently, unmelted solid wax and
ward flow of the HTF. Also, it is valid during melting cooler molten wax would descend to lower part of the
Ind. Eng. Chem. Res., Vol. 43, No. 17, 2004 5353
PCM tube. The upper motion of the hotter molten and Figure 5. Transient variations in PCM radial temperature
the downward motion of the cooler molten wax would profiles at three axial locations for solidification, downward HTF
forms natural convection cells. This would enhance flow, TiH ) 15 °C, and MH ) 0.238 kg/s.
mixing within the PCM melt. (d) The PCM approaches
the HTF temperature more rapidly as the HTF tem- the large temperature differences between the PCM and
perature is increased. This is because of the increase the HTF at small times. However, for large times the
in the driving force for heating. Increasing the HTF flow PCM temperature approaches the HTF temperature.
rate gives a similar but less pronounced effect. This is Transient Temperature Contours. Transient tem-
because of the increase in the system thermal load. perature contours are shown in Figures 6 and 7. Figure
The transients of the radial temperature profiles 6 corresponds to large operating times, where the entire
during melting and solidification are shown in Figures PCM has changed to the molten phase. As is shown in
4 and 5, respectively. Examining the data shown in
Figure 6, the melt is formed of several horizontal layers
these figures confirms the findings for the transient data
of hotter melt on top of colder melt. The lowest temper-
for the axial temperature profiles along the outer
ature is found in the lower outer perimeter of the PCM
surface of the HTF tube. However, the transients of the
radial temperature profile at three axial locations give tube.
a more detailed picture for the melting and solidification The temperature contours during solidification show
processes, where: (a) the radial temperature profiles radial progression from the outer surface of the HTF
indicate higher temperature near the HTF tube during tube. As is shown in Figure 7 the coldest zone is found
the melting process and lower temperature during near the HTF tube and hottest zone is found near the
solidification, (b) at the outer surface of the PCM tube, outer surface of the PCM tube. The solidification
the temperature profile has zero gradient because of the isotherms are almost vertical and the solid layers have
effect of the insulation layer,. (c) melting and solidifica- a shape similar to that of the HTF tube. Natural
tion rates are high at small times. However, these rates convection effects during solidification are negligible
diminish at larger times. The high rates are caused by because of the continuous decrease in the melt volume
5354 Ind. Eng. Chem. Res., Vol. 43, No. 17, 2004
Figure 6. Temperature field in PCM for melting, downward HTF Figure 9. Variation in PCM Nusselt number during melting,
flow, TiH ) 65 °C, MH ) 0.238 kg/s. upward HTF flow, and as a function of Fourier number.
Conclusions
Experimental measurements are performed for phase
change energy storage in paraffin wax. The system is
formed of a vertically aligned double pipe configuration.
In this system, the heat transfer fluid is routed in the
inner tube. On the other hand, the PCM is kept in
Figure 16. Variation in PCM Fourier number during solidifica- annulus of the two pipes. The experiments included
tion, upward HTF flow, and as a function of the HTF temperature. measurements of melting and solidification times as
well as the temperature field within the PCM. These
of the cooling HTF is caused by the decrease in the
data were used to calculate the system thermal load,
driving force for heat transfer. As a result the solidifica-
the heat transfer coefficients within the PCM and HTF.
tion time increases with the increase in the HTF
The results of the experimental measurements were
temperature. Scatter of the data at constant HTF is
then used to calculate a number of dimensionless groups
caused by variations in the initial PCM temperature,
that include Nusselt number, Fourier number, Biot
where higher Fourier numbers correspond to higher
number, Stefan number, and Rayleigh number. The
initial PCM temperatures. Also, part of the scatter is
dimensionless groups were then correlated to develop
caused by variations in the HTF flow rate.
empirical relations for the Nusselt and Fourier num-
Correlation of Fourier Number. The Fourier num-
bers.
ber gives a measure of the melting or solidification
The measured temperature field during melting and
times. Fourier number is proportional to the Biot and
solidification is a new addition to the literature of phase
Stefan numbers in the PCM. The Biot number is the
change energy storage systems. Measured data and
ratio of the heat transfer rate by convection to conduc-
analysis show the presence of natural convection during
tion, while the Stefan number gives the ratio of the
melting for the case of upward HTF flow. On the other
sensible heat to the latent heat. In the Stefan number,
hand, natural convection effects are negligible during
∆T depends on the phase change process, i.e., melting
melting for the case of downward HTF flow. Similarly,
or solidification. For melting, ∆T is equal to the differ-
solidification is dominated by condition and has negli-
ence between the hot HTF and the PCM melting
gible dependence on the HTF flow direction.
temperature. For solidification, ∆T is equal to the
temperature difference of the PCM at the start of the
cooling cycle and the cold HTF temperature. Acknowledgment
The Fourier number correlations include the follow- This research was supported by the Research Admin-
ing: (a) melting with downward HTF flow istration of Kuwait University, projectELC-012.
Fo ) 0.5848 St-1.3196 Bi -0.0457 (12)
Nomenclature
with a coefficient of determination equal to 0.99; (b) A ) Heat transfer area, m2
melting with upward HTF flow Bi ) Biot number, Bi ) hH req/kP
Cp ) Specific heat at constant pressure, kJ/kg K
Fo ) 0.8118 St-1.2928 Bi -0.0957 (13) D ) Tube diameter, m
Fo ) Fourier Number, dimensionless, Fo ) (RPt)/(req)2
with a coefficient of determination equal to 0.98; (c)
g ) Gravitational acceleration, m/s2
solidification with downward HTF flow
h ) Heat transfer coefficient, kW/m2 °C
k ) Thermal conductivity, kW/m K
Fo ) 50.956 St1.3199 Bi -0.8737 (14)
LMTD ) Logarithmic mean temperature difference, °C
with a coefficient of determination equal to 0.89; and M ) Mass flow rate, kg/s
(d) solidification with upward HTF flow Nu ) Nusselt Number, dimensionless, Nu ) hP req/kP
Pr ) Prandtl number, dimensionless, Pr ) CpH µH/kH
Fo ) 262.285 St1.7196 Bi -1.1884 (15) req ) Equivalent tube radius, req ) (DoH - DoP)/2, m
Ra ) Rayleigh number, dimensionless, Ra ) gβP CpP
with a coefficient of determination equal to 0.89. F2P req3∆TH/µPkP
The above results show higher coefficient of determi- Re ) Reynolds number, dimensionless, Re ) 4MH/πDiHµH
nation for the melting process. This is because time St ) Stefan number, dimensionless, St ) CpP ∆TH/λP
measurements for all experiments cover the same t ) Time, s
temperature range, i.e., room temperature to melting T ) Temperature, °C
temperature. On the other hand, measuring the solidi- ∆TH ) Temperature scale in Rayleigh and Stefan numbers,
fication time is not as accurate. This is because switch- ∆TH ) TiH - Tm, °C
ing between the hot and cold HTF is made as all ∆TP ) Temperature difference between bottom and top of
thermocouple readings exceed the melting point. As molten PCM, °C
mentioned before, the measuring cycle for all thermo- U ) Overall heat transfer coefficient, kW/m2 °C
Ind. Eng. Chem. Res., Vol. 43, No. 17, 2004 5357