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Solidification of PCM around a finned tube: modeling and experimental

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 Journal of Basic and Applied Research
International
12(2): 115-128, 2016
ISSN: 2395-3438 (P), ISSN: 2395-3446 (O)
International Knowledge Press
www.ikpress.org

SOLIDIFICATION OF PCM AROUND A FINNED TUBE:

MODELING AND EXPERIMENTAL VALIDATION

KAMAL A. R. ISMAIL1*, MONICA M. GONÇALVES1 AND FATIMA A. M. LINO1

1
Department of Energy, Faculty of Mechanical Engineering, State University of Campinas,
UNICAMP, Mendeleiev street, 200, Cidade Universitária “Zeferino Vaz”, CEP 13083-860,
Campinas (SP), Brazil.

AUTHORS’ CONTRIBUTIONS
This work was carried out in collaboration between all authors. Author KARI head of the research group,
responsible for the research, modeling of the process, analysis and discussion of the results, and proof reading of
the manuscript. Author MMG programming and numerical treatment, Preparation of the graphs, initial
discussions. Author FAML Experimental measurements, literature revision, final check of the results and proof
reading of the manuscript. All authors read and approved the final manuscript.

Received: 7th August 2015

Accepted: 25th August 2015
Published: 14th September 2015 Original Research Article
__________________________________________________________________________________

ABSTRACT

This paper presents the results of an investigation on axially finned tubes to enhance the processes of charging
and discharging thermal storage units. The proposed model is based upon pure conduction in the solid and liquid
phases. The enthalpy approach and the finite volume method were used in the numerical treatment. The
Alternating Direction Implicit scheme (ADI) was used together with finite difference to discretize the
differential equations and the associated initial and boundary conditions. The grid points and the time step were
optimized. The numerical predictions were compared with experimental results and relatively good agreement
was observed. It was found that increasing the radial length of fins or their number enhances solidification and
reduces the time for complete phase change. The increase of the symmetry circle radius was found to increase
the complete solidification time while the increase of the fin thickness showed little influence on the
solidification process.

Keywords: Solidification; PCM; axially finned tube; energy storage.

NOMENCLATURES
C Specific heat [J kg-1K-1]
C (T ) Heat capacity per unit volume including phase change [J m-3 K]
C(T )
~
Dimensionless heat capacity per unit volume including phase change
H Enthalpy per unit volume [J m-3]
k Thermal conductivity [W m-1 K-1]
k (T ) Thermal conductivity including phase change [W m-1 K-1]

_____________________________________________________________________________________________________

*Corresponding author: Email: kamal@fem.unicamp.br;

 Ismail et al.; JOBARI, 12(2): 115-128, 2016

k (T )
~
Dimensionless thermal conductivity including phase change;
L Latent heat [J kg-1]
lf (
Dimensionless fin length = r f − rw rw )( )
nf Number of fins
r Radial coordinate [m]
R Dimensionless radial coordinate = r rw
rf Fin extreme radius [m]
rw External radius of the tube [m]
ri Internal radius of the tube [m]
re Radius of external cylinder or radius of the symmetry circle [m]
rs Radial position of the solid / liquid interface [m]
Tm Phase change temperature [K]
Tw Tube wall temperature [K]
tc Time for complete solidification.
tf Dimensionless thickness = fin thickness/rf

GREEK LETTERS
δ Dirac delta function
∆T Half the phase change temperature range [K]
θ Tangential coordinate [0]
θf Half fin angle [0]
θm Half angle between two successive fins [0]
η (u) Unit function
λ Latent heat per unit volume [J m-3]
φ Dimensionless temperature = (Tm − T ) (Tm − Tw )
ρ Density [kg m-3]
kst
τ Dimensionless time = τ=
C s ri2
τc Dimensionless time for complete solidification
ε Dimensionless phase change temperature range = (∆T ) (Tm − Tw )

SUBSCRIPTS
f Fin
l Liquid
s Solid
w Wall

1. INTRODUCTION years because of their high heat storage capacity and

Thermal energy storage such as latent heat thermal
energy storage can reduce the energy supply–demand
mismatch and improve the efficiency of thermal
energy systems because of its high thermal energy
density per unit volume.
The commercial acceptance of alternative thermal
technologies is tied to the development of efficient,
cost-effective thermal storage systems. Thermal
storage systems that utilize latent heat storage
materials have received greater attention in recent
their isothermal behavior during the charging and
discharging processes.
One major issue that needs to be addressed is that
most phase-change materials (PCM) with high energy
storage density usually have low thermal conductivity
which impairs their thermal performance. Hence heat
transfer enhancement techniques are required for most
latent heat thermal storage applications. Many
methods were investigated to increase the charging
and discharging rates by increasing the effective
thermal conductivity of the PCM, but very few were

116

implemented in practice mainly because of the
awkward conception and difficulties associated with
operation or both. The literature is rich with analytical,
numerical and experimental investigations on phase
change in latent heat storage systems. In this section,
the literature review will be restricted to enhancement
of phase change around finned tubes in storage
systems.
Finned geometries were investigated with the
objective of reducing the undesired effects of natural
convection and increase the heat transfer rate [1,2]. A
numerical study on an axially finned tube spanning
the cylindrical annulus was realized by Padmanabhan
and Murthy [3]. Their model was based on pure
conduction and the equations were solved by finite
difference approach. Ismail and Alves [4] and Ismail
and Gonçalves [5] studied the phase change around
axially finned tubes submersed in the PCM.
Lacroix [6] presented a theoretical model for
predicting the transient behavior of a shell-and-tube
storage unit with the PCM on the shell side. The
numerical model was validated with experimental
data. Other studies were realized on finned tube both
numerically and experimentally as in [7-11].
Stritih [12] studied experimentally the heat-transfer
characteristics of a latent-heat storage unit with a
finned surface and compared the results with those of
a heat-storage unit with a plain surface.
Mohamed [13] investigated the enhancement of the
solidification of phase change material around a
vertical cylindrical surface by generating air bubbles
in the phase change material to accelerate the ice layer
growth at the solid–liquid interface. The effect of air
bubbles agitation was found to increase the ice layer
growth rate and solidification front velocity by about
of 20–45%. As a consequence the stored thermal
energy was increased by about 55–115% with
increasing air bubbles flow.
Shokouhmand and Kamkari [14] presented a
numerical investigation on melting of PCM inside a
double pipe heat exchanger. They performed
numerical simulations for melting of PCM in an
annulus with inner finned pipe and compared the
results with those of finless tube. They concluded that
melting can be enhanced by using longitudinal fins on
the inner tube.
Basal and Unal [15] presented an investigation on
thermal energy storage system consisting of a triple
concentric-tube arrangement to achieve performance
enhancement. A numerical investigation was
conducted by using enthalpy method and the effects
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Ismail et al.; JOBARI, 12(2): 115-128, 2016
of system parameters such as mass flow rate and the
inlet temperature of the heat transfer fluid and the
variation of the tube radii on the system performance
were investigated. The results indicate a significant
enhancement in the system performance.
Al-Abidi et al. [16] investigated the application of a
triplex tube heat exchanger with a PCM in the middle
tube to use with a liquid-desiccant air-conditioning
system. Results indicated that heating both sides
achieved complete PCM melting within a short time.
In another work [17] they investigated numerically
heat transfer enhancement by using internal and
external fins for PCM melting in a triplex tube heat
exchanger. A two-dimensional numerical model was
developed. The number of fins, fin length, fin
thickness, Stefan number, triplex tube heat exchanger
material, and the latent heat storage unit geometry
were found to influence the time for complete melting
of the PCM.
This paper presents a model for solidification around
a vertical axially finned tube submerged in PCM. The
developed model is based on the enthalpy method and
the control volumes approach. The number of fins,
radial length of the fin, fin thickness and the geometry
of the annular space were investigated. The proposed
model and the numerical predictions were compared
with experimental results and good agreement was
found.
2. FORMULATION OF THE PROBLEM
Fig. 1 shows a transversal section of a latent heat
storage unit where finned tubes are submersed into
PCM enclosed by a cylindrical shell thermally
insulated. As can be seen each finned tube is
surrounded by a symmetry circle representing the
limiting boundary beyond which there is no
temperature gradient and consequently no phase
change. Fig. 2 shows a section of the finned tube and
the details of the symmetry region used in the model
and numerical simulation, where the three symmetry
surfaces are represented as thermally insulated while
the tube wall is maintained under constant
temperature.
Consider that the heat transfer process is controlled
only by pure conduction, one can write the conduction
equation for the solid and liquid phases respectively
as:
∂T s 1 ∂  ∂T  1 ∂  k s ∂T s 
ρ s cs =  rk s s  +   (1)
∂t r ∂r  ∂r  r ∂θ  r ∂θ 
∂Tl 1 ∂  ∂Tl  1 ∂  k l ∂Tl 
ρ l cl =  rk +   (2)
∂ t r ∂r  l ∂r  r ∂θ  r ∂θ 
 Ismail et al.; JOBARI, 12(2):
1 115-128, 2016

Fig. 1. Transversal section in a latent heat axially finned storage unit

The energy balance equation at the solid

solid-liquid Taking into account the sudden increase of the
interface can be written as: enthalpy by λ when phase change occurs, the specific
heat of the phase change material becomes:
 1  ∂rs  
2
 ∂T s ∂T ∂r
dH (T )
− kl l = ρsL s (3)
 ks  1+  
 ∂r ∂r  rs2  ∂θ   ∂t C (T ) = = C (T ) + λδ (T − Tm ) (7)
dT
The specific heat and the latent heat per unit volume
for the solid, liquid and the latent heat per unit volume C ( T ) when T < Tm−
respectively as: C (T ) =  s (8)
C l ( T ) when T > Tm+
Cs = ρs c s ; C l = ρ l c l ; λ = ρ s L (4)
where δ (T − Tm ) is the Dirac function, and
while the enthalpy per unit volume can be written for
the phase change material as:
Tm− = Tm − ∆T
H (T ) = ∫ C (T )dT + λη (T − Tm ) (5)
T Tm+ = Tm + ∆T

η (u ) = 10 when u≥0 (6)

Where (2 ∆ T ) is the phase change temperature
 when u<0 range.

Fig. 2. Details of the finn

finned tube and the symmetry region

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 Ismail et al.; JOBARI, 12(2): 115-128, 2016

By using Eq. (8), then Eqs. (1) and (2) become:

∂T 1 ∂  ∂T  1 ∂  k (T ) ∂T 
C (T ) =  rk (T )  +   (9)
∂t r ∂r  ∂r  r ∂θ  r ∂θ 
where:


k s ( T ) ; T ≤ Tm − ∆ T
 (10)
k ( T ) =  k l ( T ); T ≥ Tm + ∆ T
 kl − ks
 k s ( T ) + 2 ∆ T (T − (Tm − ∆ T )); Tm − ∆ T < T < Tm + ∆ T

Assuming a linear variation of k with T in the phase change temperature range and


C s ( T ); T ≤ Tm − ∆T

C ( T ) = Cl ( T ); T ≥ Tm + ∆T (11)
 λ Cl + C s
 2 ∆T + ; Tm - ∆T < T < Tm + ∆T
2

where the value of C (T ) in the phase change range.

Eq. (9) is reduced to Eq. (3) when the temperature approaches the phase change temperature Tm and
consequently Eq. (9) alone is the governing equation for this phase change problem.

To solve the 2-D heat conduction in the fin, Eq. (9) is used with the corresponding fin material properties such
as density, specific heat and thermal conductivity specified as below:

C (T ) = ρ f c f = C f
(12)
k (T ) = k f

To facilitate the numerical treatment and enable investigation of the parameters of the problem, the following
dimensionless variables are adopted:

T − Tw r kst ∆T
φ= ; R= ; τ= ; ε= (13)
Tm+ − Tw ri C s ri2 Tm − T w

 
1 ; φ ≤ 1 − 2ε 
~  
k ( φ ) = k l ks ; φ f1 
 kl − k s  φ − 1 
  (14)
1 +  + 2 ; 1 - 2ε ≤ φ ≤ 1
 2k s  ε  
kf 
~ 
k (φ ) = for the fin
ks 

and

119
 Ismail et al.; JOBARI, 12(2): 115-128, 2016

 
1; φ ≤ 1 − 2ε 
~  
C ( φ ) = Cl C s ; φ f1 
 λ C + Cs  (15)
+ l 1 - 2ε ≤ φ ≤ 1 
 ;
 2C s ∆T 2C s 
Cf 
~ 
C( φ ) =
Cs 

When the new dimensionless variables are substituted in Eq. (9), it becomes:

∂φ  1 ∂  k (φ ) ∂φ 
~
~ ∂φ 1 ∂ 
C (φ ) =  Rk (φ )  +   (16)
∂τ R ∂R  ∂R  R ∂θ  R ∂θ 

The corresponding boundary conditions in terms of [19,20]. In the present study we adopted the
the new variables are: Alternating Direction Implicit formulation because it
is unconditionally stable. More details about the
φ = 1, w hen R = 1 (17) numerical solution, numerical trials to optimize the
grid points can be found in [18].
∂φ r
= 0, when R= e (18) 3. EXPERIMENTAL SET-UP
∂r ri
The experimental set-up used in the tests shown in Fig.
∂φ
= 0, when θ = 0 (19)
3 is composed of a copper tube with axial fins
∂θ attached externally to the tube surface. The finned
tube is fixed coaxially in a larger diameter tank
∂φ containing the PCM and is submersed into a constant
= 0, when θ = θ m (20) temperature water bath heated by a controlled electric
∂θ heater. The whole system is thermally insulated as
shown in Fig. 3. Cooling water at temperature less
The initial and final conditions are given by: than the phase change temperature is circulated in the
finned tube to provoke solidification of the PCM. The
φ = 1, w hen τ = 0 (21) cooling water flow rate and its inlet and exit
φ = 1 − 2ε , when τ = τ c (22) temperatures are measured by calibrated orifice plate
and thermocouples, respectively. A digital camera is
installed axially and focused over the finned tube. The
where τ c is the dimensionless time at the end of camera is operated manually. A precision scale is
process. fixed near to the finned tube and is photographed
always with the tube. The photographs of the finned
The discretization of Eq. (16) is realized by using the tube, the attached precision scale and the solidified
control volume technique, where the domain of the PCM are used to determine the true position of the
problem is divided into a convenient number of interface.
control volumes and Eq. (16) is integrated over R, φ
and τ to obtain, after some mathematical The PCM used in the experiments is paraffin wax
manipulations, the required algebraic equations. The whose thermal properties are; fusion temperature is
same is done with respect to the boundary conditions 56-58°C, density is 900 kg/m3, specific heat is 3.26
of the problem. Details of the mathematical kJ/kg°C, thermal conductivity is 0.21 W/ m°C and a
manipulations can be found in [18]. With the latent heat of 147.0 kJ/kg [21].
algebraic equations in hand it is possible to use for
their representation explicit formulation, implicit The thermocouples were calibrated and have precision
formulation, Crank Nicholson formulation, of ± 0.1°C, the interface position was determined with
Alternating Direction Implicit formulation (ADI) or a precision of ± 0.1 mm and the cooling water flow
conjugate Alternating Direction Implicit with Crank rate (not used in the present calculations) was
Nicholson. Details of these methods can be found in determined with a precision of ± 1.0 cm3/s.

120

Fig. 33. Details of the experimental rig
To start a test, the water bath and the PCM tank were
filled with water and Paraffin, respectively. The
electric heater was switched on and the thermostatic
control was set at a temperature slightly higher than
the phase change temperature of the PCM. The
temperature of the water bath and the PCM tank were
monitored until achieving thermal equilibrium with
the PCM temperature about 1°C C above the phase
change temperature. Under these conditions the
testing is started.
1. Allow the cooling water under constant head
and constant temperature conditions to flow
into the finned tube. The radial temperature
gradient provokes solidification of the Paraffin
forming a layer of solidified mass on the
external surface of the tube and fins. Register
the surface temperature of the tube, the
temperatures of the cooling water at entry and
exit, the water low rate and photograp
photograph the
finned tube and solidified PCM around it.
2. Repeat this procedure for all selected time
intervals and register at the end of each interval
the temperatures, flow rate of cooling water
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Ismail et al.; JOBARI, 12(2):
1 115-128, 2016
and photograph the finned tube and solidified
mass.
3. The solidification is considered complete when
the above procedure is repeated for at least two
successive time intervals with no change in the
solidified mass. The total time of the
experiment is the time for complete
solidification.
4. Shut down the test rigig and proceed to change
the finned tube and adjust the test conditions as
required.
The photographs are digitalized and the real position
of the interface is obtained for each time interval by
comparison with the image of the precision scale.
From the realal positions of the interface and the time
intervals it is possible to determine the interface
velocity and the real solidified mass fraction.
4. RESULTS AND DISCUSSION
In order to validate the model and the numerical
method comparisons between the present results and
available numerical and experimental data were
 Ismail et al.; JOBARI, 12(2): 115-128, 2016

realized. The present model was adapted for the case
of finless tube and the predicted results were
compared with Sparrow et al. [22] and also with the
experimental results of Sparrow et al. [23]. As can be
seen from Fig. 4 the numerical results from the two
models have the same tendencies. The differences are
attributed to the adopted numerical treatments. The
experimental results from Sparrow et al. [23] are
closer to the present numerical predictions especially
for long periods of phase change. In the meantime the
authors’ experimental results agree well with the
present numerical predictions.
The numerical predictions are compared with the
available results of Sinha and Gupta [24]. The data
used by Sinha and Gupta was used in the present
numerical code and the results are plotted in Fig. 5
together with Sinha and Gupta results [24]. As can be
seen the agreement is fairly good.

Fig. 4. Comparison of the predicted phase front position with time with available numerical
and experimental results from [22,23] for the case of tube without fins

Fig. 5. Comparison of the present predictions of the dimensionless position of the phase front
with the results from [24] for the case of tube without fins

122
 Ismail et al.; JOBARI, 12(2): 115-128, 2016

The influence of the number of fins on the solidified
mass fraction is investigated. The experimental results
are compared with the numerical predictions as shown
in Fig. 6. As can be seen the increase of the number of
fins from three to four increases the solidified mass
fraction by about 10 to 12%. This enhancement is due
to the increase of the heat transfer area, the
corresponding increase of the heat transfer rate and
also due to the penetration effect of the fins in the
PCM mass.
As mentioned before the increase of the number of
fins increases the heat transfer area, the heat transfer
rate, the interface velocity and this leads to reducing
the time for complete phase change. Fig. 7 shows the
effect of the variation of the number of fins on the
time for complete solidification determined both
numerically and experimentally. The experiments
were realized using paraffin initially at its phase
temperature of 57°C. When solidification is complete,
the elapsed time is taken as the complete solidification
time. As can be seen the agreement between
experiments and the numerical prediction is
reasonably good.
The numerical simulations were extended to evaluate
the effects of the number of fins, the radial length of
the fin, the fin thickness, and the ratio of re/rw on the
solidified mass fraction and the time for complete
solidification.

Fig. 6. Variation of the solidified mass fraction with the number of fins

Fig. 7. Variation of the dimensionless solidification time with the number of fins

123
 Ismail et al.; JOBARI, 12(2): 115-128, 2016

Fig. 8 shows the predicted influence of the number of
fins on the solidified mass fraction and comparison
with the bare tube case. As mentioned before the
increase of the number of fins increases the heat
transfer area, the heat transfer rate and consequently
the solidified mass fraction as indicated also in Fig. 9.
Fig. 10 shows the enhancement effect due to
increasing the fin radial length in comparison with the
finless case. As can be seen the increase of the fin
radial length increases the heat transfer area and the
heat transfer rate and together with the penetration
effect of the fin surface enhance the phase change
process.

Fig. 8. Effect of the number of fins on the solidified mass fraction

Fig. 9. Variation of the solidified mass fraction with the number of fins

124
 Ismail et al.; JOBARI, 12(2): 115-128, 2016

Fig. 11 shows the variation of the solidified mass
fraction with the fin radial length.
One can observe the beneficial effect of increasing the
radial fin length which increases the heat transfer area
and the heat transfer rate. After reaching the optimum
fin length any additional increase in the fin radial
length does not change the solidification rate. This is
due to the fact that at the optimum radial length there
is no temperature gradient between the fin tip and the
surrounding PCM sufficient to drive the phase change
thermal process and consequently the solidification
process stops.

Fig. 10. Effect of the radial length of the fin on the solidified mass fraction

Fig. 11. Variation of the solidified mass fraction with the fin radial length

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 Ismail et al.; JOBARI, 12(2): 115-128, 2016

The size of the symmetry circle is defined by the ratio
re/rw where re is the radius of the symmetry circle and
rw is the radius of the finned tube. Fig. 12 shows the
effect of increasing the ratio re/rw on the solidification
time necessary to achieve a certain solidified fraction.
This can be explained by the fact that increasing the
ratio re/rw leads to extending the symmetry circle
radius to a region where the temperature gradient is
small and this reduces the heat transfer rate and
consequently reduces the rate of solidification of
PCM and increases the solidification time.
The increase of the ratio re/rw leads to the increase of
the limiting radius (radius of the symmetry circle)
where the temperature gradient is zero and this leads
to reducing the temperature gradient, reducing the
heat transfer rate, and consequently reducing the
phase change rate as shown in Fig. 13.
In a similar manner the increase of the ratio re/rw
reduces the interface velocity resulting in increasing
the total solidification time as shown in Fig. 14.
Fig. 15 shows the effect of the fin thickness on the
solidified mass fraction. As can be seen the effect is
marginally small since the fin thickness contribution
to the heat transfer area is very small.

Fig. 12. The effect of varying the ratio re/rw (size of the symmetry circle) on the solidified mass fraction

Fig. 13. Effect of the ratio re/rw on the solidified mass fraction

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 Ismail et al.; JOBARI, 12(2): 115-128, 2016

Fig. 14. Variation of the dimensionless solidification time with the ratio re/rw

Fig. 15. Variation of the solidified mass fraction with the fin thickness

5. CONCLUSIONS mass fraction and improves their performance.

The numerical predictions agree reasonably well with COMPETING INTERESTS

available numerical and experimental results. It is
found that the fin radial length and the number of fins
enhance the solidified mass fraction and reduce the
time for complete solidification. The increase of the
ratio of re/rw impairs the performance of the finned
tube due to increasing the time for complete
solidification. The fin thickness is found to have
marginal effect on the complete solidification time or
the solidified mass fraction. The use of finned tubes in
the latent heat storage units increases the solidified
Authors have declared that no competing interests
exist.
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