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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Preliminary Assessment for the Electric Load Shifting Potential of Integrating Thermal Energy Storage with Heat Pumps in Residential Buildings in Texas of United States

The widespread adoption of electric-driven heat pumps for heating and cooling is expected to significantly increase electric demand. Cooling electric demand will result in an increase in peak hours electric loads, placing additional strain on the grid during peak hours. This challenge, combined with the current rapidly increasing demand from data centers, exacerbates the electric demand duck curve problem. Integrating thermal energy storage (TES) with heat pump can shift electric use for heating and cooling from peak to off-peak hours of the electric grid, which can help flatten the daily electric demand profile of a building. This paper presents a novel design that integrates heat pump with TES (HP-TES), which uses phase change materials (PCM). Heat pump charges TES by melting or freezing PCM during off-peak hours when there is no thermal demand from the building. TES is then discharged (i.e., by freezing or melting PCM) during peak hours to provide a more favorable heat source or heat sink for the heat pump to meet the thermal demand of the building with lower electricity use than conventional air-source heat pumps. Computer simulations were developed to predict the performance of HP-TES applied to a typical single-family house in the US. The building-level simulation results were scaled up to preliminarily assess the aggregated impacts of deploying HP-TES across all single-family houses in Texas of the United States, including reduction of peak demand of the electric grid.

Anees, Fady [ORNL]↗
DOE OSTI2024

Predictive model using artificial neural network to design phase change material-based ocean thermal energy harvesting systems for powering uncrewed underwater vehicles

Uncrewed Underwater Vehicles (UUVs) are a major beneficiary of the phase change material (PCM)-based ocean thermal energy harvesting technology for their mission needs. However, this technology relies on different parameters and energy conversion steps that could be critical to the general energy generation efficiency. Sea trials showed that the design performed lower than their laboratory design specifications. This underperformance results from different factors, mainly the UUV’s trajectory, travel time, underwater ocean currents, temperature fluctuations, and biofouling on the heat exchanger due to long term underwater operations. Therefore, there exists a need to continuously monitor the ambient energy harvesting system and predict system performance, for mission planning purposes. Two major parameters influencing the energy harvesting system include the final pressure inside the hydraulic energy storage vessel or accumulator, and the electrical load value. Here, this work focuses on the hydraulic to electric energy conversion system. Therefore, a combination of numerical model and experimental testing is used to develop a predictive model using artificial neural network using MATLAB. After validation with experimental testing, 1000 data samples obtained from the numerical model are used to train the ANN. Compared to the experimental results, the developed ANN model can predict in less than a second the designed benchtop system’s total efficiency with less than 15 percent maximum error range. This predictive model development represents a cost-effective way for optimization and a computational energy efficient mode aboard UUVs for mission planning for deployed UUVs using PCM-based ocean thermal energy harvesting technology.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Advanced blade-shaped thermal energy storage device: Development and application

Thermal energy storage (TES) using phase change materials (PCMs) is a promising approach for capturing and reusing excess thermal energy, yet widespread adoption is limited by low thermal conductivity, bulky configurations, and inadequate scalability. Here, this study presents a modular, blade-shaped TES prototype designed to address these challenges. The device integrates a lightweight aluminum shell, an embedded serpentine coil for active or passive heat exchange, and a cost-effective corrugated metal mesh for enhanced PCM thermal conductivity. With thickness-to-length and thickness-to-width ratios of 0.03 and 0.08, respectively, the blade-shaped TES achieves a compact, modular form factor suitable for space-constrained applications. Experimental testing demonstrated the efficient charge and discharge behavior of blade-shaped TES, capturing PCM superheating, phase-change transitions, and subcooling dynamics, with charging and discharging efficiencies of 94.9% and 94.6%, respectively. Also, the system can potentially achieve higher energy density than that of conventional TES designs. When integrated into a household refrigerator during the study, three blade-shaped TES modules successfully shifted 100% of peak-time compressor operation to off-peak hours, reducing energy consumption while maintaining more stable compartment temperatures. The blade-shaped TES's thin geometry, modularity, and enhanced thermal performance support scalable deployment across residential, commercial, and industrial applications, providing a versatile, cost-effective solution for high-efficiency, demand-flexible thermal energy management.

Blade-shaped↗
DOE OSTI2024

Recharge Demand Mitigation for Latent Heat Thermal Energy Storage at Off-peak Hours

The utilization of integrated heat pump thermal energy storage (HP-TES) systems for space conditioning applications can reduce electrical power demand and achieve utility savings resulting from peak shaving and load shifting. However, issues arise when the energy required to recharge the TES exceeds the shifted energy demand, especially in extreme climates where high-temperature lifts between the outdoor air conditions and phase-change materials (PCMs) during recharging may occur. In this work, a single room-temperature (22°C) PCM-TES is integrated into a single-speed heat pump system using a secondary hydronic loop where the TES is recharged using the outdoor unit during off-peak hours. Three recharge strategies were investigated as potential pathways to reduce recharging power demand: (i) considering different heat source/sink temperatures, (ii) using a variable-speed compressor, and (iii) using a variable-speed pump. Simulations were conducted using Modelica for HP-TES recharging at different heat source/sink temperatures from -30 – 20℃ in heating mode and 0 – 30℃ in cooling mode. Results show that the most effective recharge demand reduction strategy is an HP-TES system using a single-speed compressor with a variable-speed pump for the hydronic loop run at preferable heat source/sink temperatures when the temperature lifts were reduced. Utilizing a variable-speed compressor for the HP-TES system reduced recharge time in extreme cases at the cost of additional compressor power input. The findings motivate potential control strategies that minimize recharge energy and maximize peak energy savings, hence reducing overall operating costs and annual energy consumption for HP-TES systems for space conditioning applications.

25 ENERGY STORAGE↗
DOE OSTI2023

Multiscale Electricity Modeling for Evaluating Carbon Capture and Sequestration Technologies (Final Report)

Carbon capture and sequestration (CCS) technologies that can operate with a high degree of operating flexibility could provide necessary electric grid flexibility in a system with high shares of variable renewables. This project examines the deployment and dispatch potential of twelve unique flexible CCS (FLECCS) technologies that encompass post-combustion carbon dioxide (CO 2 ) capture designs, concepts using a storage media to enable energy arbitrage, and hybrid processes that integrate CCS with direct air capture (DAC) for flexibility with net zero or negative CO 2 emissions. FLECCS technology potential is explored with a multi-model, multi-scale framework including the Regional Energy Deployment System (ReEDS) electric sector capacity expansion model (CEM) and the PLEXOS production cost model (PCM). Innovative methods were developed to represent FLECCS technology operating modes, performance, and cost in the two models. ReEDS was then used to simulate nine scenarios for each FLECCS technology, three CO 2 emissions price futures reaching $\$$150, $\$$225, and $\$$300/tCO 2 in 2050; and three scenarios for FLECCS technology deployment favorability relative to competing technologies. For each CO 2 price and reference FLECCS favorability, the 2050 infrastructures from ReEDS model are downscaled and implemented in PLEXOS to examine hourly dispatch under detailed operational constraints that are not included in ReEDS. FLECCS technologies exhibited a wide range of deployment potential ranging from none to several hundred gigawatts of capacity, with outcomes highly sensitive to input cost and performance parameters that are inherently highly uncertain. When deployed, FLECCS tended to displace a combination of wind, solar, and natural gas-based technologies rather than supporting increased renewable deployment. As a result, CO 2 emissions reductions facilitated by FLECCS deployment tended to come with higher overall system costs and electricity prices. When economically competitive, FLECCS technologies can contribute significant flexible generation and firm capacity to the grid, but continued technology development and an expanded analytical scope are necessary to fully understand FLECCS deployment potential its impact on the electric power sector. Follow-on analysis incorporating captured CO 2 tax credit value from the Inflation Reduction Act (IRA) and other potential policy scenarios could be particularly valuable, as this policy can substantially change the relative competitiveness of FLECCS technologies.

03 NATURAL GAS↗
DOE OSTI2021

A Study on Computational Cost Reduction of Simulations of Phase-Change Material (PCM) Embedded Heat Exchangers

Thermal storage can be implemented using Phase-Change Materials (PCM), which absorb significant latent heat with a relatively small temperature change. PCM phase-change processes are transient and are driven by thermal diffusion and natural convection – the latter, especially for melting process. Modeling and simulation of PCM heat exchangers (HX’s) is typically computationally intensive due to the relatively complex time-dependent physics. Most of the PCM modeling work in the literature uses high-order modeling tools such as Computational Fluid Dynamics (CFD) and Lattice-Boltzmann Method (LBM). For design purposes, the existing PCM modeling approaches are not practical, limiting researchers in their ability to investigate new ideas and different PCM’s with faster turnarounds. This paper presents a study investigating the reduction of computational cost of PCM embedded HX’s CFD models by evaluating the feasibility of spatial reduction without losing accuracy. The analysis consists of comparing full and partial domain under full melting conditions. The subject of this study is a single straight tube with circular transverse fins in the vertical orientation, using PCM’s with 35oC nominal melting temperature. Different tube and fin dimensions are investigated. Results indicate that the reduced domain reproduces - in half the run time - the same behavior as the full domain since the buoyancy effects are localized and patterned. The outputs from the partial domain simulation were used to build a non-general correlation for the PCM heat transfer characteristics and demonstrated how it can be implemented in a Finite Control Volume Reduced Order Model (ROM). The ROM can accurately reproduce the CFD simulations at 4 to 5 orders of magnitude faster.

25 ENERGY STORAGE↗
DOE OSTI2021

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗
DOE OSTI2020

Ceramic encapsulated metal phase change material for high temperature thermal energy storage

Thermal energy storage (TES) is a broad-based technology for reducing CO₂ emissions and advancing concentrating solar, fossil, and nuclear power through improvements in efficiency and economics. Phase change materials (PCMs) are of interest as TES media because of their ability to store large amounts of heat in relatively small volumes. The volume expansion during a phase change, typically between a solid and liquid, can cause breakage of protective coatings. This paper reports on the fabrication of a ceramic encapsulated metal (CEM) high temperature TES technology using a rotary calcining furnace and a fluidized bed chemical vapor deposition coating technique. Aluminum beads were chosen as the PCM because Al has a high melting point (660 °C), low cost, high heat of fusion, and an ability to form a thin, strong alumina layer capable of supporting the Al melt for subsequent processing. Quite remarkably, this study shows that 1 mm diameter Al can be fluidized up to at least 1500 °C in an appropriate atmosphere while maintaining a spheroid geometry. This allowed for producing a first of a kind CEM whereby Al particles were encapsulated in pyro-carbon (PyC) and high purity, dense chemical vapor deposited SiC. The CEM with a PyC only coating was exposed to thermal cycling to test the performance with a differential scanning calorimeter; the melting point and latent heat were measured to be 648.4 ± 2.8 °C and 293.3 ± 6.2 J/g respectively. It was demonstrated that the CEM design is possible to produce, laying the foundation for manufacturing of high temperature, tunable, TES media.

25 ENERGY STORAGE↗
DOE OSTI2025

Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Here, the present study examines the thermal energy storage (TES) effectiveness and printability of microencapsulated phase-change material (MEPCM) combined with thermoplastic polyurethane (TPU) for fused filament fabrication (FFF). Two formulations were assessed: 24D MEPCM, which changes phase at 24 ° C, compounded with TPU pellets and 43D MEPCM, which changes phase at 43 ° C, integrated with TPU powder. These combinations are designed to evaluate the effectiveness of the form of the TPU (pellets versus powder) in the FFF process. The investigation includes a comprehensive analysis of thermal characteristics, encompassing phase-change temperature, latent heat of fusion, thermal conductivity, and thermal decomposition, which are assessed through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Additionally, mechanical properties, including stress-strain behavior, are examined to evaluate material suitability for TES applications, while microstructural visualization is used to provide deeper insights into material performance, structural integrity, and the quality of printed components. The 24D MEPCM and TPU pellets formulation experienced a significant loss of approximately 39.6% of PCM during filament extrusion and printing, resulting in a reduced effective latent heat. Therefore, further characterization of the pellet formulation was discontinued due to excessive leakage. In contrast, the 43D MEPCM and TPU powder formulation demonstrated minimal PCM loss, with the 60 wt.% composition achieving an effective latent heat of 132 J/g. This value represents the highest effective latent heat currently documented in the literature for PCM-polymer-composite materials produced using an FFF-based additive manufacturing process.

25 ENERGY STORAGE↗
DOE OSTI2022

Experimental Evaluation of Thermal Storage Performance of a Dual-Purpose Underground Thermal Battery

A geothermal heat pump (GHP) system is an energy-efficient building heating and cooling technology with great potential for reducing energy consumption and decarbonization. However, applications of GHP are still limited due to the high cost, of which 30% is related to the cost of installing the conventional vertical bore ground heat exchangers, which are usually installed in boreholes 60 meters deep. A dual-purpose underground thermal battery (DPUTB) has been developed to offer a low-cost ground heat exchanger with a built-in thermal storage capacity. The DPUTB innovatively integrates a shallow-bore ground heat exchanger (the outer tank), which can be installed in a borehole less than 6 m deep, with thermal energy storage (TES) (the inner tank). DPUTB has the potential to reduce the cost of a ground source heat pump system while allowing shifting the electric demand of the building served by the GHP system from peak to off-peak hours of the electric grid by charging and discharging the thermal storage. A lab-scale (1:125 in volume) DPUTB prototype was built. Phase change material (PCM) was added to increase the thermal storage capacity and maintain the supply water temperature from the TES within the desired range for direct cooling operation during the discharge period. As PCMs are critical to the TES performance of the DPUTB, this study compared the influence of different PCMs (including salt hydrate and organic PCMs) on the discharge performance of the DPUTB. The thermal State of Charge (SoC) of the DPUTB was used to compare the performance resulting from using different PCMs. Test results indicate that the organic PCM (Methyl Laurate) outperforms salt-hydrate PCMs due to a lower melting temperature and a narrower melting temperature range during the phase change process. The results of this study provide a guide for PCM selection and the optimal design of DPUTB.

Wang, Lingshi↗
DOE OSTI2025

Thermal and mechanical performance of gypsum composites containing fly ash cenosphere encapsulated phase change materials

Utilizing phase change materials (PCMs) within construction materials improves the thermal energy storage capabilities in the built environment. Notably, integrating PCMs into drywalls presents a promising avenue to reduce building energy use. However, incorporating PCMs into drywalls poses challenges, particularly reduced mechanical properties and workability limitations as it can adversely affect the hardening and cohesiveness of gypsum composites. To address these challenges, this study explores a novel strategy to incorporate PCMs into gypsum composites through fly ash cenosphere-encapsulated PCM, namely CenoPCM, aiming to enhance the mechanical properties and thermal conductivity over existing commercial counterparts. An experimental program was conducted to study the impact of the inclusion of CenoPCM on the mechanical and thermal performance of gypsum composites, and the results were compared to those of commercially available polymerencapsulated PCM benchmark (Micronal). The findings highlighted that PCM-charged samples exhibited up to 95.90 J/g (CenoPCM) of latent heat with 70 % CenoPCM loading. The results of mechanical tests also showed that CenoPCM outperformed its polymer-encapsulated counterpart, achieving 55 % higher mechanical strength on average. Here, this improvement is attributed to the rigid shell of fly ash cenosphere (FAC) serving as a PCM carrier, providing a skeleton-like structure to gypsum composites for higher load-bearing capacity. Additionally, hotbox tests demonstrated that the CenoPCM-charged wall panels yielded a 20 % higher thermal conductivity and a 22 % increased time lag compared to Micronal PCM-charged panels, indicating its potential to shift the peak load in buildings.

Ceno PCM↗
DOE OSTI2026

Thermal cycling-driven microstructural changes of eutectic Al–Si phase change materials in SS304 containers revealed by multi-modal imaging

Aluminum-based Al–Si alloys are widely used as phase change materials (PCMs) in thermal energy storage (TES) systems owing to their high volumetric latent heat and superior thermal conductivity. However, their long-term reliability is limited by degradation processes that remain insufficiently understood. In this work, we employ a multimodal, correlative characterization framework to systematically resolve the degradation behavior of eutectic Al–Si PCMs in contact with SS304 containers under repeated thermal cycling. By integrating high-resolution electron microscopy, three-dimensional X-ray fluorescence (3D XRF) imaging, and differential scanning calorimetry (DSC), we directly link spatially resolved compositional and microstructural evolution to changes in thermophysical properties. The correlative analysis reveals that elemental leaching of Fe, Cr, and Ni from the stainless-steel container into the PCM drives the formation of intermetallic compounds (IMCs) both at the interface and within the bulk PCM, leading to pronounced compositional heterogeneity. These interfacial reactions and diffusion-induced transformations progressively destabilize the Al–Si eutectic, reducing the effective phase-transforming fraction. Consistent with these observations, DSC measurements show a decrease in melting temperature and latent heat of fusion with thermal cycling. These results underscore the critical influence of interfacial reactions and material compatibility on the stability, durability, and overall performance of Al–Si-based TES systems.

25 ENERGY STORAGE↗
DOE OSTI2025

Experimental investigation on phase change material–based finned tube heat exchanger for thermal energy storage and building envelope thermal management

Phase change materials (PCMs) are attractive solutions for thermal energy storage (TES) applications by absorbing and releasing large amounts of latent heat during solid–liquid phase transitions. However, their relatively low thermal conductivity requires novel heat exchanger–based solutions to improve the power density and overall energy storage efficiency of the TES system. This work presents the design and experimental results of a finned tube heat exchanger to store collected natural thermal energy from a building envelope in a latent-based TES and to release it later for building heating/cooling applications. We experimentally evaluate the finned tube heat exchanger and evaluate the performance of TES in reducing building heating and cooling loads over 3–4 h of desired time of operation (e.g., peak load). The optimized design allows for maximum energy density by minimizing the heat exchanger volume, and the system is evaluated experimentally using commercially available heat exchanger materials and an organic PCM. Here, the experimental results reveal that the TES system is able to charge and discharge stored latent energy within 3–4 h, matching peak building electricity demand duration under an average fluid flow rate of 0.136 kg/s and temperature difference of 5.55 °C. Importantly, such optimized designs illuminate a path toward TES designs that are low-cost, scalable, and optimized for thermal energy and power availability under the desired time of operation.

25 ENERGY STORAGE↗
DOE OSTI2025

Energy performance of an operational government building retrofitted with ceiling phase change material tiles in a mixed-humid climate

The aging U.S. building stock requires various retrofit measures to enhance their energy efficiency. Here, this study explores the integration of thermal energy storage and advanced building controls as viable retrofit solutions for load flexibility and peak demand response while maintaining the occupants' comfort. A detailed assessment is conducted on the energy use of an administrative building in Sumner County, Kansas, focusing on the implementation of phase change materials (PCMs) in the ceiling of occupied zones. First, a time-resolved, whole-building energy model is developed in EnergyPlus, incorporating complex thermal behaviors such as air exchange between the plenum space and occupied zones, envelope leakage, and operational schedules. The model is then validated using experimental field test data, and subsequently a parametric assessment of key PCM properties and application strategies is performed to evaluate cooling electricity demand benefits. The parametric study shows that the optimal retrofit strategy, comprising a PCM with 23°C peak melting temperature, 0.125 in. (3.17 mm) thickness, and 150 kJ/kg latent heat, combined with active controls that include 8 h of precooling, forced convection under the ceiling, and a 2°C thermostat setback during peak hours, can result in a maximum load shift during the peak period of 99.6 % and the total electricity savings during the peak period of 98.9 % for the optimum case and thus provide significant cost savings under time-of-use pricing scenarios.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Dual-season thermal energy storage-integrated heat pump system for load shifting: experiments, modeling and nationwide analysis

Here, this paper proposes and validates a dual-season thermal energy storage-integrated heat pump (TES-HP) system that shifts building electric load in both cooling and heating modes using a single phase-change TES. The design uses the TES as a heat sink for the condenser in summer and a heat source for the evaporator in winter, thereby reducing on-peak electric demand while ensuring compatible with existing air-distribution systems. A 14-kW TES-HP prototype with six operating modes and novel refrigerant charge management strategies was experimentally tested under varied conditions. Subsequently, data-driven polynomial performance curves were developed and validated against experiments, then coupled with a phase change material (PCM) model and a calibrated building model within a rule-based controller. Single-day case studies demonstrated effective on-peak demand reduction while maintaining thermal comfort. During cooling, hourly power was lowered by up to 1.5 kW; in heating, average hourly power decreased from over 3.5 kW to 1.8 kW, compared to an HP-only system, achieving 64.5 % load shifting, and the need for resistance heating was eliminated. Seasonal simulations showed typical on-peak electricity savings of 25–35 % in cooling and 40–65 % in heating, with the largest benefits on the hottest and coldest days. Extended response-surface analysis and nationwide mapping quantified load shifting as functions of ambient and TES temperatures, revealing a seasonal trade-off in TES phase-change temperature. These results demonstrate the TES-HP system as a practical and scalable solution for grid-interactive buildings that reduces on-peak demand and electricity use while maintaining thermal comfort and enhancing grid flexibility and reliability.

Grid-interactive buildings↗
DOE OSTI2023

Hollow lattice thermal energy storage heat exchanger

Example heat exchangers and methods of use are described herein. An example heat exchanger includes a lattice structure including a plurality of conduits defining a plurality of interstitial voids between the plurality of conduits. Each of the plurality of conduits includes an inlet and an outlet, and the plurality of conduits are arranged such that, between the inlet and the outlet, each of the conduits intersects at least one other conduit to enable flow between the intersecting conduits. The example heat exchanger also includes a first manifold formed unitarily with the lattice structure, the first manifold comprising a first plurality of openings in fluid communication with each inlet of the plurality of conduits. The example heat exchanger further includes a phase change material (PCM) disposed within and substantially filling the plurality of interstitial voids.

Stoia, Michael F.↗
DOE OSTI2021

A first principles framework to predict the transient performance of latent heat thermal energy storage

Thermal energy storage (TES) is increasingly recognized as an essential component of efficient Combined Heat and Power (CHP), Concentrated Solar Power (CSP), Heating Ventilation and Air Conditioning (HVAC), and refrigeration as it reduces peak demand while helping to manage intermittent availability of energy (e.g., from solar or wind). Latent Heat Thermal Energy Storage (LHTES) is a viable option because of its high energy storage density. Parametric analysis of LHTES in terms of dimensionless numbers is highly desired as a tool to model LHTES systems. One approach is to develop a model equation so as to minimize the error between the model and data obtained from experiments or simulations. While this approach can produce an accurate correlation applicable within the range of data used for its creation, it does not provide physical understanding of the rate-limiting process controlling the transient behavior of the device. In this paper we present an alternative approach whereby the potential rate-limiting processes are identified from first principles and then the key process is determined as a function of time as a LHTES device is charged. For example, in a simple geometry, the melt-fraction can be expected to vary linearly in time if the heat transfer rate is limited by natural convection of the phase changing material and we show it scales with the PCM Grashof number as $Gr^1_p$ and PCM Prandtl number as $Pr_p^{(1/3)}$. On the other hand, if surface area of solid PCM limits the heat transfer rate, the melt fraction increases asymptotically to reach full melting. The existence of these linear and asymptotic regions and the $Gr^1_pP r^{1/3}_p$ shape of the melt fraction curve is verified using our database of 64 simulations. Of practical importance in designing LHTES devices is the melt fraction at which the heat transfer rate ceases to be limited by convection, after which the heat storage rate deteriorates. For our geometry, this is found to be about 90%. This test case of our methodology shows the value of our approach, that predicting heat storage rate based on the rate-limiting physical phenomenon as a function of time is an effective approach to modeling LHTES devices.

25 ENERGY STORAGE↗
DOE OSTI2021

Experimental Investigation of Melting and Solidification Processes of Phase Change Material Heat Exchanger

Rapid development and validation of PCM embedded heat exchangers (PCM-HX) concepts warrant a purpose-built test bench. This paper describes a test facility built for testing various PCM-HX configurations and phase change temperatures that will serve to validate the performance of novel PCM-HX designs. The entire test rig is placed in a temperature-controlled environmental chamber. Inside the PCM-HX containers, up to 48 T-type thermocouples can be spatially distributed on and around the tubes depending on the HX type to capture the phase change process over time. In this paper, a straight tube embedded in PCM having a phase change temperature of 37°C in cylindrical containers is tested. The PCM-HX uses water as an in-tube working fluid. Based on the measured data, the energy balance is analyzed, and its temperature distribution is presented. Here, the maximum deviation between the predicted stored energy and the energy stored calculated from experimental measurements is less than 5%.

36 MATERIALS SCIENCE↗