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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Thermal Charging Rate of Composite Wax-Expanded Graphite Phase Change Materials

Phase change materials (PCMs) are valuable for their ability to store heat nearly isothermally around their phase transition temperature. PCMs are at the core of latent heat thermal energy storage (LHTES) systems, which provide the ability to buffer high thermal loads or decouple the time when heating or cooling is needed from when it is produced. Thermal charging and discharging of LHTES systems often employ a constant temperature source, and the rate at which heat can be exchanged is dependent on the thermophysical properties of the PCM. For graphite composite PCMs, the high thermal conductivity of the graphite enables an increased heat transfer rate through the material, but its presence displaces PCM which reduces the effective volumetric latent heat of the composite relative to the pure PCM. This results in a tradeoff between thermal power and volumetric energy storage capacity. The thermal charging rate is the average thermal energy stored in the material for some elapsed time. In this study, composite PCMs of compressed expanded natural graphite (CENG) and n-Octadecane are studied. Samples with varying CENG mass fractions were synthesized and the thermal charging rate was measured under a constant temperature boundary condition. For evaluation of the expanded graphite-PCM composite, one boundary of the material was exposed to a 50°C constant temperature plate, above the 27.5°C melting temperature of the PCM. The melting front progression [mm-s-1] and the thermal charging rate [W-cm-2] of the PCM were determined, and the results were compared with analytical predictions for the 1-D semi-infinite phase change. For CENG addition up to 5.75% mass fraction, a 450% thermal conductivity increase was observed with a 5% decrease in volumetric energy density as compared to pure octadecane. The average thermal charging rate was increased by over 430% for the melt to penetrate a depth of 22 mm. The experimental results matched analytical predictions, indicating that higher CENG fractions can be evaluated using analytical approaches.

Hirschey, Jason↗
DOE OSTI2021

Review of Low-Cost Organic and Inorganic Phase Change Materials with Phase Change Temperature between 0°C and 65°C

Phase change materials (PCMs) that undergo a phase transition may be used to provide a nearly isothermal latent heat storage at the phase change temperature. This work reports the energy storage material cost ($/kWh) of various PCMs with phase change between 0-65°C. Four PCM classes are analyzed for their potential use in building systems: 1) inorganic salt hydrates, 2) organic fatty acids, 3) organic fatty alcohols, and 4) organic paraffin waxes. Many salt hydrates have low material costs (0.09 - 2.53 $-kg-1), high latent heat of fusion (100-290 J-g-1), and high densities (1.3-2.6 g-cm-3), leading to favorable volumetric storage density and low energy storage costs, 50-130 kWh-m3 and 0.90-40 $-kWh-1, respectively. Some salts are notably more expensive due to their scarcity or pressures from competing industries such as lithium-based salts. Fatty acids have the lowest energy storage cost in the temperature range 8-17°C at 6.50 – 40 $-kWh-1. Despite favorable latent heat (125 – 250 J-g-1) their low density gives (0.9 g-cm3) gives poor volumetric storage capacity, 32 – 80 kWh-m3. Fatty alcohols generally have high material costs 2.50 – 200 $-kg-1 which leads to high energy storage costs, 40-3000 $/kWh. With latent heat and density similar to fatty acids, fatty alcohols have poor volumetric energy storage, 43 – 55 kWh-m-3.Paraffin waxes containing only a single length carbon chain have a higher energy cost (15 – 500 $-kWh-1) than generic paraffin waxes containing many lengths of carbon chains (7 – 30 $-kWh-1). Pure waxes have a discrete phase change temperature due to their homogeneity. In contrast, a less refined generic wax with several carbon chain lengths is more likely to have a pronounced temperature glide during its phase change. Pure single carbon chain waxes are generally required for applications <45°C as generic paraffin waxes melt between 45-70°C. For many waxes, a solid-solid transition occurs at temperatures below the solid-liquid phase change. For pure paraffins with carbon content ≥22 C atoms, these transitions may appear near the same temperature resembling a temperature glide.The challenges with fatty acids, fatty alcohols, and waxes are low thermal conductivity, low density, some flammability concerns, and compatibility issues with some common engineering materials such as polymers. Challenges with salt hydrates are pronounced supercooling (>5°C), incongruent melting, and corrosiveness. All PCMs may degrade if exposed to ambient conditions and therefore require proper sealing.

Hirschey, Jason↗
DOE OSTI2021

Experimental Study of the Behavior of Phase Change Materials during Interrupted Phase Change Processes

This research article explores the behavior of a phase change material (PCM) when it undergoes interrupted melting and freezing, through experimental investigations using a heat flow meter apparatus. A fatty acid-based organic PCM, encapsulated within polyethylene and thin aluminum foil layers, was experimentally tested in this study. Experiments were designed to represent multiple interrupted phase change scenarios that could occur within PCMs applied in buildings. The experimental results were analyzed and compared with previously reported assumptions in numerical models dealing with PCM hysteresis and interrupted phase change processes. These comparisons indicated that the assumptions used in the different numerical models considered can capture the interrupted phase change phenomena with varying degrees of accuracy. The findings also highlighted the need for additional experimental research on different phase change processes that can occur in building applications of PCMs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Processing Compressed Expanded Natural Graphite for Phase Change Material Composites

Phase change materials (PCMs) are used in various thermal energy storage applications but are limited by their low thermal conductivity. One method to increase conductivity involves impregnating organic PCMs into highly porous conductive matrix materials. Of these materials, compressed expanded natural graphite (CENG) matrices have received the most attention. Despite this attention, the effect that CENG processing has on PCM saturation and overall matrix thermal conductivity has not been fully investigated. Therefore, the effect of the heat treatment process used to expand intercalated graphite flakes is evaluated here. Higher heat treatment temperatures yielded higher saturation rates and overall saturation at similar matrix porosities. For example, increasing temperature from 300 °C to 700 °C resulted in approximately 60%-70% increase in pore saturation after 100 minutes of soaking. The exposure time to heat treatment had less of an effect on PCM saturation. The exposure time had negligible effect above 30 min and above 500 °C heating temperatures. However, because the expanded graphite was found to oxidize around 700 °C, the use of longer exposure time in manufacturing applications can be beneficial if a shortened impregnation time is needed. Heat treatment conditions did not impact thermal conductivity. The composite latent heat of fusion was also reduced approximately proportionally to the PCM mass fraction. A local maximum in axial thermal conductivity was observed at around 83% porosity, which is similar to previous studies. The observed conductivity at this maximum was a factor of 81 times greater than the conductivity of the PCM.

36 MATERIALS SCIENCE↗
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 OSTI2022

Sensitivity Study of Mini-Batch Size on a Long Short-Term Memory Network for In-situ Sensing of Core-to-shell Ratio of Microencapsulated Phase Change Materials

Microencapsulated phase change materials are being studied for applications for thermal energy storage in concentrated solar fields. During fabrication, the thickness of the encapsulation cannot be readily measured for real-time control. Therefore, a machine learning network, specifically a Long Short-Term Memory network, is being developed to estimate the ratio of the shell radius to core radius based on a one second temperature history. The mini-batch size determines how often the algorithm weights are updated during network training, and shuffle indicates whether the training data is shuffled during training. A general factorial design is used to analyze the effects of varying mini-batch size and shuffle, along with the core-to-shell ratio, on the RMSE of the response from the Long Short-Term Memory network. It was found that the network performed better for smaller core to shell ratios (less than 0.6) and had the lowest RMSE when the minibatch size was 128. The minimum RMSE found was 0.00501.

Shannon, Rebecca↗
DOE OSTI2023

Wavelength-tunable infrared chiral metasurfaces with phase-change materials

Optical phase-change materials exhibit tunable permittivity and switching properties during phase transition, which offers the possibility of dynamic control of optical devices. Here, a wavelength-tunable infrared chiral metasurface integrated with phase-change material GST-225 is demonstrated with the designed unit cell of parallelogram-shaped resonator. By varying the baking time at a temperature above the phase transition temperature of GST-225, the resonance wavelength of the chiral metasurface is tuned in the wavelength range of 2.33 µm to 2.58 µm, while the circular dichroism in absorption is maintained around 0.44. The chiroptical response of the designed metasurface is revealed by analyzing the electromagnetic field and displacement current distributions under left- and right-handed circularly polarized (LCP and RCP) light illumination. Moreover, the photothermal effect is simulated to investigate the large temperature difference in the chiral metasurface under LCP and RCP illumination, which allows for the possibility of circular polarization-controlled phase transition. The presented chiral metasurfaces with phase-change materials offer the potential to facilitate promising applications in the infrared regime, such as chiral thermal switching, infrared imaging, and tunable chiral photonics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Understanding supercooling mechanism in sodium sulfate decahydrate phase-change material

Salt hydrate-based phase-change materials are considered promising for future heat storage applications in residential heating/cooling systems. Smooth phase transition from the liquid to solid phase and vice versa is essential for effective heat exchanger; however, supercooling in salt hydrates delays the onset of liquid–solid phase transition. We investigate the molecular level mechanism of supercooling in sodium sulfate decahydrate (SSD). SSD is a complex salt hydrate whose properties are governed by electrostatic forces that include pure Coulombic interactions as well as hydrogen bonds. Experimentally, we examine the importance of a nucleator in reducing supercooling temperatures. We investigated the effect of various mass concentrations of a borax nucleator on a decrease of supercooling temperatures. Molecular dynamics simulation techniques are used to obtain a basic understanding of supercooling in SSD. We observe that by introducing borax as a nucleator, there is a decrease in the supercooling temperature before nucleation. Our molecular dynamics simulations show that long-range electrostatics between sodium and sulfate ion pairs and that with polar water molecules is responsible for delayed nucleation in SSD that results in supercooling, and also, dynamics of charged molecules slows down. The lack of crystallization leads to amorphous structures in supercooled SSD.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The effect of micro-encapsulation on thermal characteristics of metallic phase change materials

Micro-encapsulated phase change material with metallic core can work under high temperature for energy storage purpose, making it an appealing candidate for renewable energy technologies, such as thermal energy storage for concentrating solar power plants. Here, the objective of this work is to study the impact of encapsulation on the thermal performance of the micro-encapsulated phase change materials under various operating conditions. To evaluate the thermal performance of the micro-encapsulated phase change material particles, the governing equation of transient heat conduction with phase change in spheres with composite walls is solved numerically. The impact of encapsulation shell on the convective heat transfer rate, total energy absorption, latent heat ratio, energy density, and duration of phase change is presented and analyzed under different operating conditions. Three different core materials including tin, aluminum and copper with distinct Stephan numbers are investigated. In addition to the encapsulation shell effect, this model can be used to study micro-encapsulated phase change materials with different material compositions, core to shell ratios, and it can be used to analyze the impact of air gaps in between materials. Understanding the thermal performance at particle level is essential, and the results of this study could potentially be used as input for thermal energy storage system level analysis, such as the charging and discharging processes.

42 ENGINEERING↗
DOE OSTI2024

Low-cost fin-tube heat exchanger design for building thermal energy storage using phase change material

Heat transfer in phase change materials (PCMs) is complex because the melting and freezing fronts change as functions of stored or released heat. In prior attempts to optimize heat exchangers (HXs) in one or two dimensions, complex geometry has often been used to maximize the melt and freeze front area. This complex geometry is difficult and hence expensive to construct. This paper proposes a multiple-scale 3D finite element modeling approach to design fin-tube HXs for low-cost latent thermal energy storage applications. Further, the optimal fin and tube designs were determined at three scales (unit-scale, medium-scale, and large-scale) by modeling the melt and freeze front in three dimensions and using measured bulk thermal properties. The finite element model was validated by comparing it with the experimental data for a referenced design of a similar type. The results indicate that commercially available organic PCMs with low conductivity (<0.3 W/m·K) can have charge and discharge times appropriate for building thermal energy storage (i.e., 4–5 h) with fin-tube HX designs at costs <$26/kWh, even when the temperature difference (5.56°C) between the heat transfer fluid and the PCM phase change temperature is small. However, as the HX increases in length, the temperature reduction along the tube limits some larger-scale designs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Impact of size and thermal gradient on supercooling of phase change materials for thermal energy storage

Phase change material based thermal energy storage has many current and potential applications in the heating and cooling of buildings, battery and electronics thermal management, thermal textiles, and dry cooling of power plants. However, connecting lab scale thermal data obtained with differential scanning calorimetry (DSC) to the performance of large-scale practical systems has been a major challenge primarily due to the dependence of supercooling on the size and temperature gradient of the system. Here we show how a phase change material’s supercooling behavior can be characterized experimentally using common lab scale thermal analysis techniques. We then develop a statistics based theoretical model that uses the lab-scale data on small samples to quantitatively predict the supercooling performance for a general thermal energy storage application of any size, including also allowing for the possibility of temperature gradients. Finally, we validate the modeling methodology by comparing to experimental results for solid-solid phase change in neopentyl glycol, which shows how the model successfully predicts the changes in supercooling temperature across a large range of cooling rates (2 orders of magnitude) and volumes (3 orders of magnitude). By accounting for thermal gradients, the model avoids ~2x error incurred by lumped approximations.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Techno-Economic Analysis of Dynamic Building Envelopes Comprising Phase Change Materials and Switchable Insulations

Integrating phase change materials (PCMs) in building envelopes is a recognized technique to reduce the space heating/cooling loads and provide load shedding and shifting capacity. However, PCM benefits have been found to reduce dramatically with increase in the insulation requirements. Dynamic building envelopes that can alter their thermal resistance based on the indoor and outdoor conditions can effectively harness free ambient heating/cooling, thereby greatly enhancing the benefits of the PCM-integrated envelope in managing thermal loads. In this study, we examine various combinations of PCMs and switchable insulations and compare their combined impact on heat flow through the building envelope. Using numerical analysis, we investigate the PCM- and switchable insulation-integrated building walls, calculate the potential energy saving benefits compared to the conventional static walls, and finally perform techno-economic analysis to estimate the acceptable cost of the technology under various payback period scenarios.

dynamic building envelopes↗
DOE OSTI2026

A Novel and Scalable Method for Microencapsulating Salt Hydrate Phase Change Materials in Core–Shell Fibers

Phase change materials (PCMs) are in high demand for applications such as thermal energy storage in buildings, electronics cooling, and thermal management of electric vehicle batteries and data centers. Among these materials, salt hydrate PCMs are particularly attractive due to their high thermal energy storage capacity and low cost. However, they suffer from two major issues: leakage in the melted phase and phase segregation during phase transitions. Microencapsulation is the primary process capable of addressing both of these challenges. However, there is no reliable or scalable method available for microencapsulating salt hydrate PCMs. As a result, the full potential of salt hydrates for building and data center applications has yet to be realized. In this work, we present an innovative method for the microencapsulation of salt hydrate PCMs using a co‐axial pushing technique. This process creates core–shell fibers, with the salt hydrate as the core and a polymer as the shell. Our approach demonstrates strong potential for scalable microencapsulation of salt hydrate PCMs. In conclusion, achieving scalability could enable their widespread use in applications such as data center cooling, battery thermal management, and building climate control.

Sharma, Jaswinder [Oak Ridge National Laboratory (↗
DOE OSTI2023

Neuromorphic Photonics Based on Phase Change Materials

Neuromorphic photonics devices based on phase change materials (PCMs) and silicon photonics technology have emerged as promising solutions for addressing the limitations of traditional spiking neural networks in terms of scalability, response delay, and energy consumption. In this review, we provide a comprehensive analysis of various PCMs used in neuromorphic devices, comparing their optical properties and discussing their applications. We explore materials such as GST (Ge 2 Sb 2 Te 5 ), GeTe-Sb 2 Te 3 , GSST (Ge 2 Sb 2 Se 4 Te 1 ), Sb 2 S 3 /Sb 2 Se 3 , Sc 0.2 Sb 2 Te 3 (SST), and In 2 Se 3 , highlighting their advantages and challenges in terms of erasure power consumption, response rate, material lifetime, and on-chip insertion loss. By investigating the integration of different PCMs with silicon-based optoelectronics, this review aims to identify potential breakthroughs in computational performance and scalability of photonic spiking neural networks. Further research and development are essential to optimize these materials and overcome their limitations, paving the way for more efficient and high-performance photonic neuromorphic devices in artificial intelligence and high-performance computing applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Techno-Economic Analysis of Dynamic Building Envelopes Comprising Phase Change Materials and Switchable Insulations: Preprint

Integrating phase change materials (PCMs) in building envelopes is a recognized technique to reduce the space heating/cooling loads and provide load shedding and shifting capacity. However, PCM benefits have been found to reduce dramatically with increase in the insulation requirements. Dynamic building envelopes that can alter their thermal resistance based on the indoor and outdoor conditions can effectively harness free ambient heating/cooling, thereby greatly enhancing the benefits of the PCM-integrated envelope in managing thermal loads. In this study, we examine various combinations of PCMs and switchable insulations and compare their combined impact on heat flow through the building envelope. Using numerical analysis, we investigate the PCM- and switchable insulation-integrated building walls, calculate the potential energy saving benefits compared to the conventional static walls, and finally perform technoeconomic analysis to estimate the acceptable cost of the technology under various payback period scenarios.

dynamic building envelopes↗
DOE OSTI2025

A Novel Approach for Microencapsulating Salt Hydrate-Based Phase Change Materials

Energy storage technologies, particularly those utilizing phase change materials (PCMs), have gained attention for their high energy density and efficient thermal management. PCMs, which store energy through solid-liquid phase transitions, can efficiently capture and release thermal energy, but face the challenge of leakage during the phase change process. Inorganic PCMs, such as salt hydrates, offer high energy storage capacity, but are difficult to encapsulate due to their corrosive nature. Conventional encapsulation techniques for inorganic PCMs are limited, particularly for scalable applications. In this work, we present an innovative method for the encapsulation of salt hydrate-based inorganic PCMs (CaCl 2 ·6H 2 O) using co-axial electrospinning. The process involves the creation of co-axial fibers, with salt hydrate as the core and polymer (e.g., PVP) as the outer shell, effectively preventing leakage and improving the stability of the PCM. This approach demonstrates the potential for scalable microencapsulation of inorganic PCMs, marking the first report of using co-axial electrospinning for this purpose. This novel technique could contribute to enhancing the performance and applicability of PCMs in thermal energy storage systems and other energy efficiency applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Experimental Analysis of Salt Hydrate Latent Heat Thermal Energy Storage System With Porous Aluminum Fabric and Salt Hydrate as Phase Change Material With Enhanced Stability and Supercooling

Phase change materials (PCMs), especially salt hydrates possess high volumetric energy storage capacity in their transition temperature range. These materials are used in applications where it is necessary to store thermal energy due to temporary load shift between demand and availability. Thus, possible applications are HVAC, recovery of waste heat, and defense thermal management. Despite salt hydrates potential, the practical feasibility of latent heat storage with salt hydrates is limited due to low power rating, supercooling, phase segregation, and long-term stability. Its low power rating and long-term stability limits its application in most applications. This work experimentally validates the stability and thermal performance of a compact heat exchanger charged with salt hydrate during melting and freezing. The compact heat exchanger was designed with fins on both the heat transfer fluid (HTF) and salt hydrate PCM side. The thermal performance of the latent heat thermal energy storage system (LHTESS) was evaluated for various operating conditions. The results show that LHTESS could achieve an average heat transfer coefficient of 124 and 87 W/(m2 K) during melting and solidification, respectively. The stability of the system in suppressing supercooling was validated over 800 cycles with nucleating agent and active homogenous nucleation techniques. The supercooling was reduced to 3 °C with zinc hydroxyl nitrate as nucleating agent and less than 1 °C with the active homogenous nucleation technique. The LHTESS showed less than 6% degradation in energy storage capacity over 800 cycles.

42 ENGINEERING↗