The Iraqi Jo The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.

1, 2008

NUMERICAL SIMULATION OF THERMAL ENERGY

STORAGE SYSTEM USING PHASE CHANGE
MATERIAL FOR FREE COOLING OF BUILDINGS

Dr. Karima E. Amori

Mech. Eng. Dep., University of Baghdad, Iraq

ABSTRACT
A numerical investigation is adopted for a two dimensional thermal energy storage
system (TES), employing finite element method to compute the time of charging or
discharging energy from a phase change material (PCM) during day or night to utilize
it in free cooling of space applying Baghdad Summer climate conditions (ambient
temperature). A computer program is developed to analyze the thermal energy unit for
different tube diameters, air flow rates and inlet air temperature for both solidification
and melting processes. This study shows that utilizing small tube diameter, low flow
rates or air inlet temperature near the fusion temperature lead to increase time of
phase change process. It was also shown that the time duration of melting is larger
than solidification.

ٌِKeywords: Free Cooling, PCM, Melting, Solidification, FEM.

‫اﻟﺨﻼﺻﺔ‬
‫ﺗﻢ أﺟﺮاء ﺗﺤﻠﻴﻞ ﻋﺪدي ﺛﻨﺎﺋﻲ اﻟﺒﻌﺪ ﻟﻤﻨﻈﻮﻣﺔ ﺧﺰن ﺣﺮارﻳﺔ ﺑﺄﺳﺘﺨﺪام ﻃﺮﻳﻘﺔ اﻟﻌﻨﺎﺻﺮ اﻟﻤﺤﺪدة ﻟﺤﺴﺎب زﻣﻦ‬
‫اﻟﺸﺤﻦ أو اﻟﺘﻔﺮﻳﻎ ﻟﻠﻄﺎﻗﺔ ﻣﻦ ﻣﺎدة ﻣﺘﻐﻴﺮة اﻟﻄﻮر ﺧﻼل اﻟﻨﻬﺎر أو اﻟﻠﻴﻞ ﻷﺳﺘﺨﺪاﻣﻬﺎ ﻓﻲ ﺗﺒﺮﻳﺪ اﻷﺑﻨﻴﺔ و ﺑﻜﻠﻔﺔ واﻃﺌﺔ‬
‫ ﺗﻢ اﻋﺪاد ﺑﺮﻧﺎج ﺑﻠﻐﺔ‬. (‫أﻋﺘﻤﺎدا" ﻋﻠﻰ اﻟﻈﺮوف اﻟﺠﻮﻳﺔ ﻟﻤﺪﻳﻨﺔ ﺑﻐﺪاد ﺧﻼل ﻣﻮﺳﻢ اﻟﺼﻴﻒ ) درﺟﺔ ﺣﺮارة اﻟﺠﻮ‬
‫ ودرﺟﺎت‬,‫ وﻣﻌﺪﻻت دﻓﻖ هﻮاء ﻣﺨﺘﻠﻔﺔ‬, ‫اﻟﻔﻮرﺗﺮان ﻟﺘﺤﻠﻴﻞ وﺣﺪة اﻟﻄﺎﻗﺔ اﻟﺤﺮارﻳﺔ ﻷﻧﺎﺑﻴﺐ ذا ت أﻗﻄﺎر ﻣﺨﺘﻠﻔﺔ‬
‫ أو‬,‫ ﺑﻴﻨﺖ اﻟﺪراﺳﺔ أن أﺳﺘﻌﻤﺎل أﻧﺒﻮب ذو ﻗﻄﺮ ﺻﻐﻴﺮ‬.‫ﺣﺮارة دﺧﻮل ﻣﺘﻌﺪدة وﻟﻜﻞ ﻣﻦ ﻋﻤﻠﻴﺔ اﻷﺗﺠﻤﺎد واﻷﻧﺼﻬﺎر‬
‫ أو دﺧﻮل اﻟﻬﻮاء ﺑﺪرﺟﺔ ﺣﺮارة ﻗﺮﻳﺒﺔ ﻣﻦ درﺟﺔ اﻷﻧﺼﻬﺎر ﻳﺆدي اﻟﻰ زﻳﺎدة اﻟﻮﻗﺖ اﻟﻼزم‬, ‫ﻣﻌﺪل ﺟﺮﻳﺎن واﻃﺊ‬
.‫ وأﻇﻬﺮت اﻟﺪراﺳﺔ أﻳﻀﺎ أن زﻣﻦ ﻋﻤﻠﻴﺔ اﻷﻧﺼﻬﺎر أآﺒﺮ ﻣﻦ زﻣﻦ ﻋﻤﻠﻴﺔ اﻷﻧﺠﻤﺎد‬.‫ﻟﺘﻐﻴﺮ اﻟﻄﻮر‬

INTRODUCTION
Phase change storage systems have been developed for many applications such as ice
storage, conservation and transport of temperature sensitive materials, building
insulation applications, etc. Employing the heat released or absorbed at melting/
solidification temperature of phase change material (PCM) in space heating or cooling
is an important feature of this process.
A review of thermal energy storage particularly on moving boundary problems in
different heat exchanger constructions is presented by Zalba et. al.(2003).A storage
unit composed of spherical capsules filled with (PCM) placed inside a cylindrical tank
is investigated numerically and experimentally by Ismail and Heriqniez (2002). They
treated the solidification process using only one dimensional heat conduction
employing finite difference approximation and a moving grid inside the spherical
capsules. Zukowski (2007) analyze the heat and mass transferred in a ventilation duct
filled with encapsulated paraffin wax (RII56) for short term heating by adapting three
dimensional fully implicit (FDM).
The objective of the present work is to design and to analyze the thermal behavior of
energy storage system shown in Fig.(1),utilizing (PCM) of melting temperature
around (29.5 Co) , in order to employ it in a free cooling of a building by releasing
heat during night and absorbing heat during day. Such application is feasible in

1
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

climates where the temperature difference between day and night in summer is about
(15 Co).

MATHEMATICAL MODEL
Assumptions
To establish a convenient mathematical model to analyze the transient temperatures
and heat transfer rates, the following assumptions have been introduced:
• The PCM is homogenous and isotropic and the thermo physical properties of
solid phase are different from that of liquid phase.
• The thermo physical properties of PCM are independent on temperature.
• Thermal losses from system external boundary and radiation heat transfer
inside the system are ignored.
• Forced convection fully developed air flow inside tubes.
• The initial temperature of the (PCM) is uniform and assumed at melting
temperature (Tm) for solidification process, and at solidifying temperature (Ts)
for melting process.

Governing Equation
The energy equation for a material undergoing a phase transformation is given as:

∂H
ρ + ρ u∇H = k∇ 2T + s (1)
∂t

For constant thermo physical properties (constant density ) of the PCM and no
heat sources , eq.(1) can be reduced to :

∂H
ρ = k∇ 2T (2)
∂t
∂T
Substituting the left hand side by ρ c p , yields:
∂t
∂T
ρ cp = k∇ 2T (3)
∂t

Geometry and Boundary Conditions

The initial condition specifies a constant temperature field at (To) at time zero. The
boundary conditions, given as:

∂T
=0 (4)
∂n

at external boundary and plane of symmetry as shown in fig.(1), while that at internal
surface of tube wall :

∂T
k = hi (T − T∞ ) (5)
∂n

The internal heat transfer coefficient (hi) is calculated for turbulent fluid flow
according to (Kays and Crawford 1993)

2
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

k (Re− 1000) * C f / 2
hi = ( ) (6)
D 1 + 12.7 C / 2 (Pr 2 3 − 1)
f

C f = 2 ( 2.236 ln(Re) − 4.639 ) −2 (7)

Where
C f is Petukhovs friction coefficient for turbulent flow (Kays and Crawford 1993) .

NUMERICAL ANALYSIS
Differential eq.(3) with initial and boundary conditions (eq.s (4) and (5) respectively),
have been descretized using finite element method, employing Galerkin procedure
leads to the following typical components of elemental mass and stiffness matrices
(Me and Ke respectively), and force vector Fe which can be defined as:

M ejk = ∫ ρ C p N j N k dΩ e (8)
Ωe

K ejk = ∫ ∇N k • (k∇N j ) dΩ e + ∫ e hi N j N k dΓ e (9)

Ωe Γ

Fke = ∫ e hi N k dΓ e (10)
Γ

The thermophysical properties during phase change process (solidification or melting)

are calculated as : (using table (1))

C p = LH (11)
(Tm − Ts )

k = Fs k s + (1 − Fs ) k m (12)

ρ = Fs ρ s + (1 − Fs ) ρ m (13)

Where the subscripts (s) and (m) refer to solid phase and melted phase respectively,
and the elemental solid fraction is calculated using linear interpolation as:

T − Ts
Fs = (14)
Tm − Ts

where T refers to the elemental average temperature.

The elemental matrices and vector (Me ,Ke and Fe)are assembled into global matrices
and global vector to obtain a system of first order time dependent differential equation

[M ] {T } + [K ]{T } = {F }
•
(15)

A recursive algorithm based on time marching technique (finite difference method) is

adopted to solve eq.(15) (Smith and Giffiths 2004), so introducing a linear
interpolation and fixed time step ∆t :

3
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

T = θ T n + (1 − θ ) T o (16)

Where
T n and T o : new and old temperature values respectively
θ : constant such that 0 ≤ θ ≤ 1 (taking =2/3 based on Galerkin approach with
unconditional stability)
Substituting eq.(16) in eq.(15) leading to the following result

[ M + θ ΔtK ]T n = [ M − (1 − θ ) Δt K ]T o + ΔtF (17)

Rearranging this equation to get a system of algebraic equations as:

[A] T n ={B} (18)

Grid Generation
The mesh shown in fig.(1) represents a symmetrical quarter of thermal energy storage
unit composed of (209) nodes and (180) quadrilateral linear four nodded elements.
The first layer of elements adjacent to fluid represents the copper tube wall while the
rest belong to PCM.

Computational Procedure
The computational steps followed in the present work are:
1- Read input data :
a. Thermophysical properties of copper tube and of calcium chloride
hexhydrate (PCM chosen in the present work is a hydrate salt) (Table (1)) .
b. TES unit size and tube diameter (Table (2)).
c. Initial temperature
d. Air inlet temperature, and flow rate.
e. Time step.
2- Generate nodes coordinates and elemental nodes (local and global) and
compute elemental area.
3- At each time step
a. Increment time
b. Form elemental matrices and vector
c. Assemble elemental matrices and vector to global system
d. Modify system matrices to form matrix A and vector B
e. Solve the system of simultaneous equations [eq.(18)] to evaluate T n
using Gauss Elimination method for symmetrical matrix A
4- Advance to the next time step
Time required to complete phase change (solidification or melting duration ) can be
determined by subtracting the time required to change the phase of the first node (t1)
from that required for the last node ((t2) in the analyzed domain.
a Fortran computer program is developed for the computational approach using
(Fortran power station 95 software). The execution time varies between (7-10 min for
time step of (10 s) depending on period of examination) on a personal computer
Pentium 4.

4
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

RESULTS AND DISCUSSION

Verification of the Computer Program
The validity of the computational procedure and the computer program developed is
examined by solving a two dimensional phase change problem which is initially at
material fusion temperature (Tf) then suddenly subjected to T1 in order to solidify the
material as shown in fig.(2a). The results obtained are compared with that published
by [ Crowley 1978 ]. Fig.(2b) shows a good agreement between the computational
and published results with maximum variation of 0.1% .

Solidification Process
Figures (3 to 5) indicate the transient temperature profile at a selected node of PCM
(namely node 20) during solidification process. Fig(3) shows that the solidification
duration decreases as the air flow rate increases, since increasing air flow rate causes
an increase in Reynolds number, hence increasing heat transfer coefficient (hi )
according to equation (6) for the same ( PCM volume) value of thermal energy
storage unit, thence increasing the heat transferred from air to PCM and decreasing
solidification duration.
It is also shown that employing larger tube diameter leads to increase the surface area
through which heat is transferred from air to (PCM), hence decreasing solidification
time with fixed air inlet temperature and flow rate as shown in Fig. (4).
The effect of temperature difference between melting temperature of (PCM) (=29.9
Co in the present work) and air inlet temperature on solidification time can be shown
in Fig.(5). Its is clear that increasing the temperature difference leads to increase the
heat transferred to air for the same flow rate and tube diameter, hence decreasing the
solidification time .
Fig.(6) shows that the variation of air flow rate has no significant effect on
solidification time for large tube diameters. While it has a considerable effect for
small tube diameters, since for the same flow rates the air velocity is higher in small
diameter which causes flow of high Reynolds number that affect the heat transfer
coefficient (hi ) as it is clear from eq.(6). It can also be deduced from this figure that
air inlet temperature has a weak effect on solidification duration for a unit of large
tube diameters while its effect is obvious for units of small tube diameters.
Fig.(7) shows that maximum energy exchanged between air and (PCM) for small
tube diameters with high flow rate values while the minimum is for large tube
diameter with low flow rate values.

Melting Process
Fig.(8) Shows the melting process during day for air inlet temperature and flow rate
of (45 Co 150 m3/hr respectively). It obviously shown that duration time of melting
process during day is larger than that of solidification process during night. The
factors affect melting process are air flow rate as indicated by Fig.(9), and tube
diameter as shown in Fig. (10), while air inlet temperature has no significant effect on
melting time for all tube diameters investigated as shown in Fig. (10). This is due to
the effect of these parameters on heat transfer coefficient.

5
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

CONCLUSION
An application of (PCM) in free cooling system is presented. Numerical experiments
are conducted to specify the main parameters influence the thermal behavior of this
system. The following concluding remarks can be drawn during this work as follows:
1- The solidification process is faster with:
a- Increasing air flow rate
b-Employing larger tube diameter
c- Increasing the difference between inlet air temperature and melting
temperature of PCM
2-A small effect for the air flow rate through large tube diameter on solidification
time has been indicated while a significant effect for a unit with small tube
diameter.
3- The variation of air inlet temperature has significant effect on solidification
time for a unit with small tube diameter.
4- The most effective parameters on melting process are air flow rate and tube
diameter of thermal energy storage unit.

REFERENCES:
Crowley A.B.,(1978)," Numerical Solution of Stefan Problems", Mass
Transfer,21,215

Holman, J.P. ;(1981) ;”Heat Transfer”, Fifth Edition, McGraw-Hill Book Company
Ismail Kar; Henriquez, JR., (2002),“Numerical and Experimental Study of Spherical
Capsules Packed Bed Latent Heat Storage System" Applied thermal engineering 22,
P.P.1705-1716.

Kays,W.M. and Crawford,M.E. (1993),"Convective Heat and Mass

Transfer",Newyork,McGraw Hill

Smith, I.M. and Giffiths, D.V. (2004),"Programming the finite element method"
,Third Edition, John Wiley & Sons Ltd. England.

Zalba B. ; Marin J.M. ;Cabeza,L.F. and Mehling H.,(2003)," Review on Thermal

Energy Storage with Phase Change Materials, Heat Transfer Analysis and
Applications ", Applied thermal engineering 23, P.P. 251-283

Zukowski M. (2007), "Mathematical Modeling and Numerical Simulation of a Short

Term Thermal Energy Storage System Using Phase Change Material for Heating
Applications", Energy Conversion & Management 48, P.P.155-165

NOMENCLEATURE:
D : Tube diameter (m)
{F} : Global force vector
k : Fluid thermal conductivity (W/m.Co)
[K] : Global stiffness matrix
[M] : Global mass matrix
n : Unit normal vector

6
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

Q : Air volumetric flow rate (m3/hr)

Re : Reynolds number
Pr : Prandtle number
t : Time (s)
T : PCM or tube wall temperature (Co)
Tin : Air inlet temperature (Co)
T∞ : Air bulk temperature (Co)
u : Velocity (m/s)

Table (1):Thermo physical Properties of PCM (CaCl 6H2O) (Zalba et al., 2003)
and Copper Tube (Holman 1981)
Melting temperature Tm = 29.9 Co
solidifying temperature Ts = 29.5 Co
Latent heat of fusion LH=187 kJ/kg
Property Solid phase Liquid phase copper
Thermal conductivity k (W/m.Co) 1.09 0.53 386
Specific heat Cp (kJ/kg.K) 1.4 2.2 0.3831
Density (kg/m3) 1710 1530 8954

Table (2):TES unit Dimensions

Tube Diameter TES unit size
(mm) Height (H) (mm) W (mm)
10 81.15 50
25 85.274 50
50 100 50

7
Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

PCM

Analyzed
Domaine

Flow Inside Tubes

(a)

19 209

Tube of x
Diameter =D
1
20

H/2

191
Insulated W
sides
y
(b)
Fig.(1): (a)Thermal Energy Storage System ,(b) Grid Generation of Quarter of
Thermal Energy Storage Unit

8
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

T1

T1
Tf

T1

2L T1

(a)
100
Computed results
90 Crowley

80

70
Solid Fraction

60

50

40

30

20

10

0 1 2 3 4 5 6 7 8 9 10
t
(b)
Fig.(2): a) Analyzed Domain ,(b)Comparison of Computational Results and Crowley
Results for Two Dimensional Phase Change Problem

Solid fraction = solid volume /(total volume)

α (time)
t= dimensionless time
L2
α : thermal diffusivity

9
Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

30.1

30.0

29.9

29.8
Temp. (C)

29.7

Q=50
29.6

Q=100
29.5
Q=150
29.4

29.3

29.2

0 5000 10000 15000 20000 25000 30000 35000 40000

Time (s)
Fig.(3): Effect of Air Flow Rate on Solidification Time for TES of Tube Diameter
D=10 mm, Tin=25 Co (Temperature history at node 20)

30.0

29.8

29.6

29.4
Temperature (C )

D=10 mm
29.2

29.0

D=25 mm
28.8

28.6 D=50 mm

28.4

28.2

0 10000 20000 30000 40000 50000 60000 70000 80000

time (s)
Fig.(4): Effect of Tube Diameter on Solidification Time for Air Flow Rate =150
m3/hr, Tin=25 Co, (Temperature profile at node 20)

10
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

30.0

29.9

29.8
Temperature (C)

29.7
Tin = 27 C
29.6

29.5

Tin = 28 C
29.4

29.3 Tin = 25 C

29.2

0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000
Time (s)
Fig.(5): Effect of Air Inlet Temperature on Solidification Time for Air flow rate =150
m3/hr and Tube Diameter = 10 mm, (Temperature profile at node 20)

28500

26000 D=10 mm

23500
Solidification time (s)

21000
Q=150 m3/hr

18500 Q=100 m3/hr

Q=50 m3/hr

16000
D= 25 mm

13500

11000

D= 50 mm
8500

6000

24.5 25.0 25.5 26.0 26.5 27.0 27.5 28.0 28.5

Inlet temp. (C)
Fig.(6): Parameterization of Flow rate, Tube Diameter and inlet Temperature on Time
of Solidification Process

11
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

Q=150 m3/hr
Q=100 m3/hr

Energy exxchanged during phase change (kJ)

Q=50 m3/hr
Tin=28 C
Tin=27 C
Tin=25 C

10000

1000

5 10 15 20 25 30 35 40 45 50 55
Tube diameter (mm)
Fig.(7): Parameterization of Flow rate, Tube Diameter and Inlet Temperature on
energy exchanged during Solidification Process

30.0

29.9

29.8

29.7 Solidification
Melting
Temperature (C)

29.6

29.5

29.4

29.3

29.2

29.1

0 10000 20000 30000 40000 50000 60000 70000 80000 90000

Time (s)
Fig.(8): Time Duration of Solidification and Melting for (Q =150m3/hr, D=50 mm at
node 20)

12
 Dr. Karima , The Iraqi Journal For Mechanical And Material Engineering, Vol.8, No.1, 2008

30.2

30.0
Q=100 m3/hr
Q=150 m3/hr
Temperature (C )

29.8

Q=50 m3/hr

29.6

29.4

29.2

0 10000 20000 30000 40000 50000

time (s)
Fig.(9): Effect of Air Flow Rate on Duration Time of Melting for
(D=10 mm, Tin=45 Co )

110000
Q=150 m3/hr
100000
Q=100 m3/hr

90000 Q=50 m3/hr

Tin=40 C
80000 Tin=45 C
Tin=48 C
70000
Melting time (s)

60000

50000

40000

30000

20000

10000

5 10 15 20 25 30 35 40 45 50
Tube diameter (mm)
Fig.(10): Parameterization of Flow rate, Tube Diameter and Inlet Air Temperature on
Melting Duration

13