Mathematical modeling,numerical simulation and experimental validation of temperature profiles of PCMs and their applications in industry 4.0: A review
Restricted accessReview articleFirst published online September, 2024
Mathematical modeling,numerical simulation and experimental validation of temperature profiles of PCMs and their applications in industry 4.0: A review
Industry 4.0 or smart factories employ phase change materials as smart materials for thermal energy storage systems. In this work the mathematical modeling (Governing equation and boundary condition) of phase change materials (PCMs) and numerical simulations, broadly performed on ANSYS workbench has been reviewed. A complete variety of most frequently used PCM’s were modeled, analyzed, and compared by using various profiles for their temperature distribution and thermal behavior. Furthermore, the different values obtained through modeling and simulation were validated with their corresponding experimental findings and the differences in the values were also supported with valid reasons ensued amongst different constituents at atomic level. This review also presents the varied applications of PCM for different temperature ranges like low, low medium, medium and high temperature ranges for industry 4.0. The automated factories of future of industry 4.0 have its major applications in solar energy, mobile telephony, building applications, vehicle applications and textile industries.
López-SabirónAMRoyoPFerreiraVJ, et al. Carbon footprint of a thermal energy storage system using phase change materials for industrial energy recovery to reduce the fossil fuel consumption. Appl Energy2014; 135: 616–624.
2.
WangYYangXXiongT, et al. Performance evaluation approach for solar heat storage systems using phase change material. Energy Build2017; 155: 115–127.
3.
OngTGrahamEWillG, et al. High-temperature phase change material (PCM) selection for concentrating solar power tower applications. Adv Sustain Syst2019; 3: 1800131.
4.
GovindanKArampatzisG. A framework to measure readiness and barriers for the implementation of industry 4.0: a case approach. Electron Commer Res Appl2023; 59: 101249.
5.
KhanMHaleemAJavaidM. Changes and improvements in industry 5.0: a strategic approach to overcome the challenges of industry 4.0. Green Technol Sustain2023; 1: 100020.
6.
CanbayKAkmanG. Investigating changes of total quality management principles in the context of Industry 4.0: viewpoint from an emerging economy. Technol Forecast Soc Change2023; 189: 122358.
7.
NuttahMMRomaPLo NigroG, et al. Understanding blockchain applications in industry 4.0: from information technology to manufacturing and operations management. J Ind Inf Integr2023; 33: 100456.
8.
RenYLiRWuKJ, et al. Discovering the systematic interlinkages among the circular economy, supply chain, industry 4.0, and technology transfer: a bibliometric analysis. Clean Responsible Consum2023; 9: 100123.
9.
MantravadiSSraiJSMøllerC. Application of MES/MOM for industry 4.0 supply chains: a cross-case analysis. Comput Ind2023; 148: 103907.
10.
DutilYRousseDRSalahNB, et al. A review on phase-change materials: mathematical modeling and simulations. Renew Sustain Energ Rev2011; 15: 112–130.
11.
Al-abidiAABin MatSSopianK, et al. CFD applications for latent heat thermal energy storage: a review. Renew Sustain Energ Rev2013; 20: 353–363.
12.
KolaitisDIFountiMA. Solar wall enhanced with phase-change materials: a detailed numerical simulation study. Adv Build Energy Res2017; 11: 87–103.
13.
AsgharianHBaniasadiE. A review on modeling and simulation of solar energy storage systems based on phase change materials. J Energy Storage2019; 21: 186–201.
14.
KlimešLCharvátPMastani JoybariM, et al. Computer modelling and experimental investigation of phase change hysteresis of PCMs: the state-of-the-art review. Appl Energy2020; 263: 114572.
15.
XiongTZhengLShahKW. Nano-enhanced phase change materials (NePCMs): a review of numerical simulations. Appl Therm Eng2020; 178: 115492.
16.
ZhanHMahyuddinNSulaimanR, et al. Phase change material (PCM) integrations into buildings in hot climates with simulation access for energy performance and thermal comfort: a review. Constr Build Mater2023; 397: 132312.
17.
ZahirMHIrshadKShafiullahM, et al. Challenges of the application of PCMs to achieve zero energy buildings under hot weather conditions: a review. J Energy Storage2023; 64: 107156.
18.
GoelVDwivediAKumarR, et al. PCM-assisted energy storage systems for solar-thermal applications: review of the associated problems and their mitigation strategies. J Energy Storage2023; 69: 107912.
19.
ChenS-BSaleemSAlghamdiMN, et al. Combined effect of using porous media and nano-particle on melting performance of PCM filled enclosure with triangular double fins. Case Stud Therm Eng2021; 25: 100939.
20.
KandiRPSudharminiMMSuryanA, et al. State of the art and future prospects for TEG-PCM systems: a review. Energy Sustain Dev2023; 74: 328–348.
21.
PathakSKTyagiVVChopraK, et al. Integration of emerging PCMs and nano-enhanced PCMs with different solar water heating systems for sustainable energy future: a systematic review. Sol Energy Mater Sol Cells2023; 254: 112237.
22.
WangXLiWLuoZ, et al. A critical review on phase change materials (PCM) for sustainable and energy efficient building: design, characteristic, performance and application. Energy Build2022; 260: 111923.
23.
ChoureBKAlamTKumarR. A review on heat transfer enhancement techniques for PCM based thermal energy storage system. J Energy Storage2023; 72: 108161.
24.
NematpourKeshteliAIasielloMLangellaG, et al. Enhancing PCMs thermal conductivity: A comparison among porous metal foams, nanoparticles and finned surfaces in triplex tube heat exchangers. Appl Therm Eng2022; 212: 118623.
25.
LiuYZhengRLiJ. High latent heat phase change materials (PCMs) with low melting temperature for thermal management and storage of electronic devices and power batteries: critical review. Renew Sustain Energ Rev2022; 168: 118623.
26.
MousaviSRismanchiBBreyS, et al. PCM embedded radiant chilled ceiling: a state-of-the-art review. Renew Sustain Energ Rev2021; 151: 111601.
27.
DhaidanNSKhodadadiJM. Improved performance of latent heat energy storage systems utilizing high thermal conductivity fins: a review. J Renew Sustain Energy2017; 9: 034103.
28.
DhaidanNSHassanAFRasheed Al-GaheeshiAM, et al. Experimental investigation of thermal characteristics of phase change material in finned heat exchangers. J Energy Storage2023; 71: 108162.
29.
TanSZhangX. Progress of research on phase change energy storage materials in their thermal conductivity. J Energy Storage2023; 61: 106772.
30.
DhaidanNS. Nanostructures assisted melting of phase change materials in various cavities. Appl Therm Eng2017; 111: 193–212.
31.
MaqboolZHaniefMParveezM. Review on performance enhancement of phase change material based heat sinks in conjugation with thermal conductivity enhancers for electronic cooling. J Energy Storage2023; 60: 106591.
32.
DhaidanNSKokzSARashidFL, et al. Review of solidification of phase change materials dispersed with nanoparticles in different containers. J Energy Storage2022; 51: 104271.
33.
KhedherNBMahdiJMMajdiHS, et al. A hybrid solidification enhancement in a latent-heat storage system with nanoparticles, porous foam, and fin-aided foam strips. J Energy Storage2022; 56: 106070.
34.
DhaidanNAl-JethelahM. Study on the effect of nanoparticle dispersion on the melting of PCM in hemicylindrical cell. In: 12th IIR conference on phase-change materials and slurries for refrigeration and air conditioning (PCM 2018), Orford, QC, Canada, 2018, pp.240–247.
35.
PatankarS. Numerical heat transfer and fluid flow. Taylor & Francis, 2018.
36.
WangWLiHGuoS, et al. Numerical simulation study on discharging process of the direct-contact phase change energy storage system. Appl Energy2015; 150: 61–68.
37.
WangPLiDHuangY, et al. Numerical Study of solidification in a plate heat exchange device with a zigzag configuration containing multiple phase-change-materials. Energies2016; 9: 394.
38.
WangMLiuLZhangX-Y, et al. Experimental and numerical investigations of heat transfer and phase change characteristics of cemented paste backfill with PCM. Appl Therm Eng2019; 150: 121–131.
39.
YangXBaiQGuoZ, et al. Comparison of direct numerical simulation with volume-averaged method on composite phase change materials for thermal energy storage. Appl Energy2018; 229: 700–714.
40.
ZhaoWElmozughiAFOztekinA, et al. Heat transfer analysis of encapsulated phase change material for thermal energy storage. Int J Heat Mass Transf2013; 63: 323–335.
41.
ZhuLYangYChenS, et al. Numerical study on the thermal performance of lightweight temporary building integrated with phase change materials. Appl Therm Eng2018; 138: 35–47.
42.
SongYZhangNJingY, et al. Experimental and numerical investigation on dodecane/expanded graphite shape-stabilized phase change material for cold energy storage. Energy2019; 189: 116175.
43.
NagarSSharmaK. Modern solar systems driven by nanoparticles-based fatty acids and paraffin wax phase change materials. J Mater Sci2021; 56: 4941–4966.
44.
LanguriEMRokniHBAlvaradoJ, et al. Heat transfer analysis of microencapsulated phase change material slurry flow in heated helical coils: a numerical and analytical study. Int J Heat Mass Transf2018; 118: 872–878.
45.
TomizawaYSasakiKKurodaA, et al. Experimental and numerical study on phase change material (PCM) for thermal management of mobile devices. Appl Therm Eng2016; 98: 320–329.
46.
ChavanSGumtapureVDAP. Numerical and experimental analysis on thermal energy storage of polyethylene/functionalized graphene composite phase change materials. J Energy Storage2020; 27: 101045.
47.
YoussefWGeYTTassouSA. CFD modelling development and experimental validation of a phase change material (PCM) heat exchanger with spiral-wired tubes. Energy Convers Manag2018; 157: 498–510.
48.
NagarSSharmaKSinghM, et al. Charging analysis and characterizations of COOH group functionalized graphene combined with paraffin wax as phase change material for thermal energy storage applications. J Therm Anal Calorim2022; 147: 11021–11038.
49.
SalariAKazemianAMaT, et al. Nanofluid based photovoltaic thermal systems integrated with phase change materials: numerical simulation and thermodynamic analysis. Energy Convers Manag2020; 205: 112384.
50.
GuerraicheDBougriouCGuerraicheK, et al. Experimental and numerical study of a solar collector using phase change material as heat storage. J Energy Storage2020; 27: 101133.
51.
JurčevićMPengaŽKlarinB, et al. Numerical analysis and experimental validation of heat transfer during solidification of phase change material in a large domain. J Energy Storage2020; 30: 101543.
52.
AbdelsalamMYSarafrazPCottonJS, et al. Heat transfer characteristics of a hybrid thermal energy storage tank with phase change materials (PCMs) during indirect charging using isothermal coil heat exchanger. Sol Energy2017; 157: 462–476.
53.
KazemianASalariAHakkaki-FardA, et al. Numerical investigation and parametric analysis of a photovoltaic thermal system integrated with phase change material. Appl Energy2019; 238: 734–746.
54.
NagarSSharmaKPandeyAK, et al. Effect of graphene and its derivatives on thermo-mechanical properties of phase change materials and its applications: a comprehensive review. Front Energy2022; 16: 150–186.
55.
MoradiRKianifarAWongwisesS. Optimization of a solar air heater with phase change materials: Experimental and numerical study. Exp Therm Fluid Sci2017; 89: 41–49.
56.
SuDJiaYLinY, et al. Maximizing the energy output of a photovoltaic–thermal solar collector incorporating phase change materials. Energy Build2017; 153: 382–391.
57.
KhodadadiJMHosseinizadehSF. Nanoparticle-enhanced phase change materials (NEPCM) with great potential for improved thermal energy storage. Int Commun Heat Mass Transf2007; 34: 534–543.
58.
ZhaoMZhuTWangC, et al. Numerical simulation on the thermal performance of hydraulic floor heating system with phase change materials. Appl Therm Eng2016; 93: 900–907.
59.
RoyonLKarimLBontempsA. Thermal energy storage and release of a new component with PCM for integration in floors for thermal management of buildings. Energy Build2013; 63: 29–35.
60.
KheradmandMAzenhaMde AguiarJLB, et al. Experimental and numerical studies of hybrid PCM embedded in plastering mortar for enhanced thermal behaviour of buildings. Energy2016; 94: 250–261.
61.
SáAVAzenhaMde SousaH, et al. Thermal enhancement of plastering mortars with phase change materials: Experimental and numerical approach. Energy Build2012; 49: 16–27.
62.
AzizSAminNAMAbdul MajidMS, et al. CFD simulation of a TES tank comprising a PCM encapsulated in sphere with heat transfer enhancement. Appl Therm Eng2018; 143: 1085–1092.
63.
Boudali ErrebaiFChikhSDerradjiL. Experimental and numerical investigation for improving the thermal performance of a microencapsulated phase change material plasterboard. Energy Convers Manag2018; 174: 309–321.
64.
ElmozughiAFSolomonLOztekinA, et al. Encapsulated phase change material for high temperature thermal energy storage – heat transfer analysis. Int J Heat Mass Transf2014; 78: 1135–1144.
65.
AssisEZiskindGLetanR. Numerical and experimental study of solidification in a spherical shell. J Heat Transf2009; 131: 024502.
66.
EzanMAOzcan DoganayEYavuzFE, et al. A numerical study on the usage of phase change material (PCM) to prolong compressor off period in a beverage cooler. Energy Convers Manag2017; 142: 95–106.
67.
HuXZhuFGongX. Experimental and numerical study on the thermal behavior of phase change material infiltrated in low porosity metal foam. J Energy Storage2019; 26: 101005.
68.
DuKCalautitJWangZ, et al. A review of the applications of phase change materials in cooling, heating and power generation in different temperature ranges. Appl Energy2018; 220: 242–273.
69.
LuY. Industry 4.0: a survey on technologies, applications and open research issues. J Ind Inf Integr2017; 6: 1–10.
70.
WangFMaidmentGMissendenJ, et al. The novel use of phase change materials in refrigeration plant. Part 1: experimental investigation. Appl Therm Eng2007; 27: 2893–2901.
71.
Ben TaherMAAhachadMMahdaouiM, et al. Thermal performance of domestic refrigerator with multiple phase change materials: numerical study. J Energy Storage2022; 55: 105673.
72.
SekharSJRajMAFRaveendranPS, et al. Cladding phase change materials in freezing and chilling zones of household refrigerator to improve thermal performance and environmental benefits. J Energy Storage2022; 55: 105476.
73.
MonaYThiangchantaSChaichanaC. Electricity peak load reduction of a refrigerator using phase change material. Energy Rep2022; 8: 48–53.
74.
KazemiMKianifarANiazmandH. A lab-scale study on thermal performance enhancement of phase change material containing multi-wall carbon nanotubes for buildings free-cooling. Sustain Energy Technol Assess2022; 50: 101813.
75.
YangSZhangYZhaoY, et al. PCM-based ceiling panels for passive cooling in buildings: a CFD modelling. Energy Build2023; 285: 112898.
76.
DeoreKSalunkeNPPawarSB. Phase change materials (PCMs) in solar still: - a review of use to improve productivity of still. Mater Today Proc2023.
77.
LoemSAsanakhamADeethayatT, et al. Testing of solar inverter air conditioner with PCM cool storage and sizing of photovoltaic modules. Therm Sci Eng Prog2023; 38: 101671.
78.
ArumugamCShaikS. Air-conditioning cost saving and CO2 emission reduction prospective of buildings designed with PCM integrated blocks and roofs. Sustain Energy Technol Assess2021; 48: 101657.
79.
HatamlehRIAbu-HamdehNHBantanRAR. Integration of a solar air heater to a building equipped with PCM to reduce the energy demand. J Build Eng2022; 48: 103948.
80.
DineshSNSaminathanRPatilMM, et al. Investigating the single pass baffled solar air heater (SAH) with an organic PCM (OPCM). Mater Today Proc2022; 62: 5245–5249.
81.
AmeriMSardariRFarzanH. Thermal performance of a V-corrugated serpentine solar air heater with integrated PCM: a comparative experimental study. Renew Energy2021; 171: 391–400.
82.
AfolabiLOEnweremaduCCKareemMW, et al. Experimental investigation of double slope solar still integrated with PCM nanoadditives microencapsulated thermal energy storage. Desalination2023; 553: 116477.
83.
SangeethaAShanmuganSAlrubaieAJ, et al. A review on PCM and nanofluid for various productivity enhancement methods for double slope solar still: future challenge and current water issues. Desalination2023; 551: 116367.
84.
Samuel HansenRBlessy Queen MaryMSomesh SubramanianS, et al. Utilization of PCM in inclined and single basin solar stills to improve the daily productivity. Mater Today Proc2022; 62: 967–972.
85.
EldokaishiAOAbdelsalamMYKamalMM, et al. Modeling of water-PCM solar thermal storage system for domestic hot water application using artificial neural networks. Appl Therm Eng2022; 204: 118009.
86.
PadovanRManzanM. Genetic optimization of a PCM enhanced storage tank for solar domestic hot water systems. Sol Energy2014; 103: 563–573.
87.
ColarossiDPrincipiP. Yearly performance of a PV-PCM and water storage for domestic hot water energy demand. Energy Build2022; 274: 112451.
88.
KrishnaJKishorePSSolomonAB. Heat pipe with nano enhanced-PCM for electronic cooling application. Exp Therm Fluid Sci2017; 81: 84–92.
89.
HeJChuWWangQ. Experimental study on pressure-enhanced close contact melting with PCMs for stable temperature control of high heat flux electronic devices. Appl Therm Eng2023; 230: 112451.
90.
ChenEZhaoYWangM, et al. Experimental investigation of a solar-assisted absorption-compression system for heating and cooling. Sol Energy2023; 257: 18–33.
91.
SinghRPSzeJYKaushikSC, et al. Thermal performance enhancement of eutectic PCM laden with functionalised graphene nanoplatelets for an efficient solar absorption cooling storage system. J Energy Storage2021; 33: 102092.
92.
AgyenimF. The use of enhanced heat transfer phase change materials (PCM) to improve the coefficient of performance (COP) of solar powered LiBr/H 2 O absorption cooling systems. Renew Energy2016; 87: 229–239.
93.
SoniVKumarAJainVK. Fast waste heat recovery in 100–150 °C using close-contact charging of nano-enhanced PCM composite. J Mol Liq2019; 285: 347–361.
94.
MalikFKKhanMMAhmedHF, et al. Performance characteristics of PCM based thermal energy storage system for fluctuating waste heat sources. Case Stud Therm Eng2022; 34: 102012.
95.
QinZJiCLowZH, et al. Geometry effect of phase change material container on waste heat recovery enhancement. Appl Energy2022; 327: 120108.
96.
DančováPKutaMWójcikTM. Phase change materials in energy sector - applications and material requirements. EPJ Web Conf2015; 92: 02043.
97.
KolaitisDIGaray MartinezRFountiMA. An experimental and numerical simulation study of an active solar wall enhanced with phase change materials. J Facade Des Eng2015; 3: 71–80.
98.
KoukouMKVrachopoulosMGTachosNS, et al. Experimental and computational investigation of a latent heat energy storage system with a staggered heat exchanger for various phase change materials. Therm Sci Eng Prog2018; 7: 87–98.
99.
KumarasamyKAnJYangJ, et al. Novel CFD-based numerical schemes for conduction dominant encapsulated phase change materials (EPCM) with temperature hysteresis for thermal energy storage applications. Energy2017; 132: 31–40.
100.
LiBZhaiXChengX. Experimental and numerical investigation of a solar collector/storage system with composite phase change materials. Sol Energy2018; 164: 65–76.
101.
MaTZhaoJLiZ. Mathematical modelling and sensitivity analysis of solar photovoltaic panel integrated with phase change material. Appl Energy2018; 228: 1147–1158.
102.
MousaviSKasaeianAShafiiMB, et al. Numerical investigation of the effects of a copper foam filled with phase change materials in a water-cooled photovoltaic/thermal system. Energy Convers Manag2018; 163: 187–195.
103.
MahdiMSMahoodHBHasanAF, et al. Numerical study on the effect of the location of the phase change material in a concentric double pipe latent heat thermal energy storage unit. Therm Sci Eng Prog2019; 11: 40–49.
104.
QiDPuLSunF, et al. Numerical investigation on thermal performance of ground heat exchangers using phase change materials as grout for ground source heat pump system. Appl Therm Eng2016; 106: 1023–1032.
105.
ReddyKMudgalVMallickT. Thermal performance analysis of multi-phase change material layer-integrated building roofs for energy efficiency in built-environment. Energies2017; 10: 1367.
106.
AbdulrahmanRSIbrahimFADakhilSF. Development of paraffin wax as phase change material based latent heat storage in heat exchanger. Appl Therm Eng2019; 150: 193–199.
107.
SilvaTVicenteRAmaralC, et al. Thermal performance of a window shutter containing PCM: numerical validation and experimental analysis. Appl Energy2016; 179: 64–84.
