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ANALYSIS OF THERMAL ENERGY STORAGE SYSTEM WITH TWO PHASE FLOW AND PCM USING FEM
* Asst. Prof. Dr. Karima E. Amori
Ameer K. Baqir**
* Univ. of Baghdad , ** MSc. Student Nahrain Univ. , (Mech. Eng. Dept. ), Baghdad/ Iraq
ABSTRACT The present study explores numerically the energy stored by a phase change material (PCM) surrounding a tube (to form a thermal energy storage unit TESU) which acts as a heat sink that receives energy from fluid flowing inside a tube embedded in the PCM. Effect of single or two phase fluid flow on the melting and the temperature distribution inside the PCMs is performed for different parameters studied such as flowing fluid inlet temperature ranged from 40C to 80C, the effect of Reynolds number of the flowing fluid ranged from (1500 to 12000), and the type of PCMs employed to investigate the effect of their thermo-physical properties. In all these cases an axial temperature distribution is obtained by adopting a computational transient (3D) simulation using FEM, and a Fortran-90 computer program is developed to solve the problem. The program was tested and verified by solving some verification cases. Results show that the time required to complete phase change (of PCM) becomes shorter with increase in inlet temperature of flowing fluid. Also the increase in Reynolds No. has a great influence on the phase transition process of the PCM. The increase in fluid flow rate is translated into an increase in heat transfer between the flowing fluid and PCM.. It is shown that using water instead of air as a flowing fluid leads to an increase in energy stored. For two phase flow the investigation indicates that an increase in the magnitude of mass dryness fraction leads to increase the energy stored in the PCM and a decrease in time of charging energy in the unit. ( ) PCM) ( . ( PCM ) (PCM) , ) 0051-00021( , o 08 o 04 . ( PCM ) 09 . . ) . ( . PCM ) ( . PCM " . . Keywords: heat storage, PCM, melting, two phase, FEM.
36
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
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 study is to explore numerically in 3-D the melting process of different phase change material (PCM) in a storage system. The heat is transferred to this material from a single or two phase flowing fluid inside horizontal tube pass through this PCM. 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 and there is no volume contraction or expansion. Thermal losses from system external boundary and radiation heat transfer inside the system are ignored. Forced convection fluid flow inside tubes. The initial temperature of the (PCM) is uniform and assumed at solidifying temperature (Ts) for melting process. No Internal chemical reactions or heat sources Governing Equation The energy equation for a material undergoing a phase transformation is given as Zalba et. al.(2003): H (1) + uH = k 2T + s t For constant thermo physical properties (constant density ) of the PCM and no heat sources , eq.(1) can be reduced to : H (2) = k 2T t
37
c p
T = k 2T t
T , yields: t
(3)
The initial condition specifies a constant temperature field at (To) at time zero. The boundary conditions, given as: T (4) =0 n at external boundary and plane of symmetry as shown in fig.(1), while that at internal surface of tube wall :
k T = hi (T T ) n
(5)
Single Phase Flow The internal heat transfer coefficient (hi) is calculated for turbulent single fluid flow according to (Kays and Crawford 1993) hi = (Re 1000) * C f / 2 k ( ) D 1 + 12.7 C / 2 (Pr 2 3 1) f (6) (7)
Two Phase Flow (Condensation heat transfer coefficient ) The local heat transfer coefficient is dependent on the mass flux G of fluid flowing through the tube. If G is greater then or equal to (100 kg/ms) the fluid is considered to be transitioning to annular flow and correlation is applied that is [Shah 1979]:
hi = htp = hl [( 1 X ) 0.8 + 3.8 X 0.76 ( 1 X ) 0.04 pr
0.38
(8)
Where Pr = Psat Pc ; Pc is the critical pressure If G is less than (100 kg/ms), then the stratified flow portion of the Dobson and Choto (1998) correlation is applied .
k 0.23 Re vo Ga Prl 0.25 htp = l { [ ] + ( 1 l ) Nu forad } 0.58 D 1 + 1.11 X tt Ja l
0.12
(9)
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
Revo =
X tt = (
GD
, Prl (Reynolds No. and Pandtl No. assuming all fluid flowing as vapor) (10)
v 0 .5 v 0 .1 1 X 0 .9 ) ( ) ( ) l l X
Ga =
g c l ( l g )D 3
l2
(11) (12)
Ja l = C pl ( Tsat Tw ) / h fg
where Ga is Galileo No. ; Ja l is Jakob No. l is the angle formed by extending an imaginary line from the top of the tube to the liquid level in the bottom of the horizontal tube. l is related to the void fraction , which is defined as the ratio of the vapor-flow cross- section area to the total cross section area [Zivi , (1964)]:
= l sin( 2 l ) 2
(13)
(14)
(15)
Cl l ( X tt ) = 1.376 + C1 X tt
c2
For
(16)
If
NUMERICAL ANALYSIS Descretizing the differential eq.(3) with initial and boundary conditions (eq.s (4) and (5) respectively) using finite element method, employing Galerkin procedure leads to the following typical components of elemental mass, stiffness matrices, and force vector (Me , Ke and Fe respectively) which can be defined as:
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Me = jk
C p N j N k d e
(17)
Ke = jk
N k (kN j ) d e + e hi N j N k d e
(18) (19)
Fke = e hi N k d e
The thermophysical properties during phase change process (melting process) are calculated as : (using table (1) for different PCM's)
C p = LH /( Tm Ts )
k = Fs k s + ( 1 Fs )k m = Fs + ( 1 Fs ) m
(20)
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:
(21) 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
Fs =
T Ts Tm Ts
[M ] {T
} + [K ]{T } = {F }
(22)
A recursive algorithm based on time marching technique (finite difference method) is adopted to solve eq.(22) (Smith and Giffiths 2004), so introducing a linear interpolation and fixed time step t : T = T n + (1 ) T o (23) n o Where T and T are new and old temperature values respectively : constant such that 0 1 (taking =2/3 based on Galerkin approach with unconditional stability) Substituting eq.(23) in eq.(22) leading to the following result [ M + tK ]T n = [ M (1 ) t K ]T o + tF Rearranging this equation to get a system of algebraic equations as: [A] T n ={B}
40
(24)
(25)
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
Grid Generation The mesh shown in fig's. (1.b,c and 2a,b) represents a symmetrical quarter of thermal energy storage unit composed of 396 nodes (66 nodes per layer) and (250) hexahydral linear eight nodded elements. The first line (e=1 to 10 in layer 1) 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 different PCM's used in the present work (Table (1)). b. TES unit size and tube diameter (Table (2)). c. Initial temperature d. Fluid 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. Compute the local (z direction) internal heat transfer coefficient hi c. Compute elemental matrices and vector d. Assemble elemental matrices and vector to global system e. Modify system matrices to form matrix A and vector B f. Solve the system of simultaneous equations [eq.(25)] to evaluate T n using Gauss Elimination method for symmetrical matrix A 4- Advance to the next time step and repeat step 3 Time required to complete phase change ( 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-90 computer program is developed for the computational approach using. The execution time varies between (710 min for time step of (10 s) depending on period of examination) on a personal computer Pentium 4. 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.(3). The results obtained are compared with that published by [ Crowley 1978 ]. This comparison shows a good agreement between the computational and published results with maximum variation of 0.1% . Single Phase Flowing Fluid: The Effect of Flowing Fluid Inlet Temperature: The effect of water inlet temperature on three dimensional melting process of the PCM around tube for inlet temperatures (40C, 60C and 80C) is shown in figures (4,5 &6), respectively (for Re=1500). These figures show the axial temperature distribution
41
within PCM (CaCl2.6H2O at initial temperature =27C) along line AA. It is clear that the melting process started and finished at (Z = 0) while at (Z > 0.4) the PCM was still in solid phase because the flowing fluid temperature decreases along tube length for different inlet fluid temperature as shown in fig.(7). The PCM needs less time to melt as inlet fluid temperature increases (6100s, 3800s and 2500s for inlet fluid temperature 40C, 60C and 80C respectively)as shown in fig.(8). fig. (9) shows that the computed heat stored in PCM during melting process increases with increasing water inlet temperature (70 kJ, 150 kJ and 210 kJ for 40, 60 and 80C respectively). The thermal behavior recorded above is due to the dependence of heat transfer between PCM (initial temperature was 27C) and flowing fluid on the temperature difference between them. The Effect of Reynolds No. (Re): Figures (5, 10, and 11) show the axial temperature distribution along line AA for Reynolds numbers 1500, 6000 and 12000 respectively and water inlet temperature equal to 60C. These figures demonstrate that the melting process started and finished at Z=0 faster than other axial position, also increasing Reynolds number leads to decrease the melting duration of PCM as shown in fig.(12), since the convection heat transfer coefficient is affected by Reynolds number (increase with increasing Reynolds number as given in eq.(6) which leads to increase the heat transfer from water to PCM as shown clearly in fig. (13). The Effect of Type of the Phase Change Material: Three types of phase change material are investigated in this work named CaCl2.6H2O, Lithium Chloride Ethanol and Zn(NO2).6H2O to study their thermal performance. figs. (5, 14 and 15) show the computational axial temperature distribution of the three types of PCM when water at 60C enters the tube with Re=1500. These figures show that Lithium Chloride Ethanol has faster thermal response than that of Zn(NO2).6H2O while CaCl2.6H2O seems to have the slowest response. This is due to the difference in their thermo physical properties. fig.(16) shows that maximum heat stored in PCM3 (Zn(NO2).6H2O) compared with the others, since it has the max. temperature difference between melting and solidifying temperatures , max. density, thermal conductivity and heat capacity as shown in table (1) . The Effect of Type of Inlet Flowing Fluid: Two types of flowing fluid were investigated (water and air) as shown in fig.s (5) and (17), for inlet temperature of 60C and Reynolds No. of 1500. From these results it can be seen that the total heat transfer in case one is more than the heat transfer in case two as shown in fig.(18) because the heat transfer coefficient is decreased when air is used as a flowing fluid. The reason for this behavior is due to higher value of density and viscosity of water than that the air, this leads to increase in the heat transfer. Two Phase Flowing Fluid: Effect of Mass Dryness Fraction (X): The two phase flow of saturated water at 60C and (0.2 bar) was studied as a flowing fluid in TESU with different mass dryness fraction (0.1, 0.3 and 0.5), figs.(19, 20 & 21) show that the total heat transfer from flowing fluid to the PCM will increase and a
42
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
decrease in melting duration time when the mass dryness fraction (X) increases for the same inlet water temperature of 60C, and Re No. of 1500, since the content of vapor (which moves faster than water) will increase and increases heat transferred.
CONCLUSION
The following concluding remarks can be drawn during this work Increase the temperature of inlet flowing fluid leads to increase the heat stored in PCM and leads to decrease the phase change duration. Increase the Reynolds No. of the flowing fluid leads to increase the magnitude of heat transfer and leads to decrease the melting duration. Increase the difference between melting and solidifying temperature leads to increase in the heat transfer and melting duration. Increase in the density and viscosity of flowing fluid leads to increase in the heat transfer, and also decreases the melting duration time. Increase in the mass dryness fraction of the two phases flowing fluid leads to increase in the heat transfer and decrease in the melting duration time.
Table (1) Properties of Three PCM Used [Zalba et.al.2003] Lithium Property CaCl2.6H2O Chloride Zn(NO2).6H2O PCM1 PCM3 Ethanol PCM2 Latent heat of fusion LH (kJ/kg) Temperature (C ) Density (kg/m3) Thermal Conductivity (kW/m.K) Specific Heat Cp (kJ/kg)
o
181.38
Solid Liquid
188.38
solid liquid Solid
136
liquid
43
PCM
Analyzed Domaine
(a)
V
A A
PCM
V
Fluid Flowing
20 mm
(b)
132 198 264 330 396
66
node No.=1
PCM
67
133
199
V
265
Fig.(1): Division of the Thermal Energy Storage Unit into a)TES Unit, b)Layers , c)Elements and nodes
331
(c)
44
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
V
y
66
e=50 55 50
61
44 39 33
22 e=10 11 17
28
50 mm
m m
25
(a)
e=1
12
23
34
45
90 80
Crowley
Insulation
T =0 n
Solid Fraction
70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10
T1
56
Fig.(3): a) Analyzed Domain ,(b)Comparison of Computational Results and Crowley Results for Two Dimensional Phase Change Problem
45
V
96
7 19
50 mm
30
3
85
6
29
e=10
18
84
(b)
V
(b)
30
29.5
29 Temperature(C)
Z=0
28.5
28
Z=80 Z=100
27.5
27
26.5
0 2000 4000 6000 8000 10000 Time(s) 12000 14000 16000 18000
Fig.(4): Temperature Distribution in PCM along Tube for Single Phase Flowing (40C) Inlet Temperature, Re =1500
30
29.5
28.5
28
27.5
27
26.5 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 Time (s)
Fig.(5) :Temperature Distribution in PCM along Tube for Single Phase Flowing Fluid at (60C) Inlet Temperature, Re =1500
46
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
30
29.5
29
Temperature(C)
27
26.5 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 Time(s)
Fig.(6) :Temperature Distribution in PCM along Tube for Single Phase Flowing Fluid at (80C) Inlet Temperature, Re =1500
90 80 70 Temperature(C) 60 50 40 30 20 10 0 0 20 40 60 Tube Length (cm) 80 100 120
Tin=40 Tin=60 Tin=80
Fig.(7): Water Temperature Variation Along Tube Length for Different Inlet Temperature
47
8000
250
200
6000
150
4000
Heat (kJ)
Time (s)
100
2000
50
0 20 40 60
Inlet Temp. ( C)
80
100
20
40
60
Inlet Temp. ( C)
80
100
Fig. (8): Melting Duration Time for Different for Inlet Water Temperature at (Z=0, Re=1500) Temperature
30
29.5
29 Temperature(C)
Z =0
28.5
Z =2 0 Z =4 0 Z =6 0
28
Z =8 0 Z =10 0
27.5
27
26.5 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 Tim e(s)
Fig. (10): Temperature Distribution in PCM Along Tube for Single Phase Flowing Fluid at (60C) Inlet Temperature, Re =6000.
48
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
30.5
30
29.5
Temperature(C)
29
28.5
Z=60 Z=80
28
Z=100
27.5
27
Fig. (11): Temperature Distribution in PCM Along Tube for Single Phase Flowing Fluid at (60C) Inlet Temperature, Re =12000
6000
5000
4000
3000
2000
1000
Heat (kJ)
0
Time (s)
Re= 1500
6000
12000
Re= 1500
6000
12000
49
29
28
27
22
21
20 0 2000 4000 6000 8000 Time(s) 10000 12000 14000 16000 18000
Fig.(14): Axial Temperature Distribution in PCM for Single Phase Flowing Fluid at (60C) Inlet Temperature, Re =1500 for Lithium Chloride Ethanol
38.5
38
36
35.5 0 2000 4000 6000 8000 Time(s) 10000 12000 14000 16000 18000
Fig.(15): AxialTemperature Distribution in PCM for Single Phase Flowing Fluid at (60C) Inlet Temperature, Re =1500 for Zn(NO2).6H2O
50
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
300
250
200
Heat (kJ)
150
100
50
29 28.8 28.6
27.2 27 26.8 0 5000 10000 15000 Time(s) 20000 25000 30000 35000
Fig.(17): Axial Temperature Distribution in PCM for Single Phase Flowing Fluid Air at (60C) Inlet Temperature, Re =1500
51
162
160
158
156
Heat (kJ)
154
152
150
148
146
144
air
air water
26
25.5
25
Temperature(C)
24
23.5
23
22.5
22
21.5 0 1000 2000 3000 4000 Time(s) 5000 6000 7000 8000 9000
Fig.(19): Axial Temperature Distribution in PCM2 (Lithium Chloride Ethanol) at Two Phase Flowing Fluid Water at (60C) Inlet Temperature, Re =1500 and at Z=0
52
Analysis of Thermal Energy Storage System With Two Phase Flow and PCM Using FEM
4000
3000
120
2000
Heat (kJ)
time (s)
80
1000
40
0.1
0.3
Dryness Faction X
0.5
0.1
0.3
Dryness fraction X
0.5
Fig. (20): Melting Time Duration for Different Mass Dryness Fraction
Fig. (21): Heat Stored in TESU for Different Mass Dryness Fraction
REFERENCES: Crowley A.B., (1978), "Numerical Solution of Stefan Problems", Int.J. Heat Mass Transfer, 21, 215 Dobson,M.K., and Chato,J.C. (1998), "Condensation in Smooth Horizontal Tubes", ASME Journal of Heat Transfer,120,193-213. 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. Jaster H., Kosky P. G., (1976), Condensation Heat Transfer in a Mixed Flow Regime, International Journal of Heat and Mass Transfer, 19,95-99. Kays,W.M. and Crawford,M.E. (1993), "Convective Heat and Mass Transfer", Newyork, McGraw Hill 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, PP. 155-165 Smith, I.M. and Giffiths, D.V. (2004),"Programming the finite element method" ,Third Edition, John Wiley & Sons Ltd. England. Shah M.M., (1979), A General Correlation for Heat Transfer During Film Condensation Inside Pipe, International Journal of Heat Transfer, 22,547-556.
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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, PP. 251-283 Zivi S.M., (1964), Estimation of Steady-State Steam Void-Fraction by Mean of the Principle of Minimum Entropy Production, ASME Journal of Heat Transfer, V.22; pp.547.556. Baqir A.K.,(2008),"Numerical Study Of Two Phase Flow Effect On Thermal Behavior Of Thermal Energy Storage System", MSc. Thesis, Mechanical Eng. Dept. Al-Nahrain Univ.
NOMENCLEATURE:
Cp D
Specific heat J/kg.K Tube diameter (m) Frlo Froude No. of all liquid {F} Global force vector h Specific enthalpy J/kg H Enthalpy J k Fluid thermal conductivity(W/m.Co) [K] Global stiffness matrix [M] Global mass matrix N Unit normal vector Greek symbols boundary
Q Re Pr s t T Tin T u X
fluid volumetric flow rate (m3/hr) Reynolds number Prandtl number Heat source J/m3 Time (s) PCM or tube wall temperature (Co) fluid inlet temperature (Co) fluid bulk temperature (Co) Velocity (m/s) Mixture dryness fraction domain
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