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Experimental study of a PCM storage system integrated with a thermal
solar collector
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
Experimental study of a PCM storage system integrated
with a thermal solar collector
A. S. Shareef1,3, F. N. Al-Mousawi1,4, and H. S. Sachit1,2
1
Mechanical Engineering Department, College of Engineering, University of Kerbala, Iraq
2
[email protected] 3
[email protected] 4
[email protected] Abstract. Recently, phase change materials (PCM) have become widely used in thermal storage systems
for both industrial and domestic applications. These materials have good thermal properties, like thermal
capacity and phase change temperature, however low thermal conductivity and high viscosity limits their
heat transfer coefficient. This paper experimentally investigates the execution of a water- PCM storage
system integrated with a flat plate solar collector. Paraffin wax is used as the PCM material and is packed in
small cylindrical aluminum containers and accommodated in a hot water tank. In this study, an experimental
test facility was designed and built and experiments were carried out in the City of Kerbala in Iraq. The
study includes two different heat source types, namely a flat-plate solar collector and an electrical heater
element. Experimental results show that the proposed configuration with the PCM material can produce hot
water with up to 9.5 0C higher than that of the basic warm water storage system. In the case of the flat plate
solar collector, the water remained hot, at about 28.5 °C more than the surrounding temperature during the
solar system tests. This study highlights the potential of using PCM materials in heat storage systems and
thermal solar energy.
Keywords: Solar water heaters; energy storage; PCM; paraffin wax
1. Introduction.
Solar energy offers a solution to the problem of electricity in Iraq, as that country has good geographical
features like high solar intensity and good annual levels of sunshine. The main characteristics of solar
energy are that it is clean, cheap, and sustainable: so, this energy can be used in heating, cooling and hot
water purposes in both domestic and commercial applications [1].
The amount of solar radiation is variable and obtainable only during the daytime. As a result, solar energy
applications need active thermal energy storage so that the amount of thermal energy collected during the
day can be stored and reused during the night. Hence, a heat storage system is required [2].
Thermal energy storage (TES) methods used in a thermal solar system can be divided into two categories:
• Sensible heat storage (SHS)
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
This system such as (water, rocks, and bricks) depends on heating storage material, where
the amount of thermal storage store depends on the materials’ specified heat and the
temperature difference between initial and final material conditions.
x Latent heat storage (LHS).
In this group, the thermal energy is stored by absorbing the energy (the latent heat of the
fusion or evaporation) during the phase change process and then releasing the heat to return
to the initial state.
The amount of energy stored in the LHS is very large if compared with the energy of SHS. The materials
that store this energy are called phase change materials (PCMs). There are many types of PCM, but they
are generally arranged into the three categories of organic, inorganic and eutectic.
Natural paraffin is a mixture of pure alkanes, with chemical formula CnH2n+ 2, melt temperature range from
20 to 70°C, and the most widely-used PCM due to its advantages of a sufficiently high latent heat
capability, limited volume changes through phase change, no sub-cooling effects, self-nucleating
behavior, chemically stable, long freeze-melt cycle and availability at low cost. However, its thermal
conductivity is low, therefore, heat transfer needs a large area [3][4].
Three techniques are utilized to harness the thermal conductivity of PCMs. The first uses macro-scale
metallic inclusions, such as fins and meshes, to extended surface area for heat transfer. The second method
uses macro-scale carbon inclusions, i.e. a porous material with high heat transfer capacity, and the third
one uses nanoscale materials[5]. Among the most important factors used to select the PCM material are
the liquefication point and the latent heat fusibility [6][4]. Choosing PCMs depends mainly on the
application temperature level. Residential, and trade buildings usually use a hot water temperature of
about 50 to 60 0C. As a result, the PCM melting point must range between 40 and 50 0C [7].
Many researchers have studied the effects of phase-changing materials and their thermophysical properties
in many industrial, domestic and commercial applications. Olubunmi, 2017 [1] deliberated the impact of
PCM on a solar water system containing commercial wax with a melting point of 45oC. Experimental tests
showed that a higher maximum daily water temperature can be achieved with PCM, compared with the
absence of PCM. Pakalka, et al. 2017 [4] studied experimentally the main parameters that affect the
rendering of a PCM storage system (paraffin with melting temperature 77–82 ºC) including the geometry
and the thermic possessions of the PCM container. Depending on the temperature range of application, it
may be possible to increase the heat transfer area by inserting a set of fins inside the PCM, although there
is a defect in this method which is a reduction in the ability of the PCM to store energy.
Chaichan, et al. 2014 [8] improved the thermal storage obtained for a solar heater used for the household
applications, and in this study, pebbles were used as sensible storage material, while the latent heat storage
substance used paraffin wax. The use of these materials led to increased system efficiency in heat storage
and storage hours increased; however, the PCM material was more efficient than the pebbles. Reddy, et al.
2014 [9] experimentally investigated use of Na2S2O3·5H2O as a PCM with melting temperature 480C
Packed in stainless steel capsules in various forms including spherical, cylindrical and square capsules.
The results produced from this study showed that when the flow rate or temperature of the incoming water
increased, the charging time decreased.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
Division, 2015 [10] studied melting/freezing issue of the PCM. Spiral thermal energy as the heat
exchanger and pure paraffin wax as PCMs were used. Results showed that the geometry of the storage
system affected on the PCM heat transfer rate. It is noted as the number of heat exchangers filled with
PCM increased, the overall efficiency of the thermal storage system increased. Xue, 2016[11] considered
the thermal rendering of a household solar water heater and tested the mass flow rate effect. The amount
of solar radiation and the primary water temperature had an effect on system performance. If global
radiation increased and water temperature decreased, the system was more efficient and vice versa.
Naeem, et al. 2016 [12] studied experimentally the charging and discharging processes in a thermal
storage system using a PCM. Spherical capsules with paraffin wax (liquefication point 580C) were
utilized. The PCM capsules were packed in four fixed bed layers in a cylindrical tank. The results
produced from this study showed that the storage time decreased when the mass flow rate increased.
Kumar et al. 2016 [13] designed a hot water tank with two parts. The first part contained cold water and
attached with the inlet and the second part contained a spiral copper tube surrounded by PCMs. This
research used a coconut oil as a phase change substance because it was freely available and cheap.
Experimental results showed that the mass flow rate had a significant effect on the system temperature
difference. Also, ANSYS modeling showed that a 16% reduction in heating time could be achieved. Kane,
et al. 2016 [14] studied experimentally an indoor test facility to analyze the dynamic behavior of a hot
water storage tank. It contained three packs of 3-liter units filled with PCM (melting temperature 58°C).
Experimental tests showed the advantages of using PCMs as a storage medium.
Profile, 2017 [15] experimentally improved the thermal transfer of phase change materials during loading
and unloading operations by adding materials with high thermal conductivity, such as copper. That study
used paraffin wax with a soft temperature of 63.7 °C. Experimental tests showed that the addition of the
brush to the PCM greatly improved heat transfer within this material and lessened the solubility time to
(90%) compared to the absence of a brush. Nasir et al. 2018 [16] researched numerically and empirically
the melting processes of 12 kg of black pure paraffin in a shell and tube heat exchanger, utilizing solar
thermal energy. Experimental results showed that increasing heliacal radiance and air ambient temperature
minimized the thaw timing of black pure paraffin; the entry line, and air temperatures had a big effect on
the fusion approach match with the volume flow rates. Numerical results showed that the temperature
distribution of black pure paraffin gave perfect effectiveness.
In this study, we used paraffin wax (which was packed into small cylindrical vessels with a volume of
about 0.3 liters each) in a heating storage system joined with a solar warming water system in the city of
Kerbala, Iraq. Kerbala has a latitude of 32.5 º N, and longitude of 44.3 º E. Experiments were carried out
outdoors using two cases. In the first case a flat plate solar collector was used as a heat source while in the
other, a heater element was used as an external heat source.
2. Experimental investigation.
The copper absorbing plate has dimensions of 1 m, 0.85 m, and 0.001 m and it was painted in a black
paint with absorption of 0.9, to increase the portion of solar radiance realized by the plate and to diminish
long wavelength radiation losses from the absorbing surface. The absorber plate was surrounded by a
wooden box and it was insulated with glass wool from the bottom and sides by 10 cm, 5 cm thickness
respectively to reduce the conduction losses. Two copper headers had a diameter of 20 mm and were 97
mm long, and ten copper risers had 10mm diameter and were 96 mm long.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
A cylindrical steel storage tank with a capacity of 49 liters was used, 750 mm high and 285 mm inner
diameter. It was sheltered with 100 mm glass wool. The tank contained 32 thin cylindrical containers
made of aluminum. These containers were chosen to reach a relatively large heat transmitting surface area
and to reduce the thermal resistance between the PCM material and the fluid that conveys heat. The
container capacity was 0.3 liters and it was filled with 0.2 kg of paraffin wax. The PCM containers were
placed inside the water tank and gathered on two rows, with the assistance of two metal clips that were
pre-drilled, each containing 16 containers. The thermo-physical properties of the paraffin wax are listed in
Table 1. A 1000-Watt electric heater was connected to the lower section of the storage tank.
Table 1. Thermo-physical properties of the PCM.
melting latent heat ρ (s.ph.) ρ (l.ph.) Cppcm Kpcm Viscosity μ Thermal
temperature fusion expansion
44 ᵒC 190 kJ/kg 930 kg/m3 830 kg/m3 2.1 0.21 0.031 kg/m.s 11*10-3 1/k
±2 kJ/kg.k w/m.k
The temperature recording and measuring system included thirteen thermocouples of type K that had been
pre-calibrated. One on the inlet tube and one on the outlet tube of the collector, two thermocouples of
which one was in the upper and the other in the lower section of the water tank, to calculate the average
water temperature. One thermocouple was inserted into one of the PCM ampules at the central section of
the tank, and one used to measure the surrounding air temp, two were on the absorbing plate, to calculate
the average absorbing plate temperature, three thermocouples were on raiser pipes, and one thermocouple
at the air gap between the plate and glass.
Table 2. Thermocouple distribution in the solar collector.
No. of Location
thermocouple
1,2,3 Top surface of riser tube
4,5 Absorber plate
6 Air gap between the plate and glass
7 Inlet tube
8 Outlet tube
9 Ambient
10,11 Water temperature in the tank
12 The temperature of pcm
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
13 Glass cover
Figure 1. Schematic of network thermocouple distribution in the solar collector.
Figure 2. Schematic of storage tank
A standard 0.37 Kw circulation pump, with maximum amplitude 32 Lpm, was used to force circulation,
and to change the volumetric rate of water (1, 3, 5 Lpm).
Figure 3. Schematic of solar hot water.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
2.1 Energy balance
The beneficial energy transformer from solar radiation to useful heating energy as in Equation (1).
Qw = mw cpw ΔT = Qu ……………………………………………… (1)
where m = Mass flow rate of water (kg/s), Cpw = Specific heat of water (J/kg ºC)
and ΔT = Temperature different of water (ºC), Qu = heat gain (W).
The efficiency of the collector is one of the most important factors in evaluating the solar collector’s
performance, which can be defined as the ratio between the useful energy gained in a period and the solar
energy incident on the collector during the same time as in Equation (2).
∫
η= …………..…..……………………..…... (2)
∫
η = Overall efficiency (%) , AC = Collector absorbing plate area ( m2 ).
I = solar radiation which is incident on the Collector (W/m2).
The heat removal factor is a coefficient that expresses the amount of heat transferred to the working fluid
relative to the amount of heat absorbed by the absorbing plate.
= [ ()] ..………………………………………. (3)
Fr Heat removal factor. τ Glazing transition coefficient.
α plate absorption coefficient. UL Overall heat loss coefficient (w/m2 °C).
Tp the mean absorber plate temperature (°C).
Ta Ambient temperature (°C).
3. Results and discussion
3.1. Use of the solar system
The PCM’s performance has been tested in the storage tank under real operating conditions. The
performance of solar domestic hot water systems depends on the local climatic conditions, such as solar
radiation and ambient temperature. The measurements of solar radiation and temperature within the flat
solar complex and the storage tank were recorded using specialized measuring instruments and a 10-
minute interval between readings and from 9:00 am to 3:00 pm from 15 to 30 March 2019.
Initially the system was run in the absence of PCM (32 L water only), to measure the amount of heat that
the water could store, the temperatures that it reached and the duration of the time for which this water
would remain hot, as well as the efficiency of the solar collector and the amount of coefficient of heat
removal .
Then we re-tested the system with a variable flow rate of water by controlling the flow valves and
observing the flowmeter.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
Figure 4. The temporal variation of the average Figure 5. The useful thermal energy with daylight
water temperature in the storage tank without PCM time at a variable flow rate.
with variable flow rate.
The effect of increasing the volumetric rate in the difference between the inlet and outlet water
temperatures of the collector was evident. At the larger volumetric flow rate the water temperature outlet
of the collector was less. Figure 4 shows that water temperature in the storage tank rose faster when the
water flow rate increased. This is most evident in Figure 5, which shows the heat gained by the water. The
amount of heat gained was greatest at 12:30 pm with a volumetric flow rate of 5 liters per minute.
The effect of increasing the volumetric flow rate on the difference between the inlet and outlet water
temperatures of the collector, overall efficiency, and heat removable factor are shown in Table 3.
Table 3. Maximum difference inlet outlet collector water temperatures, overall efficiency,
collector heat removable factor, with variable flow rate.
volume flow rate Maximum (TO -Ti) overall efficiency Collector
0
C ɳ% heat removal factor
FR
1 L/m 5.8 43.9 0.693
3 L/m 3.1 61.46 0.814
5 L/m 2.1 67.83 0.91
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
The same test was conducted under similar surrounding conditions with using 32 cylindrical containers
containing 0.2 kg of paraffin wax (6.4 kg PCM) at ratio 70 % water 22.4 L, 30 % PCM 9.6 L. Figure 6
shows that the water temperature rose faster than PCM at the beginning of the heating period, where the
material was in the solid phase, and then at a temperature of about 42 ° C (which is close to the
liquefication temperature stated in Table 1) the PCM material’s temperature slightly increased until it
reached 47 °C for a period time. This is because PCM at this stage undergoes a phase change and
therefore absorbs large amounts of heat at a constant temperature. Then, the PCM temperature starts to
rise at a quicker rate, to catch up with the water temperature, and then exceeds it before reaching the end
of the heating stage. After 3:00 pm, the pump was turned off, and thus began the loss of heat from the
tank, so that the temperature of the water was less than the temperature of the PCM by 1-2 degrees and
continued until the end of the experiment at eight o'clock the next morning. During this stage, the PCM
continued to release the stored heat into the water, keeping the water hot for a longer period of time.
Figure 6. The average water temperature, PCM Figure 7. The average water temperature in the
temperature, and the ambient temperature vs time. storage tank, with and without PCM vs time.
Figure 7 shows the main advantage that was obtained from using the PCM in this study, as it is clear that
the water temperature using PCM was higher than that without PCM by about 9.5 ᵒC. This is most obvious
in Figure 8, which shows the final water temperatures with and without PCM.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
Figure 8. The final midpoint storage tank Figure 9. The tank water & ambient difference
water temperature, at with and without PCM, temperature, with and without PCM, vs time, at
vs volume flow. the water flow rate 5 Lpm.
Regarding Figure 8, we note the benefit of using PCM to keep the water warm at a higher temperature
than in the absence of PCM, as well as the effect of increased flow rate. The difference in temperature was
the highest value (9.3 ºC) at the flow rate 5 liters per minute. Figure 9 shows that the water remained hot,
at about 28.5 °C more than the surrounding temperature. Table 4 shows the improvement in hot water
temperature during solar system tests.
Table 4. The improvement in hot water temperature solar system tests.
Volume flow rate (Lpm) Improved water temperature
1 19.95 %
3 22.47 %
5 23.1 %
3.2. Storage performance with external heat source
In this state, the storage water tank was isolated from the solar collector by closing the input and output
line valves. The electric heater was turned on for two hours to heat the water to the highest temperature,
from 9:00 am to 11:00 am. Then, the heater was switched off and we continued recording the water
temperature measurement for another 22 hours.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
Figure 10. The temporal variation of the average Figure 11. The temporal variation of the difference
water temperature in the storage tank, with and in temperature between the tank water and the
without PCM. ambient, with and without the PCM containers.
Figure 10 shows average tank water temperatures with and without using PCM. We notice that the water
warms faster in the absence of PCM due to the large volume of the heat absorbed by the PCM. The
maximum tank water temperature at 11:00 am reaches 76.5 ᵒC, 71.9 0C without and with PCM
respectively, the advantage obtained by using the PCM is that of keeping the water temperature higher (by
about 7.50C) than was the case without PCM. Figure 11 shows that the water remained hot, at about 27.9
0
C more than the surrounding temperature, as a result of using PCM.
3.3. Comparison with similar work
To make sure that the results of our research were correct, we compared them to a similar study by Al-
Hinti, et al. 2010 [17]. That research was conducted in Jordan during April 2008, the author used a 107-
liter iron tank containing 38 vessels of aluminum with a volume of 1.3 liters filled with 1 kg of wax,
which dissolves at 52 °C. The total amount of wax was 38 kg. The volume of wax bottles accounted for
46% of the tank and 54% of the water. The water tank was heated by 2000 watt for 3 hours, and the
highest water temperature was 76 °C. Results showed that water temperature using paraffin wax was 13
°C higher than that of water alone, and the water remained at a level of 36 0C higher than the
surroundings. In the present work, 6.4 kg of paraffin wax was used, and the volume of wax bottles
accounted for 30% of the volume of the tank. The main advantage of the current work is the maintenance
of a higher water temperature (by about 7.5 o C) than that without PCM. Also, the water remains hotter,
about 27.9 °C above the ambient temperature. Figure 12 illustrates this comparison. The difference in
results between the current work and previous work [17] is due to the different amounts of paraffin wax
and different packaging size used in the experiments, and the effect of totally different weather conditions.
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3rd International Conference on Engineering Sciences IOP Publishing
IOP Conf. Series: Materials Science and Engineering 671 (2020) 012018 doi:10.1088/1757-899X/671/1/012018
Figure .12 Comparison between reference [17] and present work.
4. Conclusion
An experimental test facility, of a water PCM storage system integrated with a flat plate solar collector,
was designed and built under the climate conditions of the city of Kerbala in Iraq to improve the
performance of both the storage system and the solar collector for residential and commercial applications.
The main results of this study can be listed as:
• The use of PCM in the storage of solar thermal energy has proved to be an effective solution to
reduce fossil energy consumption and to permit greater reliance on solar energy.
• Excess heat can be stored in a PCM during the day in the form of latent heat, and used at night to
keep the water warm and suitable for use in all household applications.
• As the volume flow rate decreased, the outlet collector water temperature increased.
• Use pf the proposed configuration (with PCM) provided 9.3 °C in stored hot water temperature, the
storage water temperature remained higher at 28.5 °C above ambient temperature.
• The improvement in hot water temperature during the solar system tests was 23.1 %.
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