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CFD Modeling of a Metal Phase Change Material Thermal Storage System for High-Temperature Heat Accumulation and Steam.

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Title: CFD Modeling of a Metal Phase Change Material Thermal Storage System for High-Temperature Heat Accumulation and Steam.
Authors: Melka, Bartlomiej1 (AUTHOR) bartlomiej.melka@polsl.pl, Klimanek, Adam1,2 (AUTHOR), Rojczyk, Marek1,3 (AUTHOR), Nowak, Grzegorz1,4 (AUTHOR), Petela, Karolina1 (AUTHOR), Kugler, Felix2 (AUTHOR), Swiatkowski, Tomasz3 (AUTHOR), Barnetche, Magdalena4 (AUTHOR), Szlek, Andrzej1 (AUTHOR)
Source: Energies (19961073). May2026, Vol. 19 Issue 10, p2360. 21p.
Subject Terms: *Phase change materials, *Computational fluid dynamics, *Multiphase flow, *Steam generators, *Heat storage devices, *Aluminum-zinc alloys, *Heat storage
Abstract: This paper develops a novel coupled model to predict the thermal behavior of a high-temperature fast heat storage unit, integrating Power-to-Heat technology with steam generation. A phase change material (PCM) made of a ZnAl6 metal alloy is used for heat storage. Electricity is used to charge the battery, and the stored energy is used to produce superheated steam during discharge. The coupled model was based on a 3D multiphase CFD model of the heat storage unit and a 1D multiphase water boiling model implemented in Python language. The CFD model solves the transient conservation equations of mass, momentum, and energy using the enthalpy–porosity method to describe phase change, while heat transfer to water is represented by a coupled 1D boiling model. The paper also presents a preliminary design, a computational strategy, and boundary conditions for the operating modes, providing an analytical foundation for detailed engineering, production, and implementation in real-world industrial environments. The presented results confirmed the correct operation of the model and enabled the evaluation of system performance, discharge behavior, and validation of the geometric assumptions required to achieve the target steam parameters. The proposed modular design allows for system scalability, while the entire system is a response to the daily variability of electricity prices resulting from periodic reductions in demand and overproduction of electricity from renewable sources. Estimated thermal behavior of the thermal storage unit for the discharging scenario allows reaching constant output power at the level of 200 kW for 85 min. Integration with a cooling reduction station allows constant system power output to be maintained by increasing the mass flow rate as the steam parameters decrease from over 400 °C to 200 °C with a lowering state of charge. [ABSTRACT FROM AUTHOR]
Database: Energy & Power Source
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Header DbId: enr
DbLabel: Energy & Power Source
An: 194141475
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Label: Title
  Group: Ti
  Data: CFD Modeling of a Metal Phase Change Material Thermal Storage System for High-Temperature Heat Accumulation and Steam.
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  Data: <searchLink fieldCode="AR" term="%22Melka%2C+Bartlomiej%22">Melka, Bartlomiej</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> bartlomiej.melka@polsl.pl</i><br /><searchLink fieldCode="AR" term="%22Klimanek%2C+Adam%22">Klimanek, Adam</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Rojczyk%2C+Marek%22">Rojczyk, Marek</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Nowak%2C+Grzegorz%22">Nowak, Grzegorz</searchLink><relatesTo>1,4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Petela%2C+Karolina%22">Petela, Karolina</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kugler%2C+Felix%22">Kugler, Felix</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Swiatkowski%2C+Tomasz%22">Swiatkowski, Tomasz</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Barnetche%2C+Magdalena%22">Barnetche, Magdalena</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Szlek%2C+Andrzej%22">Szlek, Andrzej</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Energies+%2819961073%29%22">Energies (19961073)</searchLink>. May2026, Vol. 19 Issue 10, p2360. 21p.
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  Data: *<searchLink fieldCode="DE" term="%22Phase+change+materials%22">Phase change materials</searchLink><br />*<searchLink fieldCode="DE" term="%22Computational+fluid+dynamics%22">Computational fluid dynamics</searchLink><br />*<searchLink fieldCode="DE" term="%22Multiphase+flow%22">Multiphase flow</searchLink><br />*<searchLink fieldCode="DE" term="%22Steam+generators%22">Steam generators</searchLink><br />*<searchLink fieldCode="DE" term="%22Heat+storage+devices%22">Heat storage devices</searchLink><br />*<searchLink fieldCode="DE" term="%22Aluminum-zinc+alloys%22">Aluminum-zinc alloys</searchLink><br />*<searchLink fieldCode="DE" term="%22Heat+storage%22">Heat storage</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: This paper develops a novel coupled model to predict the thermal behavior of a high-temperature fast heat storage unit, integrating Power-to-Heat technology with steam generation. A phase change material (PCM) made of a ZnAl6 metal alloy is used for heat storage. Electricity is used to charge the battery, and the stored energy is used to produce superheated steam during discharge. The coupled model was based on a 3D multiphase CFD model of the heat storage unit and a 1D multiphase water boiling model implemented in Python language. The CFD model solves the transient conservation equations of mass, momentum, and energy using the enthalpy–porosity method to describe phase change, while heat transfer to water is represented by a coupled 1D boiling model. The paper also presents a preliminary design, a computational strategy, and boundary conditions for the operating modes, providing an analytical foundation for detailed engineering, production, and implementation in real-world industrial environments. The presented results confirmed the correct operation of the model and enabled the evaluation of system performance, discharge behavior, and validation of the geometric assumptions required to achieve the target steam parameters. The proposed modular design allows for system scalability, while the entire system is a response to the daily variability of electricity prices resulting from periodic reductions in demand and overproduction of electricity from renewable sources. Estimated thermal behavior of the thermal storage unit for the discharging scenario allows reaching constant output power at the level of 200 kW for 85 min. Integration with a cooling reduction station allows constant system power output to be maintained by increasing the mass flow rate as the steam parameters decrease from over 400 °C to 200 °C with a lowering state of charge. [ABSTRACT FROM AUTHOR]
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        Value: 10.3390/en19102360
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      – Code: eng
        Text: English
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        PageCount: 21
        StartPage: 2360
    Subjects:
      – SubjectFull: Phase change materials
        Type: general
      – SubjectFull: Computational fluid dynamics
        Type: general
      – SubjectFull: Multiphase flow
        Type: general
      – SubjectFull: Steam generators
        Type: general
      – SubjectFull: Heat storage devices
        Type: general
      – SubjectFull: Aluminum-zinc alloys
        Type: general
      – SubjectFull: Heat storage
        Type: general
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      – TitleFull: CFD Modeling of a Metal Phase Change Material Thermal Storage System for High-Temperature Heat Accumulation and Steam.
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            – D: 15
              M: 05
              Text: May2026
              Type: published
              Y: 2026
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