Thermal waste heat recovery system using PCM
In this project we will model, simulate, and fabricate 'Thermal waste heat recovery system' using shell and tube type heat exchanger and phase change material (paraffin). Numerical simulation will be done on ANSYS FLUENT in 2D. Thermal heat storage through PCM is capable of storing and releas
2025-06-28 16:29:43 - Adil Khan
Thermal waste heat recovery system using PCM
Project Area of Specialization Mechanical EngineeringProject SummaryIn this project we will model, simulate, and fabricate 'Thermal waste heat recovery system' using shell and tube type heat exchanger and phase change material (paraffin). Numerical simulation will be done on ANSYS FLUENT in 2D.
Thermal heat storage through PCM is capable of storing and releasing large amounts of energy. During the phase change process, heat is exchanged between the heat transfer fluid and the phase change material. The heat transfer fluid (HTF) flows in tubes which are configured in a unique arrangement during the charging and discharging processes. Paraffin is used as the phase change material (PCM) which was contained in a cylindrical tank. Hot water (HFT) will melt PCM and store thermal energy in form of latent heat of fusion. And release that energy at later time.
Then we will study effect of orientation and number of tubes on melting time of PCM.
Project Objectives.
We have to do detailed parametric study of heat transfer processes in the melting of PCM.
We have to design the Latent Thermal Energy Storage (LTES) system in which we have to increase the melting rate of PCM in the minimum time as possible.
we have another task to melt the complete PCM in less Time.
Project Implementation MethodFirst we simulate the our design on the ANSYS FLuent, we select the best design in which PCM melt completely in low time. we use the heat exchanger with the different number of tubes and different arragement to decrease the melting time of PCM.
Then we have to manufacture the physical model according to best ANSYS model.
Finally we campare the results and analyze it.
Benefits of the ProjectThe fluctuating and intermittent nature of industrial heat sources is a crucial technical barrier limiting the implementation of heat recovery energy systems
. Latent Thermal Energy Storage (LTES) has the potential to overcome these issues by maintaining a Waste Heat Recovery (WHR) system within designed operation conditions to achieve effective and efficient operation.
Latent heat thermal energy storage has advantages of high energy density with small storage volume and, in principle,
LTES is a big source to Store the waste heat and deliver it when needed.
The applications of PCMs include refrigeration and cold storage systems, thermal storage in the building structures, water based heating and cooling system in domestic applications, and heat recovery from waste. Solar thermal energy is exchanged to PCM by storing it into a reservoir called heat transfer fluid HTF. Stored energy is then transferred into PCM by using a shell and tube heat exchanger where the PCM is kept in the shell and HTF flows through the inner tube. In recent years, a lot of studies have performed to enhance the efficiency of LTESUs by improving heat transfer within PCM.
Technical Details of Final DeliverableLatent heat thermal energy storage Unit containing the shell and tube heat exchanger in which PCM is melted along with thermocouples and complete unit (heating system for water, control flow rate and their circulation system). And simulations of the ANSYS FLUENT.
We have to simulate the results in the ANSYS FLUENT software first then we have to perform the experiment on the physical models. Finaly we have to compare the results of simulation and the physical model and draw the conclusion.
Final Deliverable of the Project Hardware SystemCore Industry Energy Other Industries Others Core Technology Clean TechOther Technologies OthersSustainable Development Goals Affordable and Clean Energy, Industry, Innovation and Infrastructure, Climate ActionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 80000 | |||
| Acrylic Shell | Equipment | 1 | 9000 | 9000 |
| Aluminium Tubes | Equipment | 600 | 5 | 3000 |
| Phase Change Material | Equipment | 4 | 1000 | 4000 |
| Data Acquisition System | Equipment | 1 | 20000 | 20000 |
| container | Equipment | 1 | 4500 | 4500 |
| Pump | Equipment | 1 | 4500 | 4500 |
| Heater | Equipment | 1 | 2500 | 2500 |
| Thermocouples | Equipment | 4 | 1500 | 6000 |
| Flow Meter | Equipment | 1 | 1400 | 1400 |
| control Valves | Equipment | 1 | 1200 | 1200 |
| PIping | Equipment | 4 | 800 | 3200 |
| Welding | Equipment | 1 | 5000 | 5000 |
| Stand | Equipment | 1 | 4500 | 4500 |
| sealing | Equipment | 4 | 300 | 1200 |
| stationary | Miscellaneous | 1 | 1400 | 1400 |
| printing | Miscellaneous | 3 | 1200 | 3600 |
| overhead | Miscellaneous | 1 | 5000 | 5000 |