Advanced phase change material-thermal energy storage for low-carbon heat: materials, reliability, and AI-driven system integration for industry, buildings, and data centers

Decarbonizing industrial heat, buildings, and data centers at scale need thermal energy storage (TES) that is compact, reliable, and easy to use. Phase change material (PCM)-based TES stores and releases heat at nearly constant temperatures in a small space. But its adoption is slowed by slow heat transfer, material degradation over repeated use, and a patchwork approach to combining materials, systems, and controls. This review provides an overview of PCM TES, including how materials are manufactured, how they degrade, how they fit into larger systems, new ways to control them, and their cost-effectiveness. We look at different types of PCMs, how they are packaged, how they age, how to predict their lifespans, and new control methods such as model-based control and digital systems. The main result is a guide connecting PCM properties and how they break down to how the system is set up, how smart controls work, and what it costs to store energy, filling a key gap in current research. Results show that reliable design and advanced controls improve response, allow more than 10,000 cycles, and cut stored energy cost below 0.05 €/kWh with frequent use. Examples from factories, buildings, and data centers show PCM TES cuts carbon dioxide (CO2) emissions and helps balance the electricity grid. The review concludes with practical advice and research tips to accelerate the rollout of reliable, smart, and affordable PCM TES for low-carbon energy use.