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Justification of Pore Configuration of Metal-Foam-Filled Thermal Energy Storage Tank: Optimization of Energy Performance

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  • Chuanqing Huang

    (Shaanxi Key Laboratory of Chemical Additives for Industry, College of Chemistry and Chemical Engineering, Shaanxi University of Science & Technology, Xi’an 710021, China)

  • Jiajie Liu

    (Shaanxi Key Laboratory of Chemical Additives for Industry, College of Chemistry and Chemical Engineering, Shaanxi University of Science & Technology, Xi’an 710021, China)

  • Jiajun Chen

    (Shaanxi Key Laboratory of Chemical Additives for Industry, College of Chemistry and Chemical Engineering, Shaanxi University of Science & Technology, Xi’an 710021, China
    Oil & Gas Technology Research Institute, Changqing Oilfield Company, Xi’an 710018, China)

  • Junwei Su

    (School of Human Settlements and Civil Engineering, Xi’an Jiaotong University, Xi’an 710049, China)

  • Chang Su

    (School of Business, Society and Technology, Mälardalens University, 72123 Västerås, Sweden)

Abstract

Thermal energy storage (TES) is a crucial technology for mitigating energy supply–demand mismatches and facilitating the integration of renewable energy. This study proposes a novel horizontal phase change TES unit integrated with partially filled metal foam (MF) and fins, divided into six sub-regions ( ε 1 – ε 6 ) with graded pore parameters. A comprehensive numerical model is developed to investigate the synergistic heat exchange mechanism and energy storage performance. The results demonstrate that porosity in Porosity-1 ( ε 1 ) and Porosity-2 ( ε 2 ) regions dominates melting dynamics. Through multi-objective optimization, targeting both minimal energy storage time and maximal energy storage rate, an optimal configuration (Case TD) is derived after technical design. Case TD features porosity values ε 1 = ε 2 = ε 3 = ε 5 = ε 6 = 0.97 and ε 4 = 0.98, where the graded porosity distribution balances heat conduction efficiency and energy storage capacity. Compared to the uniform MF case (Case 1) and the fin-only case (Case 6), Case TD reduces TES time by 51.75% and 17.39%, respectively, while increasing the mean TES rate by 102.55% and 19.12%, respectively. This design minimizes the TES capacity loss (only decreasing by 2.14% compared to Case 1) while maximizing the energy storage density and improving the efficiency–cost trade-off of the phase-change material-based system. It provides a scalable solution for rapid-response TES applications in solar thermal power plants and industrial waste heat recovery.

Suggested Citation

  • Chuanqing Huang & Jiajie Liu & Jiajun Chen & Junwei Su & Chang Su, 2025. "Justification of Pore Configuration of Metal-Foam-Filled Thermal Energy Storage Tank: Optimization of Energy Performance," Energies, MDPI, vol. 18(18), pages 1-18, September.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:18:p:4859-:d:1748290
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