Analysis of Thermal Energy Storage in Batch Processes Using Phase Change Materials

Abstract

Batch reactors are widely utilized in the chemical, pharmaceutical, and food industries due to their simplicity, ease of operation, and maintenance. However, efficient energy management remains a key challenge, especially for systems operating under intermittent conditions. While phase-change materials (PCMs) offer potential for improving energy efficiency by storing and reusing waste heat, integrating heat storage within reactors can compromise their volume and design. This study introduces a novel approach by designing and experimentally testing a PCM heat battery positioned outside the reactor to reduce energy consumption cost in batch processes. By focusing on peak load shifting, the PCM heat battery stores thermal energy during off-peak periods, reducing operational costs and enhancing energy efficiency. The results indicate that energy operating costs can be significantly reduced with a PCM heat battery. Specifically, utilizing the PCM battery under a three-time tariff allows for the efficient use of energy stored at night, reducing the energy cost per batch process by approximately 8%, from 1.72 TL ($0.041) to 1.59 TL ($0.037) for facilities starting operations at 08:00. Furthermore, the findings suggest potential applications in systems like solar energy and highlight the benefits of peak load shifting, offering a sustainable and cost-effective solution for energy management in batch processing.