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

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.