Experimental characterization, parameter identification and numerical sensitivity analysis of a novel hybrid sensible/latent thermal energy storage prototype for industrial retrofit applications

Hybrid design combinations of sensible and latent heat thermal energy storage (TES) leverage the advantages and reduce the disadvantages of both types. Thus, the range of application of said individual storage types is extended and crucial retrofit opportunities are enabled. Such hybrid TES concept consisting of a Ruths steam storage (RSS) and a surrounding layer of storage containers filled with an eutectic mixture of sodium nitrate (NaNO3) and lithium nitrate (LiNO3) as phase change material (PCM) was for the first time realized and investigated during operation in a steel production plant. In this work, the hybrid TES prototype is characterized with the help of detailed modelling and real measurement results. Uncertain model parameters are identified via parameter optimization and the numerical models show satisfactory validation results. Additional 30% of thermal energy could be stored in the PCM containers retrofitted to the lab-scale RSS. Charging/discharging times and specific thermal power of the PCM containers were roughly measured as 8 h and 12 h and 560 kWm-3/-802 kWm-3, respectively, in the typical operation region. A sensitivity analysis of the performance indicators reveals potential but also engineering challenges for following generations of the hybrid TES concept. Compared to the achieved experimental results, charging/discharging power could be increased by up to 10 and 5 times, respectively, in the future by adequate measures to increase heat transfer between both storage types.