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<p>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.</p>

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Analysis of thermal energy storage in batch processes using phase change materials

  • 期刊论文

  • 发表日期：

    2025年12月18日

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  • Nur Efşan Kaya,
  • Mehmet Akif Ceviz,
  • Faraz Afshari,
  • Emre Mandev,
  • Hüseyin Köksal

摘要

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.