Browsing by Author "Verma, Saket"

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Advances in the Utilization of Biogas in Diesel Engines: An Exergy Based Approach
(Springer, 2022-01) Verma, Saket
In order to reduce the use of fossil fuels in the transportation sector, various alternatives have been explored in the past. Biogas is an interesting candidate in this context with its large potential in countries like India, which can be utilized for vehicular as well as decentralized power generation applications. Biogas is a renewable fuel that is produced from organic waste materials through anaerobic digestion process. The produced raw biogas contains methane as the fuel; however, carbon dioxide is also present in considerable amount. This inert gas reduces the flame speed and heating value of biogas and eventually deteriorates engine performances. The auto-ignition temperature of biogas is high enough that it cannot be directly utilized in the diesel engines. One of the easiest and flexible ways to utilize biogas in diesel engines is through ‘Dual Fuel (DF)’ technique. In this technique biogas is used as the main gaseous fuel and another liquid fuel (commonly diesel) is used as the pilot fuel. In this way, existing diesel engines can use biogas as the fuel with minimum engine modifications. Nevertheless, the performance of biogas DF engine has been found to be much poor than the standard diesel engine, especially at the low loads. It has been shown that there are many engine parameters, e.g. engine load, type and quantity of biogas, injection timing of the pilot fuel etc., which can affect the performance and emission characteristics of a DF engine. This article presents an overview of these effects on a biogas operated DF engine and suggests various techniques to enhance the performance of the engine.
Analysis of grid interfaced power converter for uninterrupted hydrogen production using PEM electrolyzer
(Elsevier, 2025-07) Verma, Saket
Phase-shift full bridge (PSFB) converter is widely used for high-power applications in battery charging, and data centers. However, it also has a strong application for the electrolyzer system to produce hydrogen. But, in this condition, the supply power factor can be distorted due to the nonlinearity of the electrolyzer-interfaced power circuitry. Further, the electrolyzer operates relatively at a lower voltage and higher ripple-free current for its prolonged operation. Therefore, the PSFB converter can be integrated with the interleaved buck (IB) converter that has an almost steady current at its output terminal. In this study, a three-stage power converter is proposed to connect the electrolyzer with the single-phase utility grid. In the first stage, the Vienna rectifier is utilized to connect the single-phase utility grid to the electrolyzer via the cascaded PSFB-interleaved buck converter. The utility grid operates the electrolyzer and exhibits the unity power factor operation, therefore, better power quality can be ensured. Moreover, the modeling and control of the proposed configuration of the cascaded PSFB-IB power converter have been performed. As there are many active switches in the proposed converter circuit, they can be subjected to open-circuit/short-circuit faults. The faulty operation of the power converter can stop the hydrogen production leading to catastrophic failure of the complete system. Therefore, an analysis of the fault-tolerant operation of the studied cascaded converter configuration has also been performed. After the open circuit/short circuit fault occurs in any switch of the PSFB converter, the converter still operates in the symmetric half-bridge configuration, to guarantee the hydrogen as well as oxygen production. For two electrolyzer units of each rating 0.72 kW, the hydrogen and oxygen production rates are maintained at ≈ 354 L/h and ≈177 L/h, respectively under the no-fault as well as in faulty condition. The simulation of the proposed circuit is performed using the OPAL-RT OP4610 XG real-time simulator
Analysis of metal hydride storage on the basis of thermophysical properties and its application in microgrid
(Elsevier, 2020-10) Verma, Saket
Present study focuses on the analysis of metal hydride hydrogen storage in renewable power generators-based microgrid (µG) system. The design of metal hydride storage unit requires parametric analysis on the basis of its thermophysical properties such as activation/deactivation energy, enthalpy of formation, equilibrium pressure, reaction kinetics and external thermal management system. This parametric analysis helps to assess suitability of the hydride storage with hydrogen generation (electrolyzer) and utilization (fuel cell) units in µG. Application of metal hydride in the µG creates a sophisticated system which requires careful analysis and operating strategy for achieving manifold benefits such as higher efficiency, durability of the components and self-sufficiency. In the present study, different hydrides are selected namely, LaNi5, TiCr1.6Mn0.2, hydroalloy C5 graphite and MgH2 for performance analysis on the basis of their thermophysical properties. The performance is evaluated in different operating modes aiming for higher efficiency, components durability and system self-sufficiency (minimum grid-dependency). A detailed mathematical modelling is performed in the MATLAB simulation tool for performance evaluation of overall µG system, which consists of 5 kW photovoltaic (PV), 1 kW fuel cell (FC), 5 L hydride storage and 0.6 kW electrolyzer. It was observed that the hydrogen charging and discharging processes in the hydride storage unit strongly depend on its thermophysical properties and hence require certain specific operating conditions for efficient working. Considering suitable discharging characteristics at low temperature and pressure, LaNi5 and C5 hydroalloy can be suitable for transient operation with proton exchange membrane fuel cell application. Overall energy efficiency of up to ≈ 95.49% is achieved in such type of storage-based µG. Grid-dependency ratio (load demand met by grid power/total load demand) was found between 0.26 and 5.83% in different operating modes.
A comparative exergetic performance and emission analysis of pilot diesel dual-fuel engine with biogas, CNG and hydrogen as main fuels
(Elsevier, 2017-11) Verma, Saket
In this experimental study coupled with exergy analysis, a small compression ignition engine is modified to operate in dual fuel (DF) mode with biogas, CNG and hydrogen as main fuels, and diesel as pilot fuel. Injection timing (IT) advance is studied as a strategy to improve the low load performance and emission characteristics of DF engine. Experiments were performed at ITs of 20, 23, 26, 29 and 32 degree crank angles before top dead center (°BTDC) for two engine loading conditions of low and full loads at the operating points corresponding to maximum diesel substitutions. It was found that maximum diesel substitution was considerably affected by the type of main fuel and engine load, however, relatively less affected by IT advance. Highest maximum diesel substitution was observed with CNG, and lowest with hydrogen as main fuels in DF mode. It was also found that IT that gave highest performance or lowest emission varied with both the type of gaseous main fuels and engine loads. At low load, ITs of 32, 29 and 26 °BTDC showed highest exergy efficiencies of 8.5%, 11.1% and 11.9% for biogas, CNG and hydrogen DF operations respectively, compared to 12.6% for diesel only operation. At these operating conditions, exergy destructions of 73.67%, 64.86% and 60.96% (% of total input exergy) were found for DF operations compared to 62.98% for diesel only operation. At full load condition, hydrogen DF operation exceeded exergy efficiency by 2% compared to that with the diesel only operation. On the emissions side, HC, CO and smoke emissions were found to be reduced with advanced ITs; however, NOx emissions were significantly increased.
Degradation Estimation of Polymer Electrolyte Fuel Cell under Different Cycling Load Profiles
(Springer, 2023-04) Verma, Saket
Polymer electrolyte fuel cells (PEFC) finds a suitable application in automotive vehicles as the prime mover. During its lifetime operation, a PEFC is subjected to various types of loading conditions, most of which is cyclic in nature. However, cyclic loading has been found to adversely affect the Pt catalyst cathode of a PEFC by dissolution and agglomeration of the Pt particles. It results in reduction of active electrochemical surface area, and hence reduced performance of the PEFC. In the present study, the degradation estimation of Pt catalyst cathode of a PEFC under various cyclic load profiles has been studied. Rectangular and trapezoidal load profiles have been selected with different duty cycles. The degradation estimation is based on the Pt agglomeration model, which can predict the electrochemical surface area (ECSA) at the end of set number of cycles. It was found that different voltage profile can affect the ECSA degradation in the PEFC. Degradation effect is evaluated based on the change in the electrochemical surface area, which renders to performance degradation. The Ostwald ripening effect for the Pt particles with operating time is also studied. It was concluded that Ostwald ripening lead to growth of Pt particles, which further inversely affect the ECSA and causes performance degradation.
Dynamic modelling and control strategy of a temperature-driven metal hydride cooling system for buildings
(Elsevier, 2025-03) Verma, Saket
A temperature-driven coupled metal hydride (MH) based thermal energy storage (TES) system can allow to shave and shift the peak energy demand in buildings. The high energy density and long-term (seasonal) energy storage capability are its major advantages over other energy storage methods. The dynamic nature of the MH operation, however, requires controlled hydrogen transfer between the coupled MHs at a rate needed to meet the building’s transient load. While temperature-driven MH systems are studied in the literature, their application in buildings and control are scarcely reported. This paper presents a control-based dynamic modeling of the temperature-driven coupled MH-TES system for building cooling applications. The dynamic model is developed in MATLAB® Simulink environment, considering the thermodynamic and kinetic behaviors of the MH systems. Based on a preliminary analysis of a property database of over 337 hydrides, we select around 1600 MH pairs suitable for building cooling applications. Each of these MH pairs is studied for their performance using the dynamic model, and among all, Zr0.76Ti0.24Ni1.16Mn0.63V0.14Fe0.18–Ti0.85Zr0.15Cr1.2Mn0.8 MH pair showed fast dynamics along with high coefficient of performance (COP) of 0.71. A parametric investigation is performed on this MH pair to understand the effect of operating temperatures. Finally, three proportional-integral (PI) feedback controllers are investigated to regulate the temperature, pressure and mass exchange between the coupled MH pairs. The developed PI controller is sufficiently capable of rejecting the signal noise from the hydrogen flow and internal heat exchange processes with root mean square error of 5.78 W between reference and actual cooling load.
Effect of Hydrogen Enrichment Strategy on Performance and Emission Features of Biodiesel-Biogas Dual Fuel Engine Using Simulation and Experimental Analyses
(ASME, 2020-12) Verma, Saket
In the present work, hydrogen enrichment in biogas is studied as a potential approach to improve the performance and emission features of a biodiesel-biogas dual fuel engine. A single-cylinder diesel engine is modified to operate in dual fuel mode using Jatropha curcas biodiesel as the pilot fuel and biogas as the main fuel. An electronic control unit is developed in-house to study 5−20% hydrogen enrichment in biogas using the timed manifold injection (TMI) technique. A three-dimensional computational fluid dynamics-based simulation methodology is presented for optimal selection of TMI parameters to ensure efficient and safe operation of the engine. Subsequently, the optimized injection conditions are used for the experimental evaluations, which are performed for performance and emission characteristics of the engine at low and high engine loads. Engine performance is analyzed based on energy and exergy analyses, whereas hydrocarbon (HC), carbon monoxide (CO), oxides of nitrogen (NOx), and smoke emissions are analyzed for emission characterization. The simulation results show that the injection angle and injection pressure influence in-cylinder mixture formation and hydrogen accumulation in the intake manifold. A combination of injection angle = 60 deg and injection pressure = 150 kPa offers good mixture formation. Experimental results show that at 20% hydrogen enrichment, exergy efficiencies of the dual fuel engine are increased from 8.4% to 10.1% at low load and 23.3% to 25.5% at high load. However, maximum reductions in HC and CO emissions of 35.6% and 50.0%, respectively, are calculated at low load
Effect of hysteresis band control strategy on energy efficiency and durability of solar-hydrogen storage based microgrid in partial cloudy condition
(Elsevier, 2020-12) Verma, Saket
Varying solar radiation during the partial cloudy condition may lead to the frequent switch ON/OFF events of the electrolyzer and fuel cell components in microgrid. The transient operation can ultimately lead to early degradation of these components leading to additional replacement costs. Present work is focused on the analysis of various operating modes on the operational characteristics of hydrogen storage based microgrid system during partial cloudy condition. Different operating modes for the electrolyzer and fuel cell are defined such as rated, variable power and hysteresis band control (HBC) for comparative study of system performance. Present study proposes a strategy in which the FC is operated at maximum efficiency power based on HBC. It was found that proposed HBC strategy significantly reduces the number of switch ON/OFF events of the fuel cell system and operational cost ≈ by 25% and 40%, respectively in microgrid as compared to conventional HBC.
The effects of compression ratio and EGR on the performance and emission characteristics of diesel-biogas dual fuel engine
(Elsevier, 2019-03) Verma, Saket
In this study, an experimental investigation on diesel-biogas dual fuel (DF) engine is presented based on energy and exergy analyses. The effects of change in compression ratio (CR), exhaust gas recirculation (EGR) and EGR temperature on the performance and emission characteristics of DF engine have been studied. In the first stage, engine was studied with increasing CRs of 16.5, 17.5, 18.5 and 19.5 in stepwise manner. It was found that the higher CRs were not only advantageous to the engine performance from first and second-law point of view but also to the exhaust emissions. In the second stage, DF engine was studied at the highest CR (19.5) and the effects of EGR were analysed. The engine was studied with EGR percentages of 5%, 10% and 15%, which caused slight improvements in engine efficiency at low load and simultaneous decrease in oxides of nitrogen (NOx) emissions. However, high EGR percentages at high loads showed slight decrease in engine efficiency. In the third stage, hot EGR was employed and the results obtained were compared with the cold EGR case. The results showed that the highest efficiencies both at low and high loads were obtained with hot EGR cases and at the same time exhaust emissions could also be kept in check.
Effects of varying composition of biogas on performance and emission characteristics of compression ignition engine using exergy analysis
(Elsevier, 2017-04) Verma, Saket
Growing energy demands and environmental degradation with uncontrolled exploitation of fossil fuels have compelled the world to look for the alternatives. In this context, biogas is a promising candidate, which can easily be utilized in IC engines for vehicular as well as decentralized power generation applications. Primary constituents of raw biogas are methane (CH4) that defines its heating value, and carbon dioxide (CO2) that acts like a diluent. This dilution effect reduces the flame speed and heating value of biogas, eventually deteriorating the engine performances. Present article focuses on experimental evaluation and quantification of these variations of the engine performance. Three compositions of biogas: BG93, BG84 and BG75 (containing 93%, 84% and 75% of CH4 by volume respectively) were studied on a small CI engine in dual fuel mode. Moreover, to evaluate individual process inefficiencies, exergy analysis based on second-law of thermodynamics is implemented. Exergy balances for different compositions of biogas are presented. Biogas dual fuel operation showed 80–90% diesel substitution at lower engine loads. At higher loads, total irreversibility of the engine was increased from 59.56% for diesel operation to 61.44%, 64.18% and 64.64% for BG93, BG84 and BG75 biogas compositions respectively. Furthermore, combustion irreversibility was found to be decreasing with higher CO2 concentrations in biogas. BG93 showed comparable results to that of diesel operation with 26.9% and 27.4% second-law efficiencies respectively.
Energy and exergy based performance evaluation of variable compression ratio spark ignition engine based on experimental work
(Elsevier, 2019-03) Verma, Saket
The present communication deals with the study of energy and exergy analysis of variable compression ratio four stroke spark ignition engine based on experimental work. The effect of varying compression ratio from 6 to 10 is analysed on both energy and exergy based approach. Both energy and exergy distributions are evaluated at different compression ratios for different rpm. The results show that as compression ratio increased from 6 to 10, the maximum power output is obtained at compression ratio 10 at 1800 rpm i.e. 3.80 kW. The maximum energy and exergy efficiencies are found to be 28.55% and 27.35% respectively at compression ratio 9 for 1200 rpm. Entropy generation found to be maximum for compression ratio 7 i.e. 36.47 W/K at 1800 rpm and minimum for compression ratio 9 i.e. 15.68 W/K at 1200 rpm. The results of this work revealed that exergy destruction of 10.87 kW found to be maximum at compression ratio 7 for 1800 rpm. This conclusion drawn from the study that applying both energy and exergy analysis give a more valuable understanding of performance and improvement of internal combustion engines by locating and then reducing the exergy loss at that location. Application of alternative gaseous fuels, exhaust heat recovery techniques, lean and low temperature combustion strategies reduce these exergy losses.
Exergy Analysis of Hydrogen-Fueled Spark Ignition Engine Based on Numerical Investigations
(Springer, 2017-02) Verma, Saket
Hydrogen fuelled IC engines (H2ICEs) have been considered as one of the most promising systems for pollution free transportations and their performance and combustion merits have been extensively discussed in the literature. However, studies related to these discussions have largely been linked to first-law analysis. On other hand, second-law of thermodynamics coupled with first-law, also known as exergy analysis, can give better insight into the engine performances. Bearing it in mind, this work presents second-law quantification of hydrogen engine processes and sub-processes, which helps to understand its true potential to deliver the output and simultaneously estimates various losses. This study quantifies different process inefficiencies in terms of irreversibilities thereby identifying the gaps to be addressed for further improvements. A computational fluid dynamics model has been prepared to simulate hydrogen-fueled spark-ignition engine (H2SIE) operations and second-law equations have been coupled to ascertain different exergy terms. Present study shows that combustion process is the biggest source of irreversibility in IC engines. It has also been found that the level of irreversibility for a hydrogen-operated engine is substantially lesser as compared to that with gasoline engine under identical ranges of operating conditions. Combustion irreversibilities for H2SIE and gasoline engine were found to be 15% and 23.6% of the total input fuel exergy respectively. Moreover, significant increase in second-law efficiency for H2SIE as 44.4% compared to 36.8% that for gasoline engines has been found. Another important conclusion from this work includes exergy distribution for H2SIE, which is considerably diverse from gasoline engine operation. It indicates that optimization and improvements of different H2SIE processes require specific attentions; nevertheless, show much better ability to deliver.
Experimental analysis on the effect of hydrogen supply systems in a diesel dual fuel engine
(ISEES, 2019) Verma, Saket
An experimental investigation on dual fuel (DF) operation of a diesel engine with hydrogen as the main fuel and diesel as the pilot fuel has been performed. The focus has been made on gaseous fuel delivery system for performance enhancement during DF operations. Two techniques of hydrogen delivery namely, manifold port induction and manifold port injection are compared in the DF engine. In the case of manifold induction, the gas is introduced with the help of a gas mixture in the intake manifold, whereas in the case of manifold injection, the gas is introduced with the help of an injector. The injector is located close to the intake valve and its timing is controlled through an electronic control unit. It was found that hydrogen manifold injection improves the diesel substitution and thermal efficiency of the DF engine as compared to manifold induction technique. The diesel substitution was improved by 2.3% and 1.5% at low and high loads respectively. Similarly, the brake thermal efficiency was improved by 0.4% and 0.5% at low and high loads respectively.
Experimental and numerical investigation for optimization of a hybrid battery thermal management system based on phase change material and air convection
(ASME, 2024-12) Verma, Saket
This work presents the design and optimization of a phase change material (PCM)-based hybrid battery thermal management system (HBTMS). In the first stage, experiments are performed to measure the battery cell temperatures under various charge rates with and without the usage of PCM. Thereafter, a numerical model is developed to conduct a parametric study on the effect of the thickness of PCM layer around the battery cell. The results show that with the PCM thicknesses of 6–12 mm, the maximum cell temperature (36.35 °C) and thermal nonuniformity are within the safe range. In the second stage, a parametric study is conducted in the 6S1P battery module to optimize the spacing between the cells at constant inlet velocity. The result shows that an increase in cell spacing decreases the maximum temperature within the cells. The maximum temperature is within the optimal range when the cell spacing is 10 mm. At the constant cell spacing of 10 mm, an increase in inlet velocities from 0.25 m/s to 2.5 m/s gradually improves the thermal uniformity. The maximum temperature and thermal nonuniformity for the 6S1P battery module are found to be 42.07 °C and 1.17 °C respectively. In the third stage, the 6S1P battery module is optimized for PCM thickness, cell spacing, and inlet air velocity. It is found that effective thermal management is possible with PCM-based HBTMS at a low airflow rate of up to 1.5 m/s. The optimized PCM-based HBTMS shows 53.95% and 40% reductions in PCM mass and air flowrate, respectively.
Experimental and numerical investigation of nanoparticle assisted PCM-based battery thermal management system
(Springer, 2024-04) Verma, Saket; Bhattacharyya, Suvanjan
Li-ion batteries generate a large amount of heat in the electric vehicles. The poor heat dissipation from the battery causes temperature rise and affects its performance and life. If the battery temperature is not controlled, it may lead to serious damage to the battery cells; in extreme scenario, it may lead to fire hazards. A properly designed battery thermal management system (BTMS) controls the battery temperature ensuring its safe and efficient operation. In the present work, a nanoparticle assisted phase change material (PCM) and active cooling based BTMS technique has been investigated. The study employs both experimental and numerical approaches in the development of a water-composite PCM-based hybrid BTMS (combination of active and passive cooling techniques). Firstly, the investigation is performed to optimize the amount of PCM in the BTMS as it affects the thermal performance and mass of the system. It is found that an excess amount of PCM results in heat accumulation at the heating surface, which leads to rise in the cell temperature. The reduction in thickness of PCM from 40 to 5 mm results in 26.98% reduction in the maximum temperature. Moreover, it is found that introduction of nanoparticles between 1 and 20% (by volume) in PCM results in improved thermal conductivity. The melting fraction of PCM is improved by 29.33% and 28.0% with 20% concentration of CuO and Al2O3 in the PCM, respectively. It further helps in 70.79% improvement in the thermal non-uniformity in PCM-based hybrid BTMS.
An Experimental Comparison of Enriched Biogas and CNG on Dual Fuel Operation of a Diesel Engine
(IOP, 2019) Verma, Saket
In the present work CNG and enriched biogas (93% CH4 by vol.) have been experimentally compared for performance and emission characteristics in a dual fuel diesel engine. The diesel is used as the pilot fuel, which is directly injected into the engine cylinder. The CNG and biogas are used as the main fuels, which are inducted with the intake air in the intake manifold. The experimental observations are taken for steady state conditions at varying engine loads for maximum pilot fuel substitution conditions. The performance of the engine is evaluated based on energy and exergy analyses. The emission characteristics are shown for oxides of nitrogen (NOx), hydrocarbon (HC), carbon monoxide (CO) and smoke emissions. It was found that enriched biogas showed the performance similar to that with CNG, whereas slight variations in the emissions were observed. The exergy efficiencies of 27.8% and 26.9% were calculated for CNG and biogas dual fuel operations respectively at the full load. Similarly, maximum pilot fuel substitutions were found 73.4% and 71.4% for the above conditions respectively
An experimental investigation of biodiesel-biogas dual-fuel engine based on energy and exergy analysis
(Inder Science, 2018-06) Verma, Saket
In the present work, exergy analysis has been performed on the biodiesel-biogas dual fuel (DF) engine. The DF operation has been studied with biodiesel (Jatropha curcas) as the pilot fuel to ignite the main fuel (biogas). The experiments were performed at a constant engine speed of 1500 rpm with varying engine loads and optimised injection timings for both diesel and DF modes. The results indicate that DF operation at low load produces poor performance and emission characteristics, however, no significant variations were observed between diesel-DF and biodiesel-DF operations. At 23% of engine load, exergy efficiencies were found to be 8.53% and 8.4% for diesel-DF and biodiesel-DF operations respectively; compared to 12.57% for pure diesel operation. Nevertheless, at higher loads, exergetic performances of DF operations were significantly improved. Furthermore, oxides of nitrogen (NOx) emissions from DF operations were significantly reduced compared to that with diesel operation.
An experimental investigation of exergetic performance and emission characteristics of hydrogen supplemented biogas-diesel dual fuel engi
(Elsevier, 2018-01) Verma, Saket
An experimental investigation of a conventional diesel engine with diesel, biogas and hydrogen as fuels has been carried out, while the engine is modified to operate in dual fuel mode using diesel as the pilot fuel and biogas as the main fuel respectively. In order to improve the biogas-diesel dual fuel engine performance and emission characteristics, small percentages of hydrogen supplementations, viz. 5%, 10%, 15% and 20%, in biogas were studied and the comparison was also made to that with the neat biogas-diesel dual fuel operation. Engine performance characterization has been done with exergy based approach, and major sources of irreversibilities in various engine processes are also investigated and compared for the above mentioned cases. The results show that hydrogen supplementations in biogas have lesser effect on the combustion characteristics at low load, while, at high load, the combustion patterns change significantly with higher heat release rates and peak combustion pressures. Furthermore, performance and emission characteristics are found nearly unaffected with 5% of hydrogen addition both at low and high loads. Nevertheless, further addition of hydrogen in biogas causes improvements in performance and emission characteristics of the dual fuel engine
An experimental study on gas-to-liquids and biogas dual fuel operation of a diesel engine
(Inder Science, 2021-10) Verma, Saket
In the present configuration, GTL replaces diesel, and biogas is used as gaseous fuel in the dual fuel (DF) operations. The effects of this substitution have been evaluated from the perspectives of second-law of thermodynamics. The results are compared with the diesel single-fuel, GTL single-fuel and GTL-biogas DF operations. Also, engine out emissions have been compared to understand the environmental impact of these fuel combinations. The results show that DF operation offers up to 80% pilot liquid fuel replacement by biogas, however, some reductions in energy and exergy efficiencies are observed.
Numerical investigation of phase change material-based hybrid battery thermal management system for mass optimization
(Taylor & Francis, 2023-12) Verma, Saket
In this work, a hybrid battery thermal management system using active cooling and Phase Change Material (PCM) has been studied. The additional weight of PCM poses design challenges, and hence its optimization is required. In this regard, a PCM enclosure of a cylindrical structure with six cylindrical cells is considered in 6-row and 1-column arrangement in the present work. The thermal performance of the proposed system is numerically investigated with different thicknesses of PCM layers at constant heat generation and coolant (air) flow rates. It is found that the battery thermal management with only PCM shows unsatisfactory performance under extended severe operating conditions. However, the addition low-flow convectional cooling improved the performance and the system’s reliability. It is found that for the proposed system, PCM thickness of 1 mm for the first battery cell and 2 mm for the subsequent battery cells help in better heat dissipation showing minimal thermal non–uniformity (1.1 °C) and reduced maximum temperature (39.6 °C) within the battery pack. Consequently, the optimized system shows 68.3% reduction in PCM mass as compared to the case of uniform thickness of the PCM.