PCM Phase Change Material Manufacturers for AC Air Conditioner

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Phase Change Material Cooled AC Office building in Netherlands with PCM in walls.

Phase Change Material for Air Condition & Cold Storage PCM Manufacturers

Phase Change Materials (PCMs) are "latent" thermal storage materials. They use chemical bonds to store and release heat. The thermal energy transfer occurs when a material changes from a solid to a liquid or from a liquid to a solid form. This is called a change in state or "phase." Initially, these solid-liquid PCMs perform like conventional storage materials; their temperature rises as they absorb solar heat. Unlike conventional heat storage materials, when PCMs reach the temperature at which they change phase (their melting point), they absorb large amounts of heat without getting hotter. When the ambient temperature in the space around the PCM material drops, the Phase Change Material solidifies, releasing its stored latent heat. PCMs absorb and emit heat while maintaining a nearly constant temperature. Within the human comfort and electronic-equipment tolerance range of 20°C to 35°C, latent thermal storage materials are very effective. The main applications for Phase Change Materials PCMs are when space restrictions limit larger thermal storage units in direct gain or sunspace passive solar systems. PCMs may be used in Thermal Enclosures like Telecom Chambers BTS or BT Shelters or solar domestic hot water heating or passive solar space heating/cooling systems. They are also useful for equalization of day & night temperature and for transport of refrigerated products.

Glauber's salt, Soda ash, Sodium Acetate and paraffin wax are the most commonly used Phase Change Materials in solar heating systems. Although these compounds are fairly inexpensive, the packaging and processing necessary to get acceptable performance from them is complicated and costly. They are not offering a reliable pattern of releasing heat as the chemicals in these PCMs separate and stratify when in their liquid state. These PCMs have not always re-solidified properly. When temperatures dropped, they did not completely solidify, reducing their capacity to store latent heat. These problems have been addressed by packaging phase change materials in thin or shallow containers and by adding clumping agents. Many salt hydrate Phase Change Materials have the disadvantage that during extraction of stored heat the material super-cools before freezing. This reduces the utility of the materials and if too severe, it can completely prevent heat recovery. They lose their heat storage property after some cycles. These types of PCMs, however, compare unfavorably with the newer generation of low-cost, highly efficient PCMs. Researchers now label these older compounds as "limited utility" PCMs. Phase Change Materials perform best in containers that have a depth of one inch (25.4 millimeters). However, our T-Series Latest™ PCMs have defied this restriction. The packaging material should conduct heat well; and it should be durable enough to withstand frequent changes in the storage material's volume as phase changes occur. It should also restrict the passage of water through the walls, so the materials will not dry out. Packaging must also resist leakage and corrosion. Aluminum, steel and polyethylene are common packaging materials.

We cannot help making a negative comment on the products offered by other brands. Most of the brands are offering Thermal-Salt 29 that freezes at less than 18^oC, making them practically useless in tropical regions. The shelf life of some of the vendors is hardly 45-60 day, making its use by long distance importers almost impractical. Most of such vendors are not manufacturer of the major ingredients but only compounders. Often, they are one-man-show manufacturers and quote fancy prices for the product. With the information technology to their aid, they make fancy web sites and manage to squeeze the buyers. We have six manufacturing units, owned and managed by family members and most of the ingredients are manufactured by us.

Latest 29T: Phase Change Material, PCM Latest^TMBrand with Melting Point 29°C and Latent Heat of fusion 175 KJoule/Kg or 255 KJoule/liter. It is best suited for Air-Condition Back-up to BT Shelter or Telecom Shelter. It is also a good alternative to bear with when temperature changes from 15°C at night and rises to 40°C in the day. This will act as a heater at night and a cooler in the day.

Latest 22T: Phase Change Material, PCM Latest^TM Brand with Melting Point 22°C and Latent Heat of fusion >175KJoule/Kg or 255 KJoule/liter). It is best suited for Free Air-Conditioning in an area where day and night temperature difference permits it. The material can be placed in an external heat exchanger or in the false ceiling and/or partition walls.

Power Failure is very common in developing countries. The following write up is talking about Air Condition in Telecom Shelters, though it is applicable to any other shelter like site office or Polymer wall-paneled room. It can easily provide human-comfort level, almost through out the day.

Most BT Shelters or Telecom Shelter or Electronic Enclosures Chambers are equipped with Electronic Equipments and Battery for emitting proper signal to the cell-phone users. The Telecom Shelter or BTS is Air conditioned AC. When the power fails, the temperature inside the BTS start rising very rapidly due to heat generated by the equipments and also due to ambient conditions. Diesel Generators are provided to give Air conditioned AC back up. However they are largely depended on the alertness of the watchman cum operator at the site. The contractors often delay in sending diesel aggravating the problem. To minimize the dependence on generators, Back-up air-conditioning may be provided by PCM. Latest™ 29T is used in India for giving back-up to Air-Condition. 240kg of Latest™29T is generally used per BTS. 240kg*175 J/kg 42000 K Joules of backup. This is equal to 42000/3600 = 11.6 KWH of energy (Theoretical Latent Heat of Latest™29T is 188 KJ/Kg i.e. 12.5 KWH of Energy).

In case of inhabited rooms or offices human comfort level can be achieved by using an External Heat-Exchanger with an inverter switched fan or by using Phase Change Material in wall-panels and ceiling.

Live-Site Trial in a Telecom Shelter after Retro-fitting it with 210 Kg of PCM Latest29T (10 KWH back-up)

210 Kg of Latest29T PCM (10KWH) filled profiles were installed in an Existing Telecom Shelter of 2m Length by 2.5m width by 2.7m Height. Five thermometers were installed to measure temperature at various points. The Air-condition was switched off when the temperature was 17.3^oC. Ambient temperature was also measured. The battery voltage was observed as per the instruction of the site-officer. The permissible maximum temperature that can be reached was targeted to 35^oC. This temperature was not reached in 6 Hours of the run. In a blank reading with-out Latest29T PCM the target maximum temperature crossed in less than 1 hour.

TECHNO-COMMERCIAL STATEMENT OF PCM PRODUCT T-SERIES LATEST™

PCM Energy P. Ltd.	PCM Latest™
Product	Latest™29T
Series	T-series Latest™
Description	Viscous Semi-Solid near Phase Change Temperature
Appearance	Translucent
Base Material	Inorganic Salts
Phase Change Temperature	28-30oC
Sub Cooling	2oC max
Specific Gravity	1.48-1.50
Latent Heat Practically	175 Joules/g
Latent Heat Theoretical	188 Joules/g
Spec. Heat	2 Joules/g oC
Thermal Conductivity	1Watt/m oC
Congruent Melting	Yes
Flammability	No
Hazardous	No
Thermal Stability	> 10000 cycles
Max. Operating Temperature	100oC
Rates	Available on request

Phase Change Materials perform best in containers that—when combined with the PCM—total one inch (25.4 millimeters). However, our T-Series Latest™ PCMs have defied this restriction. T-series is the Latest in PCM technology, Generation-X. It is not degradable with time. It can be used in thicker layers greater than 1” (> 25mm). This product has made the earlier PCMs obsolete.

Table of Cycle No. V/s Latent Heat & Sub Cooling for PCM Latest™29T

Cycle No	100	200	300	400	500	1000	1000	1500	2000	1500	2000	2500	3000
Latent Heat KJ/Kg	196	188	188	192	185	178	178	175	170	172	175	178	170
Sub Cooling oC	0.5	1.0	0.9	0.8	0.7	1.0	1.0	1.1	1.2	1.3	1.2	1.3	1.4

The measurement error in Latent Heat can be upto 5% and the Thermometer sensor can be off by 0.5^oC

Our Thermal Salt Latest™29T is a mixture of several ingredients. Most of these items are manufactured by us or by our sister concerns. Its properties are as under:

Specific Gravity: 1.5
Freezing Point: 28^oC
Melting Point: 29^oC
Latent Heat of Fusion : >175 KJoule/Kg (40 K. Cal/Kg). 255 KJ/ltr (60000 KCal/Cu.m)
*Most manufacturers report the heat of fusion in a temperature range, like 20^oC to 35^oC. The specific heat of PCM in this range will get added to the values. For this temperature range
*Latent Heat of Fusion: 210 KJoule/Kg (50 K. Cal/Kg).
Shelf Life: Infinite
Max. Operating Temp.: 100^oC

For Advanced Users: Most PCM users are at the elementary stage of using the Phase Change Materials PCMs. They are ordinarily not conditioned to talk of any deviations from the systems, they have heard of. Using PCM-29 itself is more than adequate mental kick for them. Some vendors manage to convince them that the use of PCMs will save energy charges for them. The primary purpose of the PCMs is to provide a back-up to Air Condition AC and avoid the use of Diesel Generator. The site managers and the watch-man cum operator of the site may not be sufficiently professional. They often fail to keep the diesel at site and restore to "Keep the Door Open for Cooling" ways to cut corners. The relevance of Phase Change Materials PCMs is more, if the power failure is a norm in the area of usage. We have a Brain-Wave. Instead of giving 4-6 hours of Back-up, why not give 12-18 hours of Back-up and eliminate the Diesel Generator???!!! This will of course need a better battery capacity.

In a remote area a site was running on diesel generator and there was no electricity in the region. On receiving an enquiry for installing Phase Change Material PCM in the BT Shelter, we had the impulse of telling them that PCM will be of no use to them. One of their junior engineer was very bright and he discussed the details with our senior scientist. He summarized that their diesel generator is installed for working in the extreme conditions of weather and telecom traffic. the generator works on full load, irrespective of the traffic and weather. If PCM back-up is installed, then it will reduce their diesel cost by 50% and hence he ordered for installing the PCM back-up. To the good luck of the junior engineer his theory did work.

Weather Information on Bangalore

Month

Mean Temperature oC

Mean Total Rainfall (mm)

Mean Number of Rain Days

Remarks

Daily

Minimum

Maximum

Jan

15.1

2.7

0.2

22-23oC can be maintained all the time

Feb

16.6

29.6

7.2

0.5

22-23oC can be maintained all the time

Mar

19.2

32.4

4.4

0.4

22-23oC can be maintained for a few hours

Apr

21.5

33.6

46.3

PCM Cooling can be used if the acceptable

May

21.2

32.7

119.6

Melting Point of PCM is 23oC.

Jun

19.9

29.2

80.6

6.4

In that case Hall temp will be 25-26oC

Jul

19.5

27.5

110.2

8.3

22-23oC can be maintained for a few hours

Aug

19.4

27.4

137

22-23oC can be maintained for a few hours

Sep

19.3

194.8

9.3

22-23oC can be maintained for a few hours

Oct

19.1

27.7

180.4

22-23oC can be maintained for a few hours

Nov

17.2

26.6

64.5

22-23oC can be maintained all the time

Dec

15.6

25.9

22.1

1.7

22-23oC can be maintained all the time

The above details are the mean maximum and minimum temperatures in Bangalore.

The information is available from World Weather Information Service, India Meteorological Department.

From the above information, it appears that for more than 100days, PCM Melting at 20oC is workable

for free cooling. 4 months are marked in green back-ground and 5 months in yellow background.

In April, May and June, free-cooling can not be made available. PCM Melting at 20oC

will easily give comfortable temperature during day time for rest of the months.

Calculations based on 100 days free cooling will be on safer side.

Calculation of Quantity of PCM Required

Air Conditioning Load is stated to be 932 tons AC

932

Tons AC

1ton = 80Kcal*1000/24 so 932 tons AC is

(Refrig. AC is slightly lower)

3106667

Kcal/hr

i.e. No. of Kcal'hr*4.18KJoule/Kcal/3600sec/hr

3607

KJ/sec

At 10hours per day of Cooling or heating cycle it means

129858667

KJ/day

If PCM of 170KJ/Kg is used then we need No. of KJ/day/170 Kg of PCM

763875

Kg of PCM

At Rs.70/- per Kg the quantity of PCM will cost

(Bulk Price)

53471216

Rs.

Cost of Fixing on site @ Rs.60/- per Kg** including cost of False ceiling (1)

45832471

Rs.** Tentative

Total Cost

Rs.

99303686

Rs. Tentative

At Electricity cost of Rs.5/- per KWH Electricity Charges of AC usage (2)

18036

Per Hour

If the system is usable for 1000 hours a year, then cost of Energy Saved

18035926

Per Year

Saving on Maintenance & Depreciation of AC System at 50% of the above (3)

9017963

Per Year

Total saving/per year

27053889

Per Year

Pay Back Period if you count only cost of PCM (4)

1.98

Years

Pay Back Period if you count only cost of PCM and Cost of False Ceiling (4)

3.67

Years

III

Calculation of Surface Area of Encapsulated PCM.

Let us calculate for 76.3875MT PCM Encapsulated in a Panel or Profile of 20mm*200mm*1m

Heat Transfer Surface Area of all 4 sides will be 0.22*1*2 sq. m per piece

0.44

sq. m.

Each Profile will pack around 4kg of PCM

Number of Profiles required will be PCM/4

190969

Pieces

Heat Transfer Surface Area of 4 sides for all the pieces will be No. of Pieces*Area per piece

84026

Sq. m

i.e.

906643

Sq. ft

Surface Area of one side and all the pieces will be 0.2*1*2 sq. m

38194

Sq. m

i.e.

412110

Sq. ft

Let us say that 2 laces sq. ft of the Hall is a square one with each side as 450 ft. (5)

The four sides will be approximately 450*4 (5)

1800

After excluding non-panel-able area

Say

1500

ft say

If the wall is paneled with PCM upto 10ft we will get on one side

15000

Sq. ft

If the Ceiling is Paneled with PCM profiles we will get

200000

Sq. ft

If the under floor is paneled with PCM-filled profiles we will get

200000

Sq. ft

It is advisable to have wall paneling and ceiling paneling.

Ceiling paneling can be adjusted to have double the number of panels by cross placing

Under floor paneling may not be desirable due to wear and tear.

Assuming one side ceiling paneling as 400000 sq. ft, we will get total heat transfer area of (5)

400000*2.2 sq. ft from Ceiling and 15000 sq. ft from walls (5)

895000

Sq. ft.

86284

Sq. m

Heat Transfer Coefficient of 25 Kcal/hr.sq.m.oC & ∆T of 2oC are safe bet.

Heat Transferable in 1 hour will be U*A*∆T

25Kcal/hr/sq.m/C*Area*T*1hr

4314180

Kcal/hr

The Variation in ∆T is adequately Taken Care of here as it will always be higher.

ADEQUATE....................

Replacement Air

Human Comfort level is achieved when around 100Whr per person per day is the dissipated by air.

Sp. Heat of Air is 0.25 Kcal/Kg and density is 1.25 Kg/Cu.m.

1 Watt.Hr = 3600 KJ = 861 Kcal

100 Watt.Hr = 360000 KJ = 86100 Kcal

There are 1800 people in the building

So total heat to be dissipated by air is 154980000 Kcal/day or 1800 Kcal/sec

Flow rate of air required to dissipate this quantity of heat is 5740 m^3/sec per degree of temperature rise

For a 2 degree C temperature rise permissible for air, this becomes 2870 M^3/sec

For 2870 m^3/sec of air gushing through a 6000 sq. m. of Void (33% of Ceiling Area) in the ceiling panels

its speed will be .478 or ~ 0.5 m/sec. We can have higher by recirculation.

Turbulence in the Panels can be increased further by recirculation rate.

(1)To Check & Alter the Cost of Paneling and False Ceiling

(2) To Check & Alter the Cost of Electricity

(3) To Check and Correct the Cost of Depreciation & Maintenance of AC

(4) Intangible Benefits and Green Factor is added to this pay-back.

(5) False Ceiling would be needed either way for aesthetic purposes

(6) To Check and Alter the Side Area/Length/Breath

Night: Ambient Night Temperature is 11C for 12 hours
Target Temperature at Night is 16C for 12 hours
Day: Ambient Day Temperature is 18C for 12 hours
Daytime Hot Water available at 20-22C for 12 hours
Load as estimated by the user: 0.19 KW per Sq. m.
Desired Night Temp (12 hours): 16C

1. We suggest using LatestTM18T having Melting Point of 18C offering 175 K Joule/Kg Latent Heat.

Q (Heat Load) = 0.19 KW
Time = 12 hours = 43200 seconds
Heat load in KJ/Sq. m = 0.19*43200 = 8208 ~ 8200 KJ/Sq. m
Each Kg of PCM will release 175 KJ of Latent Heat at 18C.
Quantity of PCM required per Sq. m green house = 8200/175 = 46.9 Kg/Sq. m. ~ 50 Kg/Sq. m

By Ambient Air: The PCM can get totally recharged if the Daytime temperature is >23C.
By Hot Water: The PCM can be charged with 650 Liters/Sq. m. of hot water losing heat from 22C to 19C.
The heat transfer coefficient is adequate in both the cases to recharge the PCM.

PCM will have to be encapsulated in hermetically sealed containers.
Height of Container to accommodate 50 Kg PCM per Sq. m is 3.33 cm, considering PCM density of 1500 Kg/m^3.
Since the case demands charging PCM using hot water, we will have to provide a jacket on the underside.
PCM can be encapsulated in Carbon Steel or M.S. boxes of 3.33 cm thickness to accommodate 50 Kg PCM per Sq M), and placed on the floor.
Price/Sq. m. For 1 Sq. m of Green House requiring 50 Kg of PCM LatestTM18T, cost of PCM is US$ 150 at US$ 3 per Kg PCM.

The areas where one can install PCM-Cooled Shelters and Houses are also good areas for installing PCM-Filled Cool Furniture (Polymer based Furniture). Modular Offices with Writing Tables and Filing Cabinets help to keep the office cool and improve working efficiency.

----- PCM filled Panels ------------- PCM filled Aluminum Pipes ----- S S Ball ------

Hermetically Sealed Profile of Any Size Like 16mm*160mm*1000mm OR 20mm*200mm*850mm or …..etc, offered in Polymer or Aluminum filled with desired Grade of PCM. We can give PCMs in Aluminum or Pet Bottles, HDPE or SS Balls or in Aluminum Sinks or in any container as per your choice.

Several Types of Packing can be custom made for cold storage and shipping application. Insulated Containers having back up of PCM of appropriate temperature (like -40^oC or say +18^oC) can be offered. As a demonstration, we have shown below a small size "PCM-backed Insulated Container". It has four PCM-filled profiles inserted in a special high-class insulated box. The box was kept for 30 days at 18^oC by filling it with appropriate PCM. Containers of any size and shape can be tailor made.

PCM-Filled Insulated Boxes for Transport of Medicine, Food, Live Culture, Human Organs.

PCM for Air Condition Manufacturers
Phase Change Material for Air Conditioner Manufacturers

PCM Energy P. Ltd
Mazgaon, Mumbai 400 010, INDIA
TEL: 91-22-23770100, 23774610, 23726950, 23723564. FAX: 91-22-23728264

Important Record.
Time after Power Shut Down	0		1 Hour		2 Hours		3 Hours		4 Hours		5 Hours		6 Hours
Time in Minutes After Shut-down	0	30	60	90	120	150	180	210	240	270	300	330	360
Average Temp oC (of 5 Sensors)	17.3	22.4	25.2	27.3	29.1	30.2	31.3	32.1	32.6	32.8	33.1	33.2	33.3

Other Relevant Record
Outside Temp oC	26.5	28	29.5	30	31	31	33	33	32	30	28.5	28	26.7
Battery Voltage	25.18	24.99	24.98	24.74	24.65	24.56	24.45	24.21	24.14	23.89	23.61	23.45	22.94
Shelter Temp Centre Top oC	17.5	23.1	25.8	28.1	29.5	30.6	31	31.7	33	33.5	33.5	34	34.1

Permissible limit of Trial was up to Shelter Temperature of 35oC. The Trial was discontinued as the Battery Voltage went low.
The PCM could have lasted for 1-2 Hours more, if the Battery Voltage had not dropped.

Preliminary/Concept Presentation for Data Exchange and Technical Interaction.
Data Offered by the User:
Air Condition Load is 932 Tons of Refrigeration.	932	Tons AC Tons AC
Carpet Area of the Hall is 200000 sq ft.	200000	Sq. ft
Comfort Level is 23oC. [Phase Change Material (PCM) to start Melting at 21oC	21	oC
No. of people is 1800	1800	People
We get 19oC for at least 4hr/night for hundred nights in a year
Fan use is permitted

Phase Change Material for Air Condition & Cold Storage PCM Manufacturers

PCM for Air Condition ManufacturersPhase Change Material for Air Conditioner Manufacturers

PCM for Air Condition Manufacturers
Phase Change Material for Air Conditioner Manufacturers