Photovoltaic (PV) solar panels have a simple problem: when they get too hot, their efficiency drops. To solve this, engineers use Phase Change Materials (PCM) to absorb the extra heat. However, a new, innovative design adds a metal-foam layer to make the cooling even better. A Photovoltaic System with Metal-foam Layer Using PCM CFD simulation is the perfect tool to study and prove how well this works. This report details a CFD simulation that is validated against the results of the research paper, “Efficient thermal management of the photovoltaic/phase change material system with innovative exterior metal-foam layer” [1].

• Reference [1]: Mahdi, Jasim M., et al. “Efficient thermal management of the photovoltaic/phase change material system with innovative exterior metal-foam layer.” Solar Energy216 (2021): 411-427.

Figure 1: The schematic diagram of the PV-PCM assembly used for the analysis [1].

Simulation Process: Modeling the Photovoltaic System fluent Simulation

The simulation began with building a 2D model of the Photovoltaic System fluent assembly, which includes several layers like glass, EVA, silicon, and the crucial PCM container with the metal foam. To accurately model the melting process over time, a transient simulation was performed using ANSYS Fluent. The Solidification and Melting module was activated, which is essential for any PCM PV CFD analysis.

The entire system was modeled with a tilt angle of 30 degrees, which is important for fluid movement. A high-quality structured grid with 22,134 elements was used to ensure the results are accurate. All the material properties for the different layers were taken directly from Table 1 of the reference paper to make sure our simulation was a true validation.

Figure 2: A detailed view of the PV-PCM system integrated with the exterior metal-foam layer [1].

Post-processing: CFD Analysis, How Metal Foam Improves Heat Transfer

The simulation results provide a clear and fully substantiated story of how this system works, which begins with heat transfer. The fundamental cause of the improved cooling is the metal foam’s extremely high thermal conductivity. As the sun heats the PV panel, the metal foam acts like a “heat highway,” pulling heat away from the hot panel and distributing it deep and evenly throughout the entire volume of the PCM. The temperature gradient in Figure 4 proves this is happening, showing a smooth and uniform spread of heat from the hot top layer (around 320K) into the cooler PCM material. This prevents the formation of “hot spots” directly behind the panel, which is a common problem in standard PCM systems. This superior heat distribution is the engine that drives the entire cooling enhancement.

Figure 3: The Photovoltaic System with Metal-foam Layer Using PCM CFD Simulation validation graph, showing the excellent agreement between CFD and paper data for PV panel temperature over time.

Figure 4: The PCM melting contour from the PCM Photovoltaic System CFD simulation, showing the uniform temperature gradient and melting front created by the metal foam.

This highly efficient heat distribution has a direct and measurable effect on the panel’s temperature and the PCM’s melting behavior. Because the heat is spread so effectively, the PCM melts in a very uniform and diagonal pattern, as seen in the liquid fraction contour in Figure 4. This means more of the PCM is actively absorbing heat at any given time, maximizing its cooling potential. The direct result of this is a significantly lower operating temperature for the PV panel. The validation graph in Figure 3 confirms this, showing our CFD simulation results match the paper’s data with less than 1.8% error. This graph proves that the panel’s temperature remains 6-8°C cooler than a system without the metal foam. The most significant achievement of this CFD validation is proving that the metal foam’s ability to create a uniform temperature field (the cause) directly leads to a more effective PCM melting process, which results in a validated, sustained reduction in the PV panel’s operating temperature (the effect), thereby increasing its energy efficiency.