A multi-method approach to investigating porous media cooling for enhanced thermal performance of photovoltaic panels: Exploring the effects of porosity, flow rates, channel design, and coolant types

• Novel combinations (PCM, PM, MWCNT-water) tested in PVT-HAWSC system. • Energy and exergy analysis and thermal and electrical efficiencies for traditional and modified PVT-HAWSC systems are assessed. • The Exergy, thermal, and electrical efficiencies of traditional and modified PVT-HAWSC systems are assessed. • PCM, PM, and MWCNT-water nanofluid integration boosts efficiency by 16.49%, 56.25%, and 93.64%, respectively. • Modified PVT-HAWSC system reduces PV surface temperature by 28°C, compared to 22°C for traditional system. • Overall and exergy efficiencies for modified PVT-HAWSC are 93.64% and 14.32% compared to 79% and 14% for the traditional system. • Modified PVT-HAWSC: 93.64% overall efficiency, 14.32% exergy efficiency, outperforming traditional system's 79% and 14%. Elevated temperatures in photovoltaic (PV) panels adversely affect their efficiency and lifespan, necessitating effective cooling strategies. This study introduces a novel approach by integrating porous media within cooling channels to improve thermal management and energy output. While several cooling techniques have been explored, the integration of porous media with various coolants and their combined effects on cooling channel design, porosity size, flow rates, and porous media type have not been thoroughly investigated. This study fills this gap by conducting both experimental and numerical investigations to analyze key parameters, including porosity size (0.35–0.5), flow rates (1–4 L/min), cooling channel design, and coolant types (water, chemical alcohol, engine oil). Experimental tests were performed on 30-watt polycrystalline PV cells under real-world conditions, employing porous media such as gravel, marble, flint, and sandstone. The study was structured into three phases: (1) a comparative analysis of cooling performance with and without porous media, (2) optimization of porosity size for enhanced cooling, and (3) identification of optimal flow rates for system efficiency. The study identified optimal configurations, achieving up to 35.7% temperature reduction and a 9.4% power output increase with a porosity size of 0.35 and a flow rate of 2 L/min. ANSYS simulations validated experimental findings, with deviations in PV surface temperature below 3%. Simulations further revealed that a tapered cooling channel design (5 mm inlet to 3 mm outlet), combined with water as the coolant and sandstone as the porous medium, reduced PV temperatures to 36.6°C. This comprehensive analysis highlights the potential of porous media-integrated cooling systems to enhance PV panel performance and longevity.