Forced convection through metal foams filled in solar photovoltaic module

• Cooling with 45 PPI metal foam boosts PV efficiency up to 12.4%. • Surface temperature drops 22°C using porous metal foam chambers. • Enhancement ratio reaches 3.92 with 45 PPI foam at 7 l/min flow. • Higher PPI foam increases heat transfer and Nusselt number. This study presents a comprehensive 3D numerical analysis of fluid flow and heat transfer in a solar photovoltaic (PV) module enhanced with a sustainable cooling mechanism using highly porous aluminum metal foams. The primary objective is to improve the thermal performance of the solar panel and, in turn, enhance its electrical efficiency. The investigation considers metal foams with different pores per inch (PPI) 10, 20, 30, and 45 to evaluate their effectiveness in augmenting heat dissipation. The PV module examined has dimensions of 640 mm × 540 mm × 25 mm and is positioned at an inclination corresponding to the local latitude. The simulations are carried out under constant solar radiation heat flux, with varying inlet mass flow rates. The Darcy Extended Forchheimer (DEF) and Local Thermal Equilibrium (LTE) assumptions are applied to simulate forced convection within the porous medium. The numerical outcomes are validated against existing literature and obtained good agreement. Results reveal a significant reduction in the surface temperature of the PV module by approximately 22-25°C when high-porosity metal foams are used in the cooling channel. Consequently, the electrical efficiency of the PV module improves from 8-9% to 12–13%. Additionally, increasing the inlet fluid flow rate enhances the heat transfer but is less effective compared to the inclusion of metal foams. Among the tested configurations, the 45 PPI foam exhibits the highest thermal performance, transferring 3.92 times more heat than the non-porous case, and achieving the greatest enhancement ratio (Er), especially at a mass flow rate of 7 l/min.