Heat Transfer Model Research Articles

CFD-DEM Modeling of Cryogenic Hydrogen Flow and Heat Transfer in Packed Bed

Hydrogen is an important component of renewable energy and is essential for sustainable development. The cryogenic energy storage system can solve the problem of hydrogen storage. A packed bed can be applied in a cryogenic energy storage system. It is crucial to understand the cryogenic energy discharging in a packed bed. In the present work, the CFD-DEM coupling method is used to investigate the pore-scale flow and heat transfer characteristics of cryogenic hydrogen flowing through the packed bed. To demonstrate the characteristics of the pore-scale heat transfer of the hydrogen flow in a packed bed, the local radial-averaged and axial-averaged temperatures and velocities are analyzed in detail, depending on the local porosity distribution. The pore-scale radial-averaged velocity distribution is proportional to the local radial porosity distribution, whereas the pore-scale radial-averaged temperature characteristics are inverse. Moreover, for the heat exchange of the cryogenic hydrogen flow in a packed bed, it can be found that the cryogenic hydrogen flow is fully heated at an axial distance of approximately 7 dp. Finally, considering that the thermo-physical properties of cryogenic hydrogen are sensitive to the temperature in a packed bed, the friction factor and Nusselt number in the packed bed are also analyzed under various operating parameters, which are in good agreement with certain classic empirical correlations.

Heat exchange performance of an energy-pile group in a hybrid GSHP system and effects of pile spacing

In long-term operations, seasonal imbalance in the thermal load may adversely affect the heat transfer performance of the energy piles, potentially resulting in thermal accumulation within the ground and eventual system failure. The heat transfer performance of energy pile systems during long-term operation under unbalanced thermal loads must be investigated. Moreover, the design parameters of energy piles are usually constrained by the requirements of foundation structural design, resulting in energy piles being densely arranged. Hence, the influence of pile spacing on the heat exchange performence of energy piles must be comprehensively understood. In this study, two- and three-dimensional energy-pile heat transfer models were established and innovatively coupled based on an engineering project currently under design. Numerical simulations were performed to investigate the heat transfer behavior of energy-pile groups subjected to unbalanced thermal loads and the effect of pile spacing on their heat exchange performance. Furthermore, design recommendations regarding the determination of the proportion of thermal loads to be borne by the energy piles in a hybrid GSHP system were provided. The results indicate that the proposed 2D-3D coupled modeling approach is able to simulate the heat exchange performance of large-scale energy pile groups. Pile spacing considerably affects the long-term thermal performance of energy-pile groups, especially in cases with small pile spacings. The influence of pile spacing on the heat exchange capacity of energy piles can be considered in the design phase by incorporating a group effect coefficient η, which are calculated to be 0.165, 0.470, 0.732, and 1 for pile spacings of 2 m, 4 m, 6 m, and 10 m, respectively.

Equivalent Thermal Conductivity of Topology-Optimized Composite Structure for Three Typical Conductive Heat Transfer Models

Composite materials and structural optimization are important research topics in heat transfer enhancement. The current evaluation parameter for the conductive heat transfer capability of composites is effective thermal conductivity (ETC); however, this parameter has not been studied or analyzed for its applicability to different heat transfer models and composite structures. In addition, the optimized composite structures of a specific object will vary when different optimization methods and criteria are employed. Therefore, it is necessary to investigate a suitable method and parameter for evaluating the heat transfer capability of optimized composites under different heat transfer models. Therefore, this study analyzes and summarizes three typical conductive heat transfer models: surface-to-surface (S-to-S), volume-to-surface (V-to-S), and volume-to-volume (V-to-V) models. The equivalent thermal conductivity (keq) is proposed to evaluate the conductive heat transfer capability of topology-optimized composite structures under the three models. A validated simulation method is used to obtain the key parameters for calculating keq. The influences of the interfacial thermal resistance and size effect on keq are considered. The results show that the composite structure optimized for the V-to-S and V-to-V models has a keq value of only 79.4 W m−1 K−1 under the S-to-S model. However, the keq values are 233.4 W m−1 K−1 and 240.3 W m−1 K−1 under the V-to-S and V-to-V models, respectively, which are approximately 41% greater than those of the in-parallel structure. It can be demonstrated that keq is more suitable than the ETC for evaluating the V-to-S and V-to-V heat transfer capabilities of composite structures. The proposed keq can serve as a characteristic parameter that is beneficial for heat transfer analysis and composite structural optimization.

Heat and Mass Transfer Model for a Counter-Flow Moving Packed-Bed Oxidation Reactor/Heat Exchanger

Abstract Particle-based thermochemical energy storage (TCES) through metal oxide redox cycling is advantageous compared to traditional sensible and latent heat storage (SHS and LHS) due to its higher operating temperature and energy density, and the capability for long-duration storage. However, overall system performance also depends on the efficiency of the particle-to-working fluid heat exchangers (HXs). Moving packed-bed particle-to-supercritical CO2 (sCO2) HXs have been extensively studied in SHS systems. Integrating the oxidation reactor (OR) for discharging with a particle-to-sCO2 HX is a natural choice, for which detailed analysis is needed for OR/HX design and operation. In this work, a 2D continuum heat and mass transfer model coupling transport phenomena and reaction kinetics is developed for a shell-and-plate moving-bed OR/HX. For the baseline design, the model predicted ∼75% particle bed extent of oxidation at the channel exit, yielding a total heat transfer rate of 16.71 kW for 1.0 m2 heat transfer area per channel, while the same design with inert particles (SHS only) gives only 4.62 kW. A parametric study was also conducted to evaluate the effects of particle, air, and sCO2 flowrates, channel height and width, and average particle diameters. It is found that the respective heat transfer rate and sCO2 outlet temperature can approach ∼25 kW and >1000 °C for optimized designs for the OR/HX. The present model will be valuable for further OR/HX design, scale-up, and optimization of operating conditions.

Thermal decomposition and combustion of interior design materials

Research findings on the patterns of thermal decomposition and combustion are reported for widely used interior design materials. The experiments were conducted using a hardware and software system including a thermogravimetric analyzer (to record the characteristics of thermal decomposition), a gas analyzer (with H2, CH4, H2S, SO2, CO and CO2 sensors) and a high-speed camera (to record the characteristics of ignition and combustion). The temperature of the oxidizing medium ranged from 500 to 900°C to investigate the conditions of thermal decomposition initiation and sustained combustion. It was established that the highest concentrations of toxic emissions were typical of the combustion of polypropylene at a maximum temperature of the oxidizing medium (900°C). Wood showed the shortest ignition delay time and the longest duration of combustion. The experimental data were used for a physical problem statement and mathematical model of heat and mass transfer to explore the thermal decomposition and combustion of interior design materials in different rooms. A comparison of the experimental findings with the mathematical modeling results validates the developed model. The growth rates of carbon monoxide and carbon dioxide concentrations were determined for construction (wooden) and interior design (polymer) materials. The maximum concentrations of CO and CO2, and the minimum times taken to reach their threshold values corresponded to wood and polyvinyl chloride panels. This research provides a deeper insight into the thermal decomposition of a wide range of fuels and the formation of gaseous pyrolysis products of these fuels. The results obtained can be used to evaluate the toxicity of construction and interior design materials during compartment fires as well as to estimate the safe egress time and risks involved in the process. They can also serve as a database for the development and testing of mathematical models describing fire outbreaks and propagation in confined spaces.

Graphics‐Processing‐Unit‐Accelerated 3D Online Heat Transfer and Solidification Model for Continuously Cast Slab

A graphics‐processing‐unit (GPU)‐accelerated 3D heat‐transfer and solidification model is proposed to predict the temperature field and solidification field for continuously cast slab. The fully 3D model is developed based on the finite difference method and implemented on the compute unified device architecture (CUDA)/C++ platform. The model is verified by solving the 1D Stefan problem and validated by surface temperature measurements. The model is proven to be 18.91 times faster for the coarsest mesh of 35 million nodes and 22.92 times faster for the finest mesh of 50 million nodes than a central‐processing‐unit (CPU)‐based parallel version with 28 threads. The corresponding relative calculational times are 0.19 and 0.32, which indicate that the model has great computation efficiency. The model is proven to be robust enough for the dynamic continuous casting (CC) process via a test of dynamic casting speed. Further analysis of the nonuniform heat transfer and solidification shows that the model is able to predict the nonuniform heat transfer efficiently. In the studied cases, a higher casting speed will lead to a remarkable enhancement of the unevenness of heat transfer and solidification in general.

A Predictive Model for Wellbore Temperature in High-Sulfur Gas Wells Incorporating Sulfur Deposition

HSG (high-sulfur gas) reservoirs are prevalent globally, yet their exploitation is hindered by elevated levels of hydrogen sulfide. A decrease in temperature and pressure may result in the formation of sulfur deposits, thereby exerting a notable influence on gas production. Test instruments are susceptible to significant corrosion due to the presence of hydrogen sulfide, resulting in challenges in obtaining bottom hole temperature and pressure test data. Consequently, a WTD (wellbore temperature distribution) model incorporating sulfur precipitation was developed based on PPP (physical property parameter), heat transfer, and GSTP (gas–solid two-phase) flow models. The comparison of a 2.53% temperature error and a 4.80% pressure error with actual field test data indicates that the established model exhibits high accuracy. An analysis is conducted on the impact of various factors, such as production, sulfur layer thickness, reservoir temperature, and reservoir pressure, on the distribution of the wellbore temperature field and pressure field. Increased gas production leads to higher wellhead temperatures. The presence of sulfur deposits reduces the flow area and wellhead pressure. A 40% concentration of hydrogen sulfide results in a 2 MPa pressure drop compared to a 20% concentration. Decreased reservoir pressure and temperature facilitate the formation of sulfur deposits at the wellhead.

Finite-rate chemistry Favre-Averaged Navier-Stokes based simulation of a non-premixed SynGas/Air flame

Abstract The present paper is devoted to the study of the influence of chemical mechanisms, turbulence models and gas radiative properties models on the characteristics of a turbulent diffusion CO/H2/N2 -air flame, i.e., the so-called syngas flame in a Favre-averaged Navier-Stokes (FANS) environment. For this purpose, a transient FANS solver for combustion is used. The simulations are carried out using three distinct turbulence models, i.e., the standard k-ε (SKE), the renormalization group (RNG) k-ε, and the Shear Stress Transport (SST) models. The turbulence-chemistry interaction is modeled using the Partially Stired Reaction (PaSR) model. The chemical mechanisms used in the present study are: (i) a compact skeletal C2 mechanism, (ii) a mechanism developped by Frassoldati-Faravelli-Ranzi (FFR) containing 14 species and 33 reactions and (iii) the optimised syngas mechanism by Varga. Radiation heat transfer is handled by the P-1 method. In addition, the performances of two gas radiative properties models, i.e., the grey mean gas and the weighted-sum-of-gray-gases (WSGG) models, are assessed in radiative heat transfer modeling of the syngas flame. The predicted results reveal that the combination of the RNG turbulence model and the C2 skeletal mechanism shows the best agreement with measurements. The WSGG model used predicts results with the same level accuracy as the grey gas model in modeling of the syngas flame.

Modeling heat and mass transfer in granular flows between vertical parallel plates

Gravity-driven granular flows between vertical parallel plates at elevated temperatures are integral in the development of the next generation of particle-based heat exchangers for concentrated solar power. Efficient modeling methodologies that accurately captures the heat transfer mechanisms of temperature-dependent granular flows are essential to effectively design and evaluate these heat exchangers. Transient, pseudo-one-dimensional heat and mass transfer models were developed for inlet flow temperatures between 473 and 1073 K. The mass transfer models for the granular flows were resolved using discrete element method simulation, providing detailed temporal and spatial distributions of flow parameters in good agreement with experimental measurements. The heat transfer model employed a one-dimensional, two-phase, continuum approach, and a system of non-linear differential equations was solved via finite difference method. The particle-to-wall contact heat transfer was determined with an effective thermal conductance model. Radiative heat transfer between particles and walls was also considered. The predicted particle and wall temperatures for two different channel widths of 6.4 and 2 mm were well-correlated to previously obtained experimental measurements with Pearson’s correlation coefficients greater than 0.91. A significant disparity in particle temperature of up to 72 K was observed when radiative heat transfer was omitted, and a maximum temperature difference of 11 K was observed when temperature-dependent granular flow properties were not considered. The model revealed that radiative heat transfer potentially contributed to > 30 % of heat losses in wider channels at high inlet temperatures, and conduction was the dominated heat transfer mechanisms in narrower channels (∼70 %) due to increased particle-to-wall contact. This accurate model, leveraging discrete element method in a streamlined approach, advances the understanding and modeling of heat transfer in granular flows at elevated temperatures, enabling more efficient and reliable solar thermal energy storage and transport.

3-D stochastic modeling approach in thermal inactivation: estimation of thermal survival kinetics of Escherichia coli O157:H7 in a hamburger after exposure to desiccation stress.

Desiccation tolerance of pathogenic bacteria is one strategy for survival in harsh environments, which has been studied extensively. However, the subsequent survival behavior of desiccation-stressed bacterial pathogens has not been clarified in detail. Herein, we demonstrated that the effect of desiccation stress on the thermotolerance of Escherichia coli O157:H7 in ground beef was limited, and its thermotolerance did not increase. E. coli O157:H7 was inoculated into a ground beef hamburger after exposure to desiccation stress. We combined a bacterial inactivation model with a heat transfer model to predict the survival kinetics of desiccation-stressed E. coli O157:H7 in a hamburger. The survival models were developed using the Weibull model for two-dimensional pouched thin beef patties (ca. 1 mm), ignoring the temperature gradient in the sample, and a three-dimensional thick beef patty (ca. 10 mm), considering the temperature gradient in the sample. The two-dimensional (2-D) and three-dimensional (3-D) models were subjected to stochastic variations of the estimated Weibull parameters obtained from 1,000 replicated bootstrapping based on isothermal experimental observations as uncertainties. Furthermore, the 3-D model incorporated temperature gradients in the sample calculated using the finite element method. The accuracies of both models were validated via experimental observations under non-isothermal conditions using 100 predictive simulations. The root mean squared errors in the log survival ratio of the 2-D and 3-D models for 100 simulations were 0.25-0.53 and 0.32-2.08, respectively, regardless of the desiccation stress duration (24 or 72 h). The developed approach will be useful for setting appropriate process control measures and quantitatively assessing food safety levels.IMPORTANCEAcquisition of desiccation stress tolerance in bacterial pathogens might increase thermotolerance as well and increase the risk of foodborne illnesses. If a desiccation-stressed pathogen enters a kneaded food product via cross-contamination from a food-contact surface and/or utensils, proper estimation of the internal temperature changes in the kneaded food during thermal processing is indispensable for predicting the survival kinetics of desiccation-stressed bacterial cells. Various survival kinetics prediction models that consider the uncertainty or variability of pathogenic bacteria during thermal processing have been developed. Furthermore, heat transfer processes in solid food can be estimated using finite element method software. The present study demonstrated that combining a heat transfer model with a bacterial inactivation model can predict the survival kinetics of desiccation-stressed bacteria in a ground meat sample, corresponding to the temperature gradient in a solid sample during thermal processing. Combining both modeling procedures would enable the estimation of appropriate bacterial survival kinetics in solid food.

Modeling of Heat and Mass Transfer in Cement-Based Materials during Cement Hydration—A Review

Cement-based materials encompass a broad spectrum of construction materials that utilize cement as the primary binding agent. Among these materials, concrete stands out as the most commonly employed. The cement, which is the principal constituent of these materials, undergoes a hydration reaction with water, playing a crucial role in the formation of the hardened composite. However, the exothermic nature of this reaction leads to significant temperature rise within the concrete elements, particularly during the early stages of hardening and in structures of substantial thickness. This temperature rise underscores the critical importance of predictive modeling in this domain. This paper presents a review of modeling approaches designed to predict temperature and accompanying moisture fields during concrete hardening, examining different levels of modeling accuracy and essential input parameters. While modern commercial finite element method (FEM) software programs are available for simulating thermal and moisture fields in concrete, they are accompanied by inherent limitations that engineers must know. The authors further evaluate effective commercial software tools tailored for predicting these effects, intending to provide construction engineers and stakeholders with guidance on managing temperature and moisture impacts in early-age concrete.

Experimental and theoretical research on the temperature evolution law of overcurrent fault wires

AbstractTo investigate the problems of overload and excessive thermal insulation associated with building electrical fires caused by wires, a theoretical model of wire heat transfer is established, and the pyrolysis and combustion phenomena of the insulation layer are analyzed. The results showed that the temperature evolution of the wire underwent three stages: constant temperature, insulation heating, and high‐temperature pyrolysis. The insulation layer experiences bulging, exhausting, carbonization, dripping, and burning in sequence, and insulation layer dripping requires at least 160 A of current. As the current increases, the temperature increase rate of the wire increases gradually, and the fusing time of the wire gradually decreases. Under the same current, 160°C is the turning point at which the temperature increases. The temperature increase rate of the copper wire is greater than that of the aluminum alloy wire, and the temperature increase rate of the bare wire is greater than that of the insulated wire. The fusing time of an aluminum alloy wire is less than that of a copper wire, and the fusing time of a bare wire is less than that of an insulated wire. The research results provide theoretical guidance for the prevention and investigation of building electrical fires.

Simulation of the splitting process by hot-air drying of Camellia oleifera fruit

A heat and mass transfer and stress model in Camellia oleifera fruit was built based on the theory of heat and mass transfer and solid mechanics. The splitting process by hot-air drying was simulated using COMSOL Multiphysical software. The simulation results showed that the moisture diffusion in the splitting process by hot-air drying of Camellia oleifera fruit gradually promoted from the center to the surface, moisture near the surface first migrated and moisture far away from the surface lagged. The internal and external moisture did not move outward simultaneously with different diffusion rates, and the temperature promoted the moisture diffusion. The moisture gradient in the peel caused the stress difference, which shrank and cracked under the action of stress, and its shape gradually changed from arch to flat. With the continuous moisture loss from the peel under the effect of temperature, the shrinkage and deformation of the peel become more severe, increasing the distance between the peels continuously; finally, the peel was removed. The peel’s arc length and width directions were contracted during the splitting process by hot-air drying of Camellia oleifera fruit. The maximum deviation between the simulated and experimental values in the arc width direction was 8.9%, and the average deviation was 5.7%. The maximum deviation of the arc length between the simulated and experimental values was 7.4%, and the average deviation was 4.2%. The results showed that the simulation was consistent with the actual splitting law of Camellia oleifera fruit, which could be used to optimize the splitting process by the hot-air drying of Camellia oleifera fruit.

Contribution to the use of palm kernel oil methyl esters as liquid bio-insulators in distribution transformers: Experimentation and simulation of heat transfer

This work examines the potential use of palm kernel oil methyl esters (PKOME) as liquid bio-insulators in distribution transformers. A mathematical model of heat transfer inside a transformer is developed and solved using COMSOL Multiphysics software. The results of the model are validated by experimental data, showing a temperature variation of 31–81.8 °C in the measurements and 31–82.5 °C in the simulation. This validation confirms the accuracy of the model in predicting the temperature distribution inside the PKOME-filled transformer, paving the way for their use in distribution transformers.

Analysis of the Combined Effect of Major Influencing Parameters for Designing High-Performance Single (sBHE) and Double (dBHE) U-Tube Borehole Heat Exchangers

In this paper, a comprehensive analysis of the combined effect of major influencing parameters on heat transfer in a single U-tube BHE (sBHE) and a double U-tube BHE (dBHE) with two independent circuits was performed by using a validated numerical heat transfer model. Geometrical parameters, such as shank spacing (with maximum, average, and minimum values), borehole diameter (large, medium, and small borehole sizes), and borehole depth (shallow, average, and deep borehole depths) as well as the thermal conductivity of soil and grout, which ranges from minimum to high values, were considered. The combined impact of these parameters was included under the following four major cases: (1) the combined effect of borehole depth, borehole size, and shank spacing; (2) the combined effect of borehole depth and soil and grout thermal conductivity; (3) the combined effect of soil and grout thermal conductivity and borehole size; and (4) the combined effect of soil thermal conductivity, borehole size, and shank spacing. Each of these major cases has nine different design options for both sBHEs and dBHEs. A series of results of heat transfer per unit borehole depth were generated for all the considered various cases. With the given parameters, the BHE case that provides the highest heat transfer among the various cases of sBHEs and dBHEs were obtained.

Numerical and experimental investigation on NbTi superconducting liquid helium level sensor based on a resistance heating

A resistance-heated NbTi superconducting liquid helium level sensor based on the principle of thermal conduction is proposed. A heat transfer model for the sensor was established, and its mathematical model was characterized. The effects of temperature, current, heating resistance value, and superconducting wire diameter on the sensor performance were investigated. It indicates that the temperature of the sensor in the vapor phase is decreased linearly from high to low, and the voltage is decreased with the increase of the liquid level. And the 45 μm diameter superconducting wire has a minimum propagation current, a minimal heat input to the system, and a small measurement error. The variation of the sensor output voltage with a level height was studied experimentally. The linear correlation coefficients R2 of the 1 Ω, 5.1 Ω, and 10 Ω sensors are all greater than 0.999, which are almost identical to the simulation results. The sensor’s response time is all less than 1 s, the sensitivity is 8.7070 mV/mm, 8.0110 mV/mm, and 6.9660 mV/mm, respectively, and the accuracy is 0.8226%, 0.8611%, and 0.9030%.

Validation of Continuous Conjugate Heat Transfer Model through Experimental Data

Validation of Continuous Conjugate Heat Transfer Model through Experimental Data

Predictive Modeling for Microchannel Flow Boiling Heat Transfer under the Dual Effect of Gravity and Surface Modification

This paper investigates the heat transfer performance of flow boiling in microchannels under the dual effect of gravity and surface modification through both experimental studies and mechanistic analysis. Utilizing a test bench with microchannels featuring surfaces of varying wettability levels and adjustable flow directions, multiple experiments on R134-a flow boiling heat transfer under the effects of gravity and surface modification were conducted, resulting in 1220 sets of experimental data. The mass flux ranged from 735 kg/m2s to 1271 kg/m2s, and the heating heat flux density ranged from 9 × 103 W/m2 to 46 × 103 W/m2. The experimental results revealed the differences in the influence of different gravity and surface modification conditions on heat transfer performance. It was found that the heat transfer performance of super-hydrophilic surfaces in horizontal flow is optimal and more stable heat transfer performance is observed when gravity is aligned with the flow direction. And the impact of gravity and surface modification on heat transfer has been explained through mechanistic analysis. Therefore, two new dimensionless numbers, Fa and Conew, were introduced to characterize the dual effects of gravity and surface modification on heat transfer. A new heat transfer model was developed based on these effects, and the prediction error of the heat transfer coefficient was reduced by 12–15% compared to existing models, significantly improving the prediction accuracy and expanding its application scope. The applicability and accuracy of the new model were also validated with other experimental data.

Design optimization of the cooling systems with PCM-to-air heat exchanger for the energy saving of the residential buildings

Driven by a rapid surge in cooling demand in buildings, the energy consumption dedicated to cooling has experienced remarkable growth. To address this challenge, the adoption of latent heat thermal energy storage utilizing phase change materials (PCM) has gained significant momentum in recent years. This paper presents the design and evaluation of an integrated latent heat thermal energy storage (ILHTES) system tailored for residential buildings. This system integrates a PCM-to-air heat exchanger (PAHX) with an air conditioning unit. Modelica language is utilized to develop a numerical model for the ILHTES system. The heat transfer model of the PAHX is developed and validated using existing literature data. To simulate the dynamic behavior and energy consumption of the residential building, the open-source library AixLib is adopted. The developed ILHTES system model is used for the optimization of key design variables, including the PCM slab thickness and air flow rate, based on the results of long-term simulations covering the entire cooling season. Evaluation of the energy saving potential of the optimized ILHTES systems is carried out in comparison to conventional air conditioning systems, considering various climatic conditions in five European cities. The results highlight the profound impact of PCM types on the Energy Saving Ratio (ESR) throughout the entire cooling season. Among the four commercially available PCMs examined—RT27, RT25, RT20, and RT18—RT25 consistently outperforms the others. Across all five cities investigated, using RT25 leads to a minimum ESR of 16% in Catania and a maximum ESR of 44.7% in Stockholm for the entire cooling season.

Assessment of evaporative porous clay cooler for Building-Integrated photovoltaic systems via energy, exergy, economic and environmental approaches

A thorough study has been conducted for the energy, exergy, economic and environmental analysis to investigate the feasibility of utilizing an evaporative porous structure cooler for the building-integrated photovoltaic (BIPV) system at different building’s sides and directions. Photovoltaic panels within the BIPV systems dissipate their heat to the building’s sides which contribute to rise the interior building’s temperature. In the proposed system, a water-saturated evaporative porous clay cooler is being installed on the back surface of the PV panels to absorb and dissipate their heat by latent evaporation through an evaporation cooling process. A transient numerical heat and mass transfer model based on energy, exergy, economic and environmental approaches was proposed to assist the feasibility of cooling BIPV system via evaporative porous structure cooler. The model was also validated experimentally in the present study. The results exhibited that, comparing with conventional BIPV systems, the presented BIPV/Clay cooling system achieved a peak photovoltaic temperature reduction of 19.1 °C, with a maximum enhancement in the photovoltaic system’s electrical efficiency, electrical power, and exergy efficiency of 9.8 %, 12.6 % and 11.8 %, respectively. The ultimate reduction in the building’s annual thermal load was around 53.8 % when the clay evaporative cooling approach is applied, while the cost of electricity production reduced ultimately by 7.9 %, (from 0.151 $/kWh to 0.134 $/kWh). Further, the payback period decreased by 2.33 years and the annual amount of CO2 emissions decreased by 10.4 % for the utilized BIPV/Clay cooling system compared with the conventional BIPV system.