Microencapsulation of Zn-10 mass% Al alloy phase change material via dry synthesis method

[Display omitted] •Microencapsulated phase change material (MEPCM) with Zn–10mass% Al alloy was developed via dry processes.•MEPCM exhibited high latent heat density of 0.55 GJ m−3 and high thermal cyclic durability over 1000 times.•MEPCM has a potential to be introduced into thermal energy storage systems operating around 400 °C. Thermal energy storage (TES) via latent heat storage (LHS) using metal alloy phase change material (PCM) offers advantages in medium-to-high temperature operation around 400 °C and high heat storage capacity. Microencapsulation of alloys as PCMs can mitigate issues of reactivity and improve handling properties of PCM. This research presents the novel development of microencapsulated PCM (MEPCM) with a core of Zn–10 mass% Al that operates around 400 °C. The MEPCMs were synthesized using high-speed impact blending (HIB), where fine AlOOH particles mechanically coat the surface of Zn–10 mass% Al alloy microspheres, resulting in robust surface modification. Subsequent heat-oxidation treatment at 800 °C was performed to obtain stable oxide coating. The HIB treatment resulted in an AlOOH coating containing Zn nanoparticles, which the heat-oxidation process transformed into α-Al2O3 and ZnO nanoparticles. The MEPCMs exhibited heat storage densities, including latent and sensible heat (ΔT=200 °C), that were 1.9 times higher than the capacity of solar salt, which is commonly used as a sensible heat storage material. Furthermore, the MEPCMs maintained their shape and latent heat capacity after 300 and 1000 cyclic tests. These superior MEPCM characteristics hold the potential to significantly advance the development of LHS-based TES systems operating around 400 °C, with applications in energy generation and industrial processes.