Carnot battery system, particularly the Organic Rankine Cycle-based system, is an attractive energy storage solution for developing the future carbon-neutral energy system by utilizing low-grade heat (e.g., solar heat). As a cost-effective phase change material (PCM), aluminum potassium sulfate dodecahydrate (KAl(SO4)2·12H2O) offers large heat capacity during melting/solidification at medium-low temperature, which holds a promising prospect in thermal energy storage system in Carnot Batteries. KAl(SO4)2·12H2O is also one of the few types of hydrated salts without phase separation issue. In this study, binary inorganic hydrated salt mixtures of KAl(SO4)2·12H2O and magnesium sulfate heptahydrate (MgSO4·7H2O) with various mass ratios were developed and prepared as a novel energy storage material at medium-low temperatures. The sample with a 6:4 mass ratio (KAl(SO₄)₂·12H₂O:MgSO₄·7H₂O) exhibited a phase-change enthalpy of 181.3 kJ/kg. Optimized mixture was impregnated into expanded graphite (EG) to form shape-stable composites. Results showed that even minimal EG loading prevented PCM leakage (leakage rate < 3%) and enhanced thermal conductivity (up to 5.23 W/(m·K)). The composite containing 8wt% EG exhibited a phase-change enthalpy of 175.7 kJ/kg, enabling rapid heat transfer. Thermal-cycling tests confirmed excellent reliability with negligible enthalpy loss. These properties made the composites highly suitable for thermal storage in Carnot batteries.
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