Optimizing Electrical Efficiency and Levelized Cost of Energy in Photovoltaic Systems Through Thermal Management Using Microchannel Heat Sinks

Solar energy is a ubiquitous renewable resource for photovoltaic (PV) power generation; however, higher operating temperatures significantly reduce the efficiency of PV modules, impacting their electrical output and increasing the levelized cost of energy (LCOE). This study aims to enhance conventional PV systems’ electrical efficiency and annual energy recovery while reducing the LCOE through thermal management using microchannel heat sinks (MCHSs) under forced convection. A 600 W monocrystalline PV module was analyzed, recognizing an efficiency reduction of ~20% under actual operating conditions due to thermal effects, with the surface temperature reaching up to 63.76°C without cooling. In addition, analytical calculations were used to determine an incident solar irradiance of 957.33 W/m² for an industrial location in Lahore, Pakistan. Similarly, computational fluid dynamics (CFDs) simulations were conducted using single and dual-layer MCHSs configurations with water as the coolant at inlet velocities ranging from 0.01 to 1.0 m/s. The dual-layer MCHSs significantly reduced the PV module’s surface temperature from 63.76 to ~25.65°C at an inlet velocity of 1.0 m/s, achieving a temperature reduction of 38.11°C. This thermal management increased the electrical efficiency from 18.33% (without cooling) to 22.27%, an efficiency gain of ~4%. The annual energy recovery improved substantially; at 1.0 m/s, the dual-layer configuration increased the annual energy output by 227,954 kWh/year (about 21.89%) compared to the no-cooling scenario, reaching 1,269,131 kWh/year. Furthermore, the LCOE was reduced to as low as 6.27 PKR/kWh over a 30-year operational lifespan at lower velocities, demonstrating improved cost-effectiveness. Meanwhile, optimal velocity was identified between 0.2 and 0.5 m/s, balancing thermal performance and economic viability. Finally, this study concludes that thermal management using dual-layer MCHSs effectively enhances PV module efficiency, increases annual energy recovery, and reduces LCOE, contributing to sustainable and economical solar energy integration in industrial applications.