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materials. Polymer materials testing expertise at NREL and the University of Minnesota has fulfilled that need. NREL concentrated on identifying and testing good candidates for glazings and absorbers; this work is described in the SH&L project description Materials Durability. The University of Minnesota concentrated on heat exchanger design and testing and materials durability for polymer heat exchangers; this work is described in the SH&L project description Next Generation Low-Cost Polymer Solar Heating Systems. Another common problem with use of polymers is the loss of material strength at higher temperatures. Low-cost commodity plastics have an upper use temperature around 80oC, depending on imposed stress. The stagnation temperature of flat-plate collectors, however, is in the range 130o–180oC. Thus, over-temperature protection is a key approach for use of low-cost polymers with glazed collectors. Approaches studied include venting, a thermochromic glazing film (at SNL: see the SH&L project description Industry Manufacturing Assistance), and a high- temperature dribble valve. Passive systems have been very limited in geographical deployment, as shown in Fig. 6a. The limitation is due to the danger of metallic pipe freeze/burst. In mild climates, traditional metallic pipes are protected with insulation. Means for extending the market northward should be considered, because passive systems without pumps and controllers tend to be less expensive and more reliable. Freeze-protection valves were studied and water consumption was quantified. Safe/Non-wasteful areas= Freeze Protection Valve + Both industry teams developed systems that presented modeling challenges. The DEG/SE ICS collector has an immersed heat exchanger in the shallow ICS tank. In addition, collector temperature under stagnation was incorrectly predicted with the constant top loss approach. (The top loss coefficient varies nearly a factor of 2 between 0o and 100oC.) The FAFCO thermosiphon collector is subject to reverse thermosiphoning at night. Because this is so unusual, this feature was not adequately modeled in existing models. Related to the modeling issues are testing issues. New test procedures are needed for ICS with immersed heat exchangers and for thermosiphon systems subject to reverse thermosiphoning. Task Title Polymer ICS Field Test ICS Development and Testing Technical Support SRCC Low-Cost Cold Climate Systems* FY 2005 Budget ($K) 210 160 490 207* 60** Insulated copper pipe Limited by Pipe Freeze freezable piping Limited by water consumption BUT: collector/store freeze? Untested, other affects? * Funding for this task came through the Golden Field Office, and is not part of the project’s $860K. ** Funding for this task came from SH&L Systems Analysis; a separate project description (“Cold Climate Solar Domestic Hot Water Systems Analysis”) is in the Solar Program Review Proceedings CD. Compared to copper heat exchangers, polymer heat exchangers have the potential to lower costs and weight. However, a number of design and materials issues arise, especially when considering use of lower-strength commodity plastics (which dictates small diameters). Oxidation and polymer degradation must be prevented, and antioxidant life must be at least 10 years. Scaling in the small-diameter heat exchanger tubing can be a problem in scale-prone waters, if scale rates are as high in polymers used as in copper piping. 3. Results and Accomplishments 3.1 Davis Energy Group/SunEarth • Produced 40 prototypes of its ICS SWH for testing and for certification. • Submitted both glazed and unglazed systems, with manuals, for SRCC certification. • Field test results corroborated initial performance projection at 29% efficiency. Fig. 5. a) Left, areas considered safe for passive SWH with insulated copper piping; b) Right, areas below 1000 gal/year water consumption (an arbitrarily chosen limit) with a freeze-protection valve configured as in Fig. 6. Solar Thermal R&D Solar Heating and Lighting 132PDF Image | DOE Solar Energy Technologies Program
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