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The strategy for cost reduction for solar heating is to use low-cost materials and manufacturing methods, such as developed in the polymer industry. New materials introduced by the polymer ICS system, however, have unknown durability in this new application. Continued exposure testing is needed to determine the projected lifetime of UV-protected polycarbonates. The polymer absorber materials lack the higher- temperature data needed to insure against premature failures from stagnation events. At the system level, pipe-freezing of the supply/return pipes has always been an issue for passive systems. Cost of manufacturing is another key element of collector cost. The development of a low-cost polymer heat exchanger represents a leap in manufacturing technology, involving the automation of a tube clip-and-weave process and a new manifold welding process with small-diameter tubing. Laser-welding processes for the RITH system, demonstrated on production equipment in the laboratory, must be transferred to the industrial partner. Current solar water-heating systems are typically backed up by conventional water heaters, which adds to system cost. Incorporating the backup heating function as part of the solar system can reduce cost. Key technical challenges for hybrid solar lighting include reducing system complexity while improving efficiency, and determining the tangible economic- and productivity-related benefits of sunlight brought indoors. Collectors/concentrators must be developed that are easier to assemble, align, calibrate, and maintain with less complex secondary mirror- and fiber-mounting arrangements and lower-cost, lightweight, and more easily manufactured components (mirrors, motors, and mounts). The number of connectors and splitters must be minimized or eliminated. There must be a better match of the chromaticity of distributed sunlight with that of co-located electric lamps. Research done by numerous organizations outside the Solar Program has indicated there are benefits of sunlight on worker and student health and performance, as well as ancillary benefits related to product sales. This research will be analyzed to identify tangible benefits and methods will be developed to credibly quantify the impact of these benefits using human-factors-based studies at alpha and or beta demonstration sites. Technical Targets Table 4.3-1 has technical targets for passive solar water-heating technology for warm climates. The LEC is based on the climate of San Diego, California, a site with an average solar resource for the Sun Belt market. Table 4.3-1 Technical Targetsa — Passive Solar Water Heating Characteristics System Description & Goals Collector size Thermal storage Annual efficiencyc Builder cost (hardware + inst) Customer cost (+ mrkt/sales) Total cost (+ O&M) Conv. RITHb Unit ICSb ICSb 2003 2004 2005 ft2 32 32 40 gals 40 40 50 % 33 40 29 $ 1800 1500 800 $ 2300 1900 1000 $ 2600 2200 1300 Polymer LECd ¢/kWh 10.4 7.2 4.7 Component Goals Collector/storage unit Balance of system Installation Marketing and salese O&M (present value) $ 900 900 300 $ 300 300 200 $ 600 400 300 $ 500 400 200 $ $300 $300 $300 a: Costs are to nearest $100; “new construction” install; mrkt./sales = 25% of bldr. cost; 5% discount rate; 20-yr. analysis period; present worth factor (PWF) = 12.5 yr. b: Production volume of 10,000 units/year assumed for conventional and polymer ICS, and 1000 units/year for RITH. c: Annual efficiency ηann derived by simulation, ηann=Qsaved,annual/Qincident,annual d: Radiation is for average Sun Belt city of San Diego, CA, at a tilt of (latitude-15); Icol = 5.6 kWh/ m2-day; LEC = (total cost)/(ηann* Icol*Acol*365*PWF). e: Marketing and sales cost is taken as 25% of the builder’s cost. Solar Energy Technologies Program Multi-Year Technical Plan 104PDF Image | Solar Energy Technologies Program
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