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I. Laser-welding processes for the RITH system, demonstrated on production equipment in the laboratory, must be transferred to the industrial partner. Coating and other fabrication processes must be integrated into a 1000-unit/yr production line. J. Manufacturing processes for the tank for the extruded PICS must be developed, building on techniques of extrusion and manifold welding that are well proven for similar polymer pool collectors (over one million collectors have been made by one U.S. manufacturer). K. The 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. 4.3.4.2 Active Cold-Climate Solar Water Heating and Solar Heating and Cooling Collector A. Cost: Reduce current FOB cost from $110-170/m2 ($10-15/ft2) to ~$54/m2 ($5/ft2) for active solar water heating and ~$22/m2 ($2/ft2) for active combined heating and cooling (CHC) systems. B. High temperatures: Collectors must withstand stagnation temperatures of ~250-450oF, depending on glazing and absorber properties. Generally speaking, metal-glass collectors handle dry stagnation without major issue, although insulation or gaskets may degrade more rapidly over time. High temperature becomes a key generally only for polymer-based absorbers. C. Installation: Today’s metal-glass collectors weigh about 3 lb/ft2, which is heavier than desirable for efficient installation. D. Durability/reliability: Lifetime of polymer collectors is expected to be less than that for metal-glass collectors. Storage E. Cost: For active systems with storage separate from the collector, storage is a major cost component. Today’s pressurized storage tanks start at ~$3/gallon, or ~$250 for an 80-gallon storage tank. Costs increase drastically if a heat exchanger is included in the storage. F. Lifetime/reliability: Today’s pressurized tanks in conventional applications have a mean life of about 12 years. Tank replacement represents the largest single expense in O&M costs. Tank lifetime should be longer than the expected collector/system lifetime, to avoid any significant costs from tank replacements. Balance of System. Balance of system includes pump/controls and piping/valving. G. Cost: Typical cost for a differential-temperature (∆T) controller plus AC-powered pump combination is ~$200 in hardware with ~$100 incremental installation cost. Running, soldering, and insulating hard copper piping is a significant part of installation cost, being estimated at $450. H. Reliability: ∆T-controller-pump failures contribute about $300 to O&M present value cost. Plumbing valves and other components have been identified individually as the cause of most installation errors and a significant contributor to reduced reliability. 4.3.4.3 Active Solar Combined Heating and Cooling A. Collector: To supply the same amount of space heating saving as SWH savings, the glazing devoted to space heating must be larger (lower incidence, lower ambient temperatures and efficiencies). For an unglazed system, the collector area is roughly twice that required for a glazed system for equivalent savings. B. Storage: Compared to SWH, space heating requires larger ratios of storage volume per unit of collector area, because energy must be stored for a longer time. The optimal storage size range is not yet well established. C. Balance of system: CHC systems need distribution systems, which may present additional cost. Distribution options include radiant floor and/or ceiling and duct fan coils. Solar Energy Technologies Program Multi-Year Technical Plan 107PDF Image | Solar Energy Technologies Program
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