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Active Cold-Climate Solar Water Heating and Solar Heating and Cooling As with passive systems, the technology development approach involves three phases, moving from initial concepts through engineering development to final product and manufacturing development. Descriptions of specific technical issues and tasks follow. Approaches proven successful in the PICS work will lower development costs. Unit-area system cost should be reduced at least 50% for SWH and at least 80% for Htg/Clg (including roofing credits). The tasks are first described for SWH followed by tasks unique to combined Htg/Clg. Similarly, the task tables are first displayed for SWH (Table 4.3-5), followed by tasks unique to Htg/Clg (Table 4.3-6). Cold-Climate Solar Water Heating 1. Collector. Glazed flat-plate collector costs need to be reduced from $130/m2 ($12/ft2) to about $54/m2 ($5/ft2). Collector configuration. When using polymer materials, overheating of the absorber under dry stagnation becomes a potential issue, because polymers generally have relatively low melting temperatures and a reduction in strength at higher temperatures. Collector designs must be analyzed and tested structurally. Finite-element analysis (with attendant measurement of material mechanical properties and creep) is necessary to insure reliability while minimizing materials. Glazings. UV-degradation testing of coated polycarbonate sheets has been ongoing, as described in Section 4.3.3. Thin-film glazings (e.g., fluorocarbons like Tefzel) are also known to weather well. They are harder to mount and maintain than sheet materials, but could be the least-cost option. Absorbers. Based on their low thermal conductivity (3 orders of magnitude lower than copper), polymer absorbers have been designed as fully wetted (i.e., no significant fins). However, it may be possible to use recently developed low-cost conductivity-enhancing additives to develop a fin-tube design, perhaps reducing manifolding connections and increasing reliability. Container/insulation. It has proven cost-effective with the PICS to eliminate a separate “container,” by forming the glazing/absorber/bottom pan constructions to join appropriately. This will likely continue with proposed flat-plate-collector concepts. Mounting. Experience in the low-cost PICS development indicates that if the collector bottom is corrugated, roof-drying is adequate when mounting the collector flat upon the roof. This simplifies the mounting procedure. 2. Storage. For active systems with storage separate from the collector, storage is a major cost component. Storage cost can be reduced significantly by using unpressurized storage, but a load-side heat exchanger with high effectiveness is then required. Historically, most active systems have used pressurized storage. Unpressurized storage can be made from thin-wall polymer tanks (roto-molded or blow-molded) or from a membrane held in place by an external structure (e.g., cylindrical insulation plus metal or nylon sleeve). Design concepts using unpressurized storage must be developed and engineered, and materials must be tested, prototypes built, and manufacturing optimized. 3. Balance of System Heat exchangers: Solar-side heat exchangers (used with pressurized storage) are smaller than load-side heat exchangers (used with unpressurized storage). Depending on approach, solar-side heat exchangers are made from copper, with designs including immersed coil, bayonet, or external wrap-around. Copper tubing for a load-side, heat-exchanger-immersed coil costs ~$150, or ~$2/gallon. If the polymer heat exchangers currently under development prove successful, a load-side heat exchanger could be priced at ~$50, or ~$0.60/gallon. Nylon and polybutylene heat-exchanger development are under way for PICS systems, and these designs can function here with geometric adjustments. Solar Energy Technologies Program Multi-Year Technical Plan 110PDF Image | Solar Energy Technologies Program
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