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LATTHE EDUCATION SOCIETYS POLYTECHNIC, SANGLI

A
PROJECT REPORT ON

ADVANCEED SOLAR WATER HEATER


BY

AVESAHEMAD S.N.HUSAINY
2008-2009

UNDER THE GUIDENCE OF

PRINCIPAL.SANJAY A.KHOT

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CERTIFICATE
This is to certify that, the project report entitled

ADVANCEED SOLAR WATER HEATER


By
AVESAHEMAD S.N.HUSAINY (T.Y.MECHANICAL)
Is record of their own work carried out by them for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Under my supervision & guidance during academic year 2008-2009

Prof.S.A.Khot

Prof.S.A.Khot

Prof.S.J.Patil

GUIDE

PRINCIPAL

H.O.D.
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ACKNOWLEDGEMENT:
We the student of third year mechanical are very much grateful to Prof. Sanjay Khot, who is our project guide and principal of our college, for giving his guidance and spirit to our project work. Our thanks are also to: 1) Prof. S.J. Patil.(H.O.D.)

2) Mr .G.M.Chavan(Workshop Head)

Last but not the least we would like to acknowledge the help provided by our friends from whom we had the benefits of innumerable useful comments & suggestions.

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INDEx
SR.N0.
1 2

PARTICULARS
ABSTRACT OF OUR PROJECT INTRODUCTION SOLAR WATER HEATER

PAGE N0
6 8

3 4 5 6 7 8 9 10 11 12 13

COMPONENENTS OF SOLAR WATER SYSTEM HOT WATER TANK WORKING OF COLLECTOR MATERIAL OF COLLECTOR PHASE CHANGE MATERIAL ADVANTAGES OF P.C.M. MACHINING OPERATION TEMPRATURE READINGS APPLICATION COST ANALYSIS CONCLUSION

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11 12 16 18 20 23 24 28 33 35

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ABSTRACT OF PROJECT

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ABSTRACT OF PROJECT:
There are many sources available to heating the water. But the most convenient method of heating water is solar energy, because of its availability. In ordinary solar water heater works on the principle of sensible heating but our solar water heater works on the principle of latent heat storing by Phase Chang Material(P.C.M.) viz,Paraffin Wax . Latent heat means, the phase change material can store some amount of heat, and dissipate whenever system necessary. The main application of our project is, it is used mainly where the space restriction limit larger thermal storage units in direct gain or sunspace passive solar system. Latent heat thermal energy storage is one of the most efficient ways to store thermal energy for heating water by energy received from sun. This paper summarizes the investigation and analysis of thermal energy storage incorporating with and without PCM for use in solar water heaters. It has been demonstrated that for a better thermal performance of solar water heater a phase change material with high latent heat and with large surface area for heat transfer is required.

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INTRODUCTION

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INTRODUCTION OF SOLAR WATER HEATER:

Solar heating systems are generally composed of solar thermal collectors, a fluid system to move the heat from the collector to its point of usage. The system may use electricity for pumping the fluid, and have a reservoir or tank for heat storage and subsequent use. The systems may be used to heat water for a wide variety of uses, including home, business and industrial uses. Heating swimming pools, under floor heating
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or energy input for space heating or cooling are more specific examples. Residential solar thermal installations can be subdivided into two kinds of systems: compact and pumped systems. Both typically include an auxiliary energy source (electric heating element or connection to a gas or fuel oil central heating system) that is activated when the water in the tank falls below a minimum temperature setting such as 50 C. Hence, hot water is always available. The combination of solar hot water heating and using the back-up heat from a wood stove chimney to heat water can enable a hot water system to work all year round in cooler climates without the supplemental heat requirement of a solar hot water system being met with fossil fuels or electricity. Among pumped options, there is an important distinction to be made regarding the sustainability of the design of the system. This relates to what source of energy powers the pump and its controls. The type of pumped solar thermal systems which use mains electricity to pump the fluid through the panels are called low carbon solar because the pumping
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negates the carbon savings of the solar by about 20%, according to data in a report called "Side by side testing of eight solar water heatings" by DTI UK. However, zerocarbon pumped solar thermal systems use solar electricity which is generated onsite using photovoltaics to pump the fluid and to operate its control electronics. This represents a zero operational carbon footprint and is becoming an important design goal for innovative solar thermal systems.

COMPONENTS OF OUR SOLAR WATER HEATER:

1) Tank 2) Collector 3) Phase Change Material,viz(Paraffin Wax) 4) Copper Tubes in Hot Water Tank
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5) Cold Water Tank

HOT WATER TANK:

The hot water tank is made by using plastic pipe which is resistant to heat up to 80 degree centigrade. It has length of 1.5feet and diameter 200mm the ends of pipes are sealed by
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placing two caps of same diameter. The cap and pipe is sealed by using M-seal & solution Inlet, outlet &collector connections are made at the face of cap. The tank is insulated from surrounding atmosphere by cladding process. A thick cladding of three inch is done by using rock wool material. The rock wool is covered with thin Aluminum sheet of thickness 26guage. This completes the tank.

COLLECTOR:

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Flat tube collectors are made of a series of modular tubes, mounted in parallel, whose number can be added to or reduced as hot water delivery needs change. This type of collector consists of rows of parallel transparent glass tubes, each of which contains an absorber tube (in place of the absorber plate to which metal tubes are attached in a flatplate collector). In some cases, the tubes are covered with a special light-modulating coating. In an evacuated tube collector, sunlight passing through an outer glass tube heats the absorber tube contained within it. The absorber can either consist of copper (glass-metal) or specially-coated glass tubing (glass-glass). The glass-metal evacuated tubes are typically sealed at the manifold end, and the absorber is actually sealed in the vacuum, thus the fact that the absorber and heat pipe
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are dissimilar metals creates no corrosion problems. Some systems use foam insulation in the manifold. Soda-lime glass is used in the higher quality evacuated tubes manufacture. Lower quality evacuated tube systems use the glass coated absorber. Due to the extreme temperature difference of the glass under stagnation temperatures, the glass sometimes shatters. The glass is a lower quality boron silicate material and the aluminum absorber and copper heat pipe are slid down inside the open top end of the tube. Moisture entering the manifold around the sheet metal casing is eventually absorbed by the glass fibre insulation and then finds its way down into the tubes. This leads to corrosion at the absorber/heat pipe interface area, also freeze ruptures of the tube itself if the tube fills sufficiently with water. Two types of tube collectors are distinguished by their heat transfer method: the simplest pumps a heat transfer fluid (water or antifreeze) through a U-shaped copper tube placed in each of the glass collector tubes. The second type uses a sealed heat pipe that contains a liquid that vapourises as it is
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heated. The vapour rises to a heat-transfer bulb that is positioned outside the collector tube in a pipe through which a second heat transfer liquid (the water or antifreeze) is pumped. For both types, the heated liquid then circulates through a heat exchanger and gives off its heat to water that is stored in a storage tank (which itself may be kept warm partially by sunlight). Evacuated tube collectors heat to higher temperatures, with some models providing

considerably more solar yield per square metre than flat panels. However, they are more expensive and fragile than flat panels. Evacuated heat tubes perform better than flat plate collectors in cold climates because they only rely on the light they receive and not the outside temperature. The high stagnation temperatures can cause antifreeze to break down, so careful consideration must be used if selecting this type of system in temperate climates.Tubes come in different levels of quality so the different kinds have to be examined as well. High quality units can efficiently absorb diffuse solar radiation present in cloudy conditions and are unaffected by

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wind. They also have the same performance in similar light conditions summer and winter. For a given absorber area, evacuated tubes can maintain their efficiency over a wide range of ambient temperatures and heating requirements. The absorber area only occupied about 50% of the collector panel on early designs, however this has changed as the technology has advanced to maximize the absorption area. In extremely hot climates, flat-plate collectors will generally be a more cost-effective solution than evacuated tubes. When employed in arrays of 20 to 30 or more, the efficient but costly evacuated tube collectors have net benefit in winter and also give real advantage in the summer months. They are well suited to extremely cold ambient temperatures and work well in situations of consistently low-light. They are also used in industrial applications, where high water temperatures or steam need to be generated. Properly designed evacuated tubes have a life expectancy of over 25 years which greatly adds to their value.

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MATERIAL FOR COLLECTOR:


1. 2. from: 3. 4. 5. better 6. 7. 8. Clear silicon caulking Aluminum foil and some felt paper One gallon of roofing tar
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Two rolls of 50-foot 20 aluminum flashing Four .060-inch thick 4X8 sheets of Kalwall

Twenty 1X4X8 pine with few or no knots Four X4X8 CDX plywood Four 1X4X8 sheet insulation R value 5 or

9. 10. 11.

One gallon of oil base paint Angle iron for mounting Sixteen X 3 lag bolts, sixteen X 1 inch machine bolts

12. 13.

1 inch and 2 inch drywall screws One pound of 1 inch galvanized nails with small heads

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PLUMBING SUPPLIES

a. b. c. d. e. f. g.

Eight 3/8 to adaptors Four inch Ts Two X X Ts One inch T Four inch unions Eight inch elbows One inch street elbow
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h. i. j. k. l.

One sweat to female pipe One pressure relief valve Four sixty foot rolls of 3/8 ID copper tubing - inch rigid copper tubing type L - inch rigid copper tubing type L or M

m. Solder and flux

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P.C.M .

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PHASE CHANGE MATERIAL:


A phase change material (PCM) is a substance with a high heat of fusion which, melting and solidifying at a certain temperature, is capable of storing and releasing large amounts of energy. Heat is absorbed or released when the material changes from solid to liquid and vice versa; thus, PCMs are classified as latent heat storage (LHS) units. PCMs latent heat storage can be achieved through solid-solid, solid-liquid, solid-gas and liquid-gas phase change. However, the only phase change used for PCMs is the solid-liquid change. Liquid-gas phase changes are not practical for use as thermal storage due to the large volumes or high pressures required to store the materials when in their gas phase.
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Liquid-gas

transitions

do

have

higher

heat

of

transformation than solid-liquid transitions. Solid-solid phase changes are typically very slow and have a rather low heat of transformation. Initially, the solid-liquid PCMs behave like sensible heat storage (SHS) materials; their temperature rises as they absorb heat. Unlike conventional SHS, however, when PCMs reach the temperature at which they change phase (their melting temperature) they absorb large amounts of heat at an almost constant temperature. The PCM continues to absorb heat without a significant raise in temperature until all the material is transformed to the liquid phase. When the ambient temperature around a liquid material falls, the PCM solidifies, releasing its stored latent heat. A large number of PCMs are available in any required temperature range from -5 up to 190oC .Within the human comfort range of 20 to 30C, some PCMs are very effective. They store 5 to 14 times more heat per unit volume than conventional storage materials such as water, masonry, or rock

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ADVANTAGES OF P.C.M.
1. Availability in a large temperature range 2. Freeze without much super cooling 3. Ability to melt congruently 4. Self nucleating properties 5. Compatibility with conventional material of construction 6. No segregation 7. Chemically stable
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8. High heat of fusion 9. Safe and non-reactive 10.Recyclable

PHASE CHANGE MATERIAL (PARAFFIN WAx):

In chemistry, paraffin is the common name for the alkane hydrocarbons with the general formula CnH2n+2. Paraffin wax refers to the solids with n=2040. The simplest paraffin molecule is that of methane, CH4, a gas at room temperature. Heavier members of the series, such as that of octane C8H18, appear as liquids at room temperature. The solid forms of paraffin, called paraffin wax, are from the
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heaviest molecules from C20H42 to C40H82. Paraffin wax was identified by Carl Reichenbach in 1830. Paraffin, or paraffin hydrocarbon, is also the technical name for an alkane in general, but in most cases it refers specifically to a linear or normal alkane whereas branched, or isoalkanes are also called isoparaffins. It is distinct from the fuel known in Ireland, Britain and South Africa as paraffin oil or just paraffin, which is called kerosene in most of the U.S., Australia and New Zealand. The name is derived from the Latin parum (= barely) + affinis with the meaning here of "lacking affinity", or "lacking reactivity". This is because alkanes, being non-polar and lacking in functional groups, are very unreactive. Paraffin wax (or simply "paraffin", but see alternative name for kerosene, above) is mostly found as a white, odorless, tasteless, waxy solid, with a typical melting point between about 47 C to 64 C ( 116.6F to 147.2F), and having a density of around 0.9 g/cm3. It is insoluble in water, but soluble in ether, benzene, and certain esters. Paraffin is
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unaffected by most common chemical reagents, but burns readily. Pure paraffin wax is an excellent electrical insulator, with an electrical resistivity of between 1013 and 1017 ohm metre. This is better than nearly all other materials except some plastics (Notably Teflon). It is an effective neutron moderator and was used in James Chadwick's 1932 experiments to identify the neutron

MACHINING OPERATIONS CARRIED OUT DURING PROJECT

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Sr. No.

Machine operation

Name of machine

Setup time In min.

Prod. Time In min.

Feed Hand/power

1 2 3 4

Copper pipe Copper cutting cutter

45

60 120 120 30

Hand Hand Hand Power

Copper pipe Burner & 15 brazing silver rod Copper pipe Burner soldering Aluminum lathe round plate turning Aluminum lathe round plate facing Aluminum Drilling round plate machine drilling 15 20

15

20

power

10

150

power

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CALCULA T IONS

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+=?
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TEMPERATURE READINGS:
T1 = TEMPERATURE OF WAX T2 = TEMPERATURE OF COPPER PIPE T3 = TEMPERATURE OF WATER T4 = TEMPERATURE OF INLET OF COLLECTOR T5 = TEMPERATURE OF OUTLET OF COLLECTOR

TIME
8.00 AM

TEMPERATURE
T1 = 30 T2 = 30 T3 = 30 T4 = 30 T5 = 30

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9.00 AM

T1 = 40 T2 = 40 T3 = 43 T4 = 44 T5 =40 T1 = 41 T2 = 41 T3 = 46 T4 = 48 T5 =41 T1 = 44 T2 = 42 T3 = 48 T4 = 48 T5 =44 T1 = 48 T2 = 46 T3 = 50 T4 = 50 T5 =48 T1 = 52 T2 = 52 T3 = 57 T4 = 54 T5 =54

10.00 AM

11.00 AM

12.00PM

1.00 PM

2.00 PM

T1 = 54 T2 = 54 T3 = 58
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T4 = 56 3.00 PM T5 =55 T1 = 55 T2 = 55 T3 = 60 T4 = 57 4.00 PM T5 =56 T1 = 57 T2 = 57 T3 = 63 T4 = 61 5.00 PM T5 =60 T1 = 60 T2 = 60 T3 = 65 T4 = 64 6.00 PM T5 =63 T1 = 60 T2 = 60 T3 = 65 T4 = 64 T5 =63

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CALCULATIONS:
1) VOLUME OF TANK = 14137166 sq.mm 2) VOLUME OF CU. PIPES =2895291sq.mm 3) CAPACITY OF TANK = 13 LITRE 4) CAPACITY OF COLLECTOR = LITRE 5) CAPACITY OF COLD WATER TANK=20 LITRE 6) AMOUNT OF WAX USED =40GM PER CU.PIPE 7) TOTAL WAX USED IN CU. PIPE= 2.5KG 8) MAX. TEMP. ATTAINED = 55 DEGREE.

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WEIGHTS OF VARIOUS PARTS:


1)

WEIGHT OF COPPER PIPE = 114 gm

2)

WEIGHT OF PVC END CAPS = 748 gm

3)

WEIGHT OF AL. PLATE = 138 gm

4)

WEIGHT OF PVC PIPE = 1945 gm

5)

WEIGHT OF WAX IN EACH CU. PIPE =43 gm

6) WEIGHT OF TOTAL WAX USED = 2752

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SOLAR WATER HEATER APPLICATIONS:

1) Domestic: Flats, Bungalows and Apartments. 2) Commercial: Hotels, Hospitals, Hostels and Dormitories. 3) Industrial: Process Industries, Preheating boiler feed water.

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In commercial & industrial sectors, where large quantity of water is required at fairly high temperature, ''Our Solar Water Heating Systems'' are designed to meet the above requirement. Depending on the distribution pattern of hot water, the system could be either modular or a big capacity single tank system.

COSTING

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COST ANALYSIS:
Sr.No. Item. Rate in Rs. Qty. Amount in Rs.

1 2

P.V.C.Pipe End cap

90 200

1.5ft 2

135 400
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3 4 5 6 7 8 9 10 11 12

Copper Pipes Collector Cladding Stand Brazing

40 4500 800 500 & 700 5oo 35 70 508 -

120ft 1 1 1 1 8m 3kg -

4800 4500 800 500 700 500 280 210 508 13,333Rs

Soldering Transportation Thermocouple Paraffin Wax Other Cost Total Cost

CONCLUSIO N

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CONCLUSION:
1) Store latent heat unlike other solar heating system 2) Heat storage capacity is large 3) More hot water is obtained with same capacity 4) Constant hot water at 50 degree Celsius is obtained 5) No much variation in temperature is observed even when cold water is added

6) It is more efficient than other system 4) It is more advantages where the space restriction limits larger thermal storage units in direct gain or sunspace passive solar system.

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PHOTO GALLERY

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