Design and Construction of an Experimental Parabolic

Trough Collector Using Low Cost Alternative Materials

Hugo M. Torres 1,a), Rubén A. M. Carrillo 2,b), Nelson M. Torres 3,c)
1
Mechanical Engineer. Universidade Federal de Itajubá – Itabira Campus, Department of Mechanical
Engineering. Addres:s 200, Irmã Ivo Drumond Street, Industrial Discrict II, Itabira –MG, 35903-087.
Phone: +55-31-986485176
2
Mechanical Engineering Doctoral Degree, Mechanical Engineering Master’s Degree, Mechanical Engineer.
Universidade Federal de Itajubá – Itabira Campus, Department of Mechanical Engineering. Address: 200, Irmã Ivo
Drumond Street, Industrial Discrict II, Itabira –MG, 35903-087.
Phone: +55-31-975233735
3
Retired Mechanic. Address: São Geraldo Street, F1 Building, apt 205, Água Fresca Neighborhood, Itabira –MG,
35900-465.
Phone: +55-31-988083238
a)
Corresponding author: hugo_machado_torres@hotmail.com
b)
ruben.miranda@unifei.edu.br
c)
nelson.nmt53@gmail.com

Abstract. This paper presents a techno-economic analysis to construct an experimental Parabolic Trough Solar collector,
using alternative materials, for academic purposes. Concentrated solar power has considerable potential for growth in
Brazil, considering the levels of direct solar irradiation, land availability and low current state of use of this technology. It
has also a good potential to replace fossil fuels in many thermal applications, helping to decarbonize Brazilian Energy
Matrix. We built the prototype manually in a garage. It was made of the following materials: plywood, with steel tube
reinforcements for the structure; copper, covered with black ink, for the collector tube; galvanized steel sheets covered with
thin aluminum sheets for the reflector. We developed a hydraulic system to run the testes, and an electronic system, using
an Arduino-UNO, a laptop and temperature and flow meter sensors to collect data. This prototype does not have neither a
solar tracking system nor a glass cover. It has an opening area of 2.34 m² and had a material cost of around $129.00. Under
an estimated direct solar irradiation of 900 W/m², the prototype was able to absorb heat at a rate of 1.2 kW (52.38% of
efficiency). We also developed a simplified method for building devices similar to ours. For the purpose we built this
prototype, the materials of the collector tube and the reflector were approved. The plywood in the structure had a low
reliability and high cost. The results we found have limitations for industrial applications, but offer strategical information
for building this type of device in universities and research centers.

INTRODUCTION
Power generation and use is one of the main challenges of 21 st century, due to projections of an increasing global
and per capita energy consumption [1]. In addition to this, we still dependent of non-renewable sources, which are
more pollutant than renewables and can wear out some day [2]. One alternative for this scenario is using renewable
sources more. In Brazil, due to climate and geographic conditions, there are many opportunities to increase the power
generation from renewable sources, mainly solar and wind power [3].
Solar energy can be used in both photovoltaic and thermal forms. Concentrated solar radiation can increase the
temperature range of solar collector and its applications. Such devices may find applications as heat source in industrial
processes [4], refrigeration systems, heating systems, desalinization and, coupled with thermodynamic cycles, power
generation. Another advantage of Concentrated Solar Power (CSP) is that its daily-generated energy can be stored and
used at night.
There are four main types of solar collectors: The first type uses a parabolic dish as mirror and reflects the sunlight
in a focal point. It is usually coupled with a Stirling Engine. The second one uses a set of mirror, called heliostats,
reflecting the sunlight to a point in a tower. This one can achieve higher concentration ratios due to its geometry and
depending on land availability. The third one uses a line focus. A trough-shaped mirror is used to reflect the sunlight
to a tube. The fourth one uses flat mirrors not to reflect, but to change the direction of sunlight rays toward a central
receiver tube. These systems can achieve up to 1500 ºC, 2000 ºC, 400 ºC and 250 ºC [5]. Figure 1 shows a scheme for
these four technologies:

FIGURE 1. Four main types of solar concentrators: Parabolic Dish (a), Central Receiver (b), Parabolic Trough Collector (c) and
Fresnel (d).

Despite its applicability, CSP is still not widely used in Brazil. There are no power plants, and the amount of
scientific studies in universities is smaller, compared to other renewable energy technologies. This present work aims
to demonstrate the procedures for designing and constructing a parabolic trough collector (PTC), for experimental
purposes. The authors used alternative materials, to test their performance and evaluate their costs. We expect that
with the findings of this study to a cheap and simply model to build a PTC device in other institutions.

MATERIALS AND METHODS

The first part of this work consists on selecting the geometry and parameters of the prototype. Before starting the
design procedure, we considered the following assumptions:
 For design purposes, the prototype is considered to be operating in steady state;
 Solar radiation of 900 W/m²;
 Room temperature and thermal fluid inlet temperature are 25 ºC;
 Water is the thermal fluid. Its properties are determined at 25 ºC (Specific heat: 4.18 kJ/kg*K; Density: 9997
kg/m³; Kinematic viscosity: 10-6 m²/s; Dynamic Viscosity: 10-3 kg/s*m; Thermal Conductivity: 0.58 w/m*k;
Thermal Diffusivity: 1.39*10-7 m²/s);
 The design procedure requires an initial length for the prototype. For this work, we selected 2400 mm;
  The absorber tube is made of copper (thermal conductivity = 401 W/m²*K). Due to commercial availability,
it has 22mm and 20 mm of outer and internal diameters, respectively. Black ink was used on the absorber, to
increase its absorption. A value of 85% for this parameter is assumed in this work.
 Galvanized steel, covered with aluminum foil is used as reflective surface. A refection of 85% is assumed.
 The prototype will reach a maximum outlet temperature of around 100 ºC, so radiative thermal loses can be
neglected;
 There is a linear heat distribution alongside the collector tube;
 There is a low temperature increase thought the tube, so heat removal factor is assumed as 1;
 Shadowing effects are not considered;
 There is no glass cover around the receiver tube. Air velocity around the tube is assumed to be 5 m/s;

Therefore, within these assumptions, we are able to stablish a simple and easy-to-find mathematical model, with
simplified equations, to design a PTC device. Considering the assumptions above, the temperature difference along
the tube is given by:

Q
ΔT = 𝑚̇∗𝐶 (1)
𝑝

Where Q is the rate heat absorbed by the thermal fluid (W), 𝑚̇ is the mass flow rate (kg/s) and Cp is the specific
heat (W/kg*K) of the thermal fluid. The heat transfer rate is given by:

𝑄′′ = 𝑈 ∗ ∆𝑇 (2)

Where 𝑄′′ is the heat transfer rate (W/m²) and U = 1/Thermal resistance. The thermal resistance is given by:
(𝑟 )
𝑟𝑖𝑛 ∗ln 𝑜𝑢𝑡
(𝑟𝑖𝑛 ) 1
𝑅𝑡ℎ𝑒𝑟𝑚 𝑡𝑜𝑡𝑎𝑙 = 𝑅𝑡ℎ𝑒𝑟𝑚 𝑐𝑜𝑛𝑑 + 𝑅𝑡ℎ𝑒𝑟𝑚 𝑐𝑜𝑛𝑣 = +ℎ (3)
𝑘𝑡𝑢𝑏𝑒 𝑖𝑛

Where Rtherm total, Rtherm conduc and Rtherm conv are the total, conductive and convective thermal resistance (m²*K/W),
respectively; ktube is the thermal conductivity of the material of the tube (W/m*K); rout and r in and the external and
internal radius of the tube, respectively (mm) and hin in the internal flow convective heat transfer coefficient. It is
given by the following equation:

𝑘
ℎ𝑖𝑛 = 𝐷 ∗ 𝑁𝑢𝐷 (4)

Where Nud is the Nusselt Number of the internal flow, k is the thermal conductivity of the working fluid and D is
the pipe diameter. For internal flow, Nusselt Number is given by Dittus-Boelter equation [6]:
4
𝑁𝑢𝐷 = 0.023 ∗ 𝑅𝑒 5 ∗ 𝑃𝑟 0,4 (5)

Where Pr is the Prandtl number, defined as the ratio of kinematic viscosity (𝜐, m²/s) and thermal diffusivity (𝛼,
m²/s) of the fluid, and Re is the Reynolds number. For internal flow, Reynolds is given by:
𝑉∗𝐷
𝑅𝑒 = (6)
𝜐

Where V is the flow velocity (m/s), D is the internal pipe diameter. The tube outside average temperature is given
by:
𝑄∗𝑅𝑡é𝑟𝑚 𝑡𝑜𝑡𝑎𝑙
𝑇𝑠 = 𝑇𝑓 + (7)
𝐴𝑖𝑛

Where Tf is the average internal temperature (ºC), and Ain in is the internal area of the pipe. Convective heat loss
is given by:
 𝑄𝑐𝑜𝑛𝑣 = ℎ𝑜𝑢𝑡 ∗ (𝑇𝑠 −𝑇𝑎𝑖𝑟 ) (8)
Where Tair is the outside air temperature (ºC) and ℎ𝑜𝑢𝑡 is the convective heat transfer coeficiente for the air flow
around the collector (W/m²*K). For airflow velocities around 5 m/s, Duffie and Becman (2013) [7] state that this
coefficient can be given by:

ℎ𝑜𝑢𝑡 = 2,8 + 3 𝑉𝑎𝑖𝑟 (9)

Where 𝑉𝑎𝑖𝑟 is the air velocity. Total solar radiation in which the collector needs to be exposed and the area required
to collect this amount of heat are given by:

𝑄+𝑄𝑐𝑜𝑛𝑣 𝑄+𝑄𝑐𝑜𝑛𝑣
𝑄𝑡𝑜𝑡𝑎𝑙 = 𝑂𝑝𝑡𝑖𝑐𝑎𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = (10)
𝐴𝑏𝑠𝑜𝑟𝑡𝑖𝑣𝑖𝑡𝑦∗𝑅𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑣𝑖𝑡𝑦

𝑄𝑡𝑜𝑡𝑎𝑙
𝐴𝑚𝑖𝑟𝑟𝑜𝑟𝑠 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝑆𝑜𝑙𝑎𝑟 (11)
𝑅𝑎𝑑𝑖𝑎𝑡𝑖𝑜𝑛

Mirrors’ width, S, is then giving dividing the area by the length. For Rim angle (φ) equals to 90º, according to
Venegas et al (2012) [8], we have that the aperture of the Solar Collector and its focal distance are given by:

𝑆 = 𝑊𝑎 ∗ 1.761 (12)
𝑊𝑎
ƒ= 4tan(φ) (13)
2

The efficiency of the solar collector is the given by the actual heat absorbed by the fluid divided by the direct solar
radiation reaching the equipment. Using the equations above, we were able to create an 8-step process for design a
PTC device, an open circuit system, in which the fluid would pass through the equipment only once. This process
consists of the following steps:

 1st step: Determine required heat collected: for this work, it was selected a net power absorption of 1500W,
based on similar works [9];
 2nd step: Determine thermal fluid flow: A initial flow of 0.1 kg/s was selected, due to low head loss and
considerable temperature gradient [8];
 3rd step: Calculate the required temperature difference in the thermal fluid: Using equation (1), mass
flow rate equals to 0.1 k/s and net heat-absorption rate equals to 1500W, we found a required temperature
difference of 3.58 ºC. Considering this value, an inlet temperature of 25ºC and a linear temperature
distribution alongside the tube, we found an outlet temperature of 28.58ºC and the average temperature, used
later for further calculation, of 26.79ºC;
 4th step: Based on flow characteristics, thermal fluid and pipe properties, determine thermal resistance:
This value is found using equations (2) and (3). For these equations, all values are known, expect the internal
convective heat transfer coefficient (hin). Therefore, this parameter is found using equation (4). Equation (4)
requires Nusselt Number, which can be found using equation (5). Nusselt number calculation requires
Reynolds Number, which is found using equation (6). We found a hin of 1620.478 W/m2*K and a thermal
resistance per area of 5.4∗10−4 𝑚2∗𝐾/𝑊.
 5th step: Given thermal resistance, internal area and fluid average temperature, determine average
temperature on the outer surface of the tube. Using equation (7), we found this value to be 32.16 ºC.
 6th step: Given the outside average temperature and the external convective heat transfer coefficient,
determine thermal loses due to convection: The external flow convective heat transfer coefficient is given
by equation (9). We found a value of 18 W/m²*K. Using equation (8), we found the convective loss to be
equals to 21.39 W.
 7th step: Based on collected useful heat rate, thermal losses and optical efficiency, determine the
required solar radiation incident on the equipment: Using equation (10), net heat transfer to the fluid,
heat loss and optical efficiency, we found a required incident solar radiation of 2105.73 W.
  8th step: Base on solar radiation requirement, direct solar radiation at the location and the equipment
length, determine its area and aperture: Using equation (11), normal solar irradiation of 900 W/m² and the
required solar incidence, we found required area of 2.339 m². Dividing it by its length, 2.4m, we found a
width of 0.975 m². Using equation (12), we found an opening of 1.716 m, and a focal distance of 0.243 m.
Calculated efficiency, given by the ratio between heat transfer to the fluid and incident solar radiation is
calculated to be 71.23%.

After calculating all parameters, a model on SolidWorks was generated. After that, we started making the
prototype. We built this prototype in a garage, using hand-tool. Figure 2 shows this process:

FIGURE 2. Manufacturing process: a) Model on SolidWorks; b) Sawing plywood; c) assembling mirrors; d) Finished
prototype.

Besides the heat collecting system, we also assembled and used a hydraulic and a data-collecting system. The data
collecting system was composed of an Arduino UNO, a Protoboard, Temperature Sensors and a Flow-Meter sensor.
Data was shown, checked and collected on a laptop. The hydraulic system was composed of a tank, a pump, hoses
and control valves. The hydraulic system allowed two different test: a single-pass test, or “open circuit” system, in
which the prototype was initially designed, and a closed circuit one, in which the water would recirculate, increasing
its temperature gradually. In the open-circuit, there are two temperature sensors: one in the beginning of the collector
tube, and another at the end. In the closed circuit, there is only one temperature sensor, in the tank. Figure 3 shows the
schemes for both hydraulic system configurations:
 FIGURE 3. Hydraulic system: a) Open circuit configuration; b) Closed circuit configuration.

The final system is composed of the hand-made prototype, the hydraulic system and the data-collecting system.
Figure 4 shows all components. For the collector tube, we used copper, due to its high thermal conductivity, painted
with black ink, to increase the absorption. For the hydraulic valves and connections, we used PVC, due to its price
and ease to find. For the same reason, black rubber hoses, resistant to higher temperatures, were used. For the tank,
we used a 25 liters Styrofoam box. For the structural tubes, we used commercial steel, due to the low price. For the
stands, we used plywood. We decided to try this material because it would be easy to work, light and cheap.
FIGURE 4: a) reflective trough; b) Receptor Tube; c) Hydraulic Connections; d) hoses; e) hydraulic valves; f) tank; g) structural
tubes; h) fixed stand; j) mobile stands.

Our system did not have a solar tracking system. Then, for testing its capacity under direct solar radiation
conditions, our tests needed to happen around noon. In the middle of November, when we scheduled to run our tests,
weather conditions were not being ideal around midday. We found the best conditions on November 18 th, 2018, and
we realized our test on this day. Even on this day, we still had a considerable presence of wind and clouds. Figure 5
shows sky condition for the test’s day.

FIGURE 5 - Sky conditions on the day of the test.

 In spite of using an open system configuration in our design procedure, we used the closed circuit in our test due
to wind and cloud conditions. Temperature gain would then be greater, and sensors’ precision would affect less our
results. We kept the water flow rate at 1.5 liters/min and all water-volume in the circuit was 10 liters. We ran our test
several times. However, in most of them, sudden cloudy conditions disturbed our data. For the best conditions we
got, we could collect data for 113 seconds, when clouds appeared and temperature stopped rising.

RESULTS AND DISCUSSION

. On the test, water in the tank was at 27.62ºC initially. It reached 30.81ºC at 110 seconds, and then stabilized
around this value. We ended the test at 113 seconds. Figure 6 shows the temperature evolution over time:

Figure 6. Temperature evolution over time - Close circuit test.

Considering a temperature gain of 3.19 ºC in 110 seconds, 10 kg of water in the circuit and using equation (1),
reorganized, we found a heat collection rate of 1212.2 W. Considering the total direct incident radiation of 2105.73W,
we found a heat absorption efficiency of 57.57%. The prototype was designed to collect heat at a rate of 1500W, with
an efficiency of 71.23 %. Three factors can explain this lower performance:

I. Non-ideal weather conditions: There was much Wind and many clouds on the day of the test. The actual
solar irradiation might have been lower than the estimated 900 W/m² value.
II. Alternative materials use: We estimated both reflectivity, for the mirrors, and absorvity, for the tube, as
85% (total optical efficiency being 72.25%). It is possible that actual values are smaller than that.
III. Non-ideal image formation: All the process was manual, using low-precision tools and alternative
materials. The prototype’s geometry, then, wasn’t perfect, so image formation on the tube was probably not
ideal, reducing the amount of heat being transferred to the tube and consequently to the fluid.

Regarding costs, we assume one American Dollar to be equals to four Brazilian Reais (1 US$ = 4 R$). We didn’t
consider labor cost, because this prototype was designed for academic purposes. Therefore, only material costs were
taken into account. We didn’t take any account for the data collecting system either and the pump, because we didn’t
have to buy any of the items. We assume other institutions wouldn’t have to buy them, either. Figure 7 and table 1
show the cost distribution for the CSP prototype and the hydraulic system. We can notice that the structural part
(plywood and steel tubes) represented 46% of the total cost.
 FIGURE 7. Costs distribution for CSP prototype and hydraulic system.

TABLE 1 - Cost distribution for CSP Prototype and hydraulic system.

Description Value (%)
Copper tube US$ 21,75 17%
Steel tubes US$ 12.50 10%
Plywood US$ 46.50 36%
Screws, hoses and valves US$ 21.25 16%
Galvanized steel sheets (mirrors) US$ 20.00 16%
25 liters Styrofoam tank US$ 6.00 5%
Aluminum foil (mirrors) US$ 1.00 1%
Total US$ 129.00 100%

In terms of performance, copper tube with black ink showed a low cost, easy maneuverability and reasonable
performance. In terms of reliability, if the prototype is often assembled or handled, the tube can lose its painting. On
the same way, galvanized steel covered with aluminum foil showed low price and reasonable performance, but very
simple works can damage its surface. Exposure to weather conditions can also damage the mirrors’ surface. Plywood
was the worse evaluated material. It didn’t fit well for structural applications, requiring steel tube reinforces. It
represented the highest share of all total cost, and it is not durable for long-term applications. All other items had
minor impact on the project, and their cost and performance were under our expectations. We build our prototype in
a modular style. Total assemble time, considering three people with no specific skills for this task, using hand-tools,
was about one hour. This value can be considered good, when compared to other similar studies [10].

CONCLUSION
Within this study, we were able to understand better about the design parameters and state-of-art regarding CSP
technology. The eight-step procedure we developed is very simplified, not having much application in the industry.
However, it offers a practical tool for initial research, especially in universities where CSP studies are non-existing or
rare. A 1.2 kW prototype, costing less than 130 dollars is an affordable price for this type of study. Our analysis of
alternative materials’ prices also offer an important piece of information for researcher who aim to develop their
practical studies with limited budget.
Plywood represented 36% of our cost, and it didn’t perform well. Thus, it should be avoided. Galvanized steel
with aluminum foil can be used, under some specific conditions. If offers a low-cost alternative of US$22.75, and
perform reasonably well in single tests. However, for repeated tests, the aluminum foil can rip or bubbles can appear.
It demands more work in repairs. Our modular system also makes possible to have improvements in the prototype,
without having to rebuild all the equipment. Its ease to be assembled and disassembled is also a differential for initial
research.
 This study is a primary study for other CSP projects. We can use the knowledge we acquired to apply in other
types of CSP dishes, like parabolic dish and central receiver. These additional studies can also be coupled with final-
endings uses for thermal energy. For high temperature collectors, we can test it with for power generation or hydrogen
production, using metal-oxide method. For medium temperature ranges, we can test our CSP equipment as a thermal
source for industrial processes or refrigeration systems.
Regarding Parabolic Trough collectors, some improvement we can do include using a vacuum tube around the
collector tube, improving our structure and developing a solar tracking system. Standardized tests, following
ASHRAE norms can also be used in future projects. If we realize some of these possible projects, CSP technology
has potential to become more popular among scholars and industrials in Brazil.

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