Evacuated Closed Loop Solar Water Heater

Designing of Closed loop Evacuated Flat Solar Water Heater _____________________________________________________________________________________

_____________________________________________________________________________________ Sher Muhammad, [email protected], 2012-ME-197, UET Lahore. P a g e | 1

DESIGNING OF CLOSED

LOOP EVACUATED

FLAT SOLAR WATER

HEATER (SWH):

BY

SHER MUHAMMAD

2012-ME-197

STUDENT OF MECHANICAL ENGNEERING

UNIVERSITY OF ENGINEERING AND

TECHNOLOGY (UET), LAHORE, PAKISTAN.

mailto:[email protected]



RECOMMENDATION

This project is of my great interest and design is the whole my effort.

As my concern is facilitation to poor people of cold climate.

Dissipating solar energy is being endeavored convert in a useful work.

It is aimed to make it pretty simple, economical and interesting for people

make their own. The whole project is detailed step by step following snaps.

Follow it up I assure you will get successful with this project.

As I have not performed practical work to check the design perfection,

so I cannot claim my design could be considered as final effort. Further

investigation and research could be carried out for still better result.




Solar Water Heater (SWH):

It is the system which is used to convert solar thermal energy to heat water

using solar thermal collector. Solar thermal collector (STC) gathers the sun's energy,

transform its radiation into heat, and then transfer that heat to water. Designing of

STC has the most fundamental importance for a high efficiency SWH. The whole

performance of system does depend on this part. Technical innovation was required

to improve performance, life expectancy, ease of use of the system and most

especially to make it economical to opportune every person with it. It has been

designed keeping the financial status of people in the first place.

I am aimed to design a STC economical and well efficient to cold climate low

budget people. Almost the backward areas like villages and mountainous areas have

the very requirement of this SWH as so far designed collectors was not pretty

economical putting people into their limits. After learning the all designs so far has

been aired completely I have come up with an idea which I am confident will win

the heart of people. I am totally concerned with people to facilitate them is my utmost

priority.

Solar Thermal Collector (STC):

Flat plate and evacuated collectors has been designed so far. Both has their

own advantages and disadvantages, former is economical strict to warm and later

uneconomical strict to cold climate. My effort is to design economical and

environment effective STC for a cold climate and easy enough to people make by

themselves after learning this report without getting dependent on market. After

putting my whole concentration I have tried to mix them up for the cost of high

efficiency with the bag of advantages.

The design is being listed step by step.

STEPS:

1. Note: All the units are in inches, unit is not being write down with a figure.

l = length, w = width, h = height, d = diameter, r = radius. (2 h =2 inch height

as like others)

2. First of all take two wooden strips of volume (45 l, 2 w and 4 h).




3. Start with one wooden strip

4. Take one wooden strip and apply the procedure as given below.

On the right side towards front of wooden strip mark two lines (0.5 h and 1

w) from bottom, cut it producing along the length (45 l).




5. On the both ends of top towards front of wooden strip mark two lines (1 l and

1 w) and cut it down producing along the height (4 h).




6. After that on the right side towards front at a distance of (1 h) from bottom

make a rectangle of area (0.2 h and 1.5 w) and take a cut along the length up

to (44.5 l).This deep cut is taken to insert later a glass of volume (44.5 l, 29 w

and 0.2 h).




7. Make the same rectangle at a distance (3.3 h) from bottom and do the same

procedures.




8. Front left end of wooden strip.

9. Drill a hole of (0.50(1/2) d) on the front left end at a distance (1.25 l, 1.25 h)

from the uncut to center point of hole and produce it along the width (2 w).

The purpose of this hole is to evacuate the box with air as box is going to get




build later to keep the maximum amount of heat for a longer period.

Evacuation is necessary as heat dissipation out of box would be 0% r decrease

to minimum level if it is properly evacuated. It helps to admit heat from the

sun and limit heat loss back to the environment.




10. On the back of wooden strip right at the hole draw a hole of (1 d) and drilled

up to (0.5 w) along the width.




11. First wooden strip is completed. Now take the second wooden strip and apply

the whole procedures except the last some steps that’s drilling of hole.

12. Back of wooden strip.




13. The two wooden strips are completed right now with all the supposed

procedures.

14. It’s time to take another two wooden strips of volume (30 l, 2 w and 4 h).

15. Take one wooden strip and apply the previous procedures as draw two lines

(1 w and 0.5 h) on the right side towards front from bottom producing it along




the length (30 l), draw another two lines (1 l and 1 w) on the both ends of top

towards front and produced it along the height (4 h) and two rectangles of area

(0.2 h and 1.5 w) on the right side towards front at a distance of (1 h) and (3.3

h) respectively from bottom and produced it up to (29.5 l).

16. Back of wooden strip.




17. Then apply the whole procedures on the second wooden strip as to first except

a little modification that’s increased the area of two rectangle (0.2 h and 2 w).

18. Back of wooden second strip.




19. Drilling of hole is left on the both wooden strips. Drill a hole of (0.25 d) on

the front left end on both the wooden strips at a distance (0.63 l and 1.125 h)

from uncut to centre point of hole and produce it along the width (2 w). Drill

another hole of (0.5 d) on the back of both strips right at the drilled hole and

produce it along width (0.5 w).




20. Back of first wooden strip.

21. Back of second wooden strip.




22. All the supposed procedures on the four wooden strips are completed then it

is time to join them to get a box like structure. I want to make everything

before passing through assembly process therefore keep it aside and start

building the rest parts.

23. Take an aluminum sheet of (90 l and 22 w) and produce 21 grooves in it to

make a room for the pipes to fit in them to tight the pipe in it later with the

help of wooden jig (23 l, 10 w and 3 h) taking a deep cut of (23 l, 1 depth and

1 w) at the centre of wooden strip and make the deep cut almost circular along

the width. Keep the sheet on the wooden strip and with the assistance of

hammer, solid cylinder (0.3 d, 23 l) and another wooden strip of (1 w, 23 l, 7

h) pushing the solid cylinder into the grooves after sheet and then wooden

strip for proper fitting into the groove. Follow the same procedure keeping a

distance of (1 l) between each groove until done with 21 grooves on the sheet.










24. After that take a total of (0.25 d and 830 long) aluminum pipes.

25. Start bending pipes at (22 l) making a series of twenty one (21) turns arranged

them in a manner to fix in the sheet grooves to make it best absorb the solar

thermal heat, weld the copper pipes at where it finish and continue until the

required turns are not obtained. Take another copper pipes and bend at (16 l)




making a series of fifteen (15) turns. Keep the distance between each turn (1

l). A pipe of (3 l) would be required for bending.




ASSEMBLY

26. Time has reached for the long awaited assembly process.

PROCEDURES:

27. First of all bring the four wooden strips together and conjoin them in this

manner.




28. Fasten them in the manner with first glue and (3 l) nails at all the ends. A

rectangular box of outer area (47 l, 30 w and 4 h) and inner area (43 l, 26 w

and 4 h) will be obtained.

29. Right side and trimetric view is as given.




30. Fix a plywood of (43 l, 26 w and 0.1 h) and then a wooden strips of total (43

l, 26 w and 0.4 h) on the outer bottom of the box, glue it first and nail of (3 h)

into it at all its required points.

31. Complete box is made. Now polish a mixture of enough wooden powder and

white paint throughout the inner of box to fill the joined sides to make sure if




any little cavity/crack left until it make a thick layer. We are on the way to

make an evacuated box that’s verily required no cavity box. White paint is

using instead black as we know white color reflect more instead absorbing

light as the absorbed light is transformed to heat energy. So it will work almost

as an insulator for the evacuated portion. The heat present in the evacuated

portion would not be absorbed and it would let the evacuated portion keep the

heat for a longer period.

32. Take a foam of (43 l, 26 w and 0.5 h). Paint enough white bottom surface of

a foam and attach it with the inner bottom surface of box.

33. Properly paint white the upper portion of foam and then insert a glass of (45

l, 29 w and 0.2 h) into the rectangular portion made earlier.

34. Now take another four foam of (43 l, 2.1 w and 0.5 h). Paint again enough

white the attaching surface of four foams and attached on the four inner sides

of box, proper glue the attaching surface and nail it. Make hole in the foam

where it is required.

35. Paint pretty enough black the series of aluminum pipes.

36. Paint sufficient black the current inner box and all the surfaces of aluminum

sheet until it make a very thick layer. When everything gets dry. Fix accurately

the pipes in the aluminum sheet grooves, tight it. Place pipe fitted aluminum

sheet onto the top of glass.

37. Paint enough white the pipe holes of box properly pass aluminum pipe

through the holes (1.5 w) along width and at the outer portion weld an ordinary

pipe of (80 l) with right side end and (12 l) on the left side end of aluminum

pipe.

38. Paint white and mixture of wood powder on the outer portions until it fills the

whole cavities, attach a foam with it gluing the joining surface and fix a

plywood nailing into it.

39. After then insert another glass, fill up the cavity it produce with a mixture of

wood powder and white paint, insert a foam (29 l,0.5 w and 0.2 h) into it and

then fix a plywood nailing into it.

40. Evacuate the box from the hole (0.5 d) earlier made with the proper device

and fill the hole with the procedures as to other hole.

41. Evacuated Flat Solar thermal collector is ready to work

42. Now choose a tank of (23d and 34.5 h) with a capacity of 200 liters (50

gallons) to store hot water into it. Open the tank, insert another series of

aluminum pipes into it.




43. From the top of tank produce a pipe of (49 l) upward and (80 l) right side

make a division between this (80 l) pipe at its centre and insert a valve to pour

heat absorbing fluid into the closed loop pipe, connect it to the collector and

weld proper all the connecting pipes. Join all pipes at corner with elbows.




44. From downward right of tank produce a pipe (142 l) along right side and

connect it to the pump which is to keep continue the circulation of fluid

through the collector and tank and then join collector with the pump with a

pipe (65 l). Join all the pipes together with elbows.




45. Weld proper the upper portion of tank and both ends of aluminum pipes with

ordinary pipes to avoid it from leakage.

46. Produce a pipe of (5 l) towards upward from the top of tank and (5 l) along

front and (39 l) downward connecting with another pump join the corners with

elbows. This pipe supply hot water to the home.




47. Heat Absorbing Fluid is another important hallmark of SWH. As I am being

designed for cold climate so mixture of ethylene glycol and water (60 to 50

%) is selected as heat absorbing fluid. As these provides effective freeze

protection.

48. Pour the mixture of fluids into the closed loop pipe under high pressure until

its get fill. Tight the opening with as screw and make sure if there id=s any

cavity.

49. Circulation of water is anti-clockwise, red pipe showing hot and blue

displaying cold water.

50. Make a wooden rack with two strip (85 h and 4 w) and another two (49 h and

4 w) with a base (47 l, 34 w and 3 h) at an angle of (55 degree).




51. Fix the collector onto the rack.




52. Now touching to the peak left with only one of the most important feature

of SWH that is insulation. As without insulation it would not be suitable for

colder climate so insulate everything pipes, tank and all sides of collector

except top with a thick insulation foam adequately.

53. Fill the tank with water. Turn the pumps on.

54. Closed Loop Evacuated Flat Solar Thermal Collector is ready for use. Use it

while investigating and researching room for improvement.

55. Full and Final Part.







A BRIEF WEATHER HISTORY OF GILGIT BALTISTAN:

Evaluation of Projected Minimum Temperatures and Precipitation for Gilgit

Baltistan, Pakistan:

Skardu (35.3°N, 75.68°E) is located in the northern areas of Pakistan. It is known for heavy snowfall in the region, its night temperature remains below freezing point for 6-7 months of the years. Some very large and significant glaciers such as Baltoro, Siachen and Biafo are located. Gilgit (35.92°N, 74.33°E) is located near rivers Gilgit and Hunza. Due to its elevation 1459 meters above mean sea level, the minimum temperature stays below zero for 4-5 months and snowfalls in winter. There are many glaciers such as Gulkin, Rakaposhi, Passau and Hispar. Tabular View for Temperature per Month in Gilgit Baltistan:

Temperature

Months Normal Warmest Coldest

January 2.5°C 7.0°C -2.0°C

February 3.8°C 8.2°C -0.7°C

March 8.8°C 14.1°C 3.4°C

April 14.2°C 20.5°C 7.9°C

May 17.7°C 24.5°C 10.8°C

June 22.3°C 29.6°C 14.9°C

July 24.1°C 30.1°C 18.1°C

August 23.5°C 29.6°C 17.5°C

September 19.8°C 27.4°C 12.1°C

October 14.1°C 22.4°C 5.8°C

November 8.1°C 15.1°C 0.9°C

December 3.4°C 8.2°C -1.5°C




Graphical view of Mean Temperature and Precipitation / month of different

Districts of Gilgit Baltistan:




Evaluation of the Site for Solar Energy:

Solar Resource Map:

Determination of the result how well the solar can work in the area for a rough idea

needs to acquire the solar resource map.




Sun Path Chart of Gilgit Baltistan:

By putting the location of G.B that’s the latitude 35.3500° N, longitude 75.9000° E and

time zone PKT (UTC+5) in a program I obtained the result.

Solar Noon Calendar:

Solar noon is when the sun crosses the meridian and is at its highest elevation in the sky, at 12 o'clock apparent solar time. Solar noon depends on the longitude and date.

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

1 11:59:56 12:09:56 12:08:37 12:00:08 11:53:30 11:54:21 12:00:25 12:02:47 11:56:27 11:45:59 11:39:55 11:45:30 2 12:00:24 12:10:03 12:08:25 11:59:51 11:53:23 11:54:31 12:00:36 12:02:43 11:56:02 11:45:40 11:39:54 11:45:53 3 12:00:52 12:10:10 12:08:12 11:59:33 11:53:17 11:54:41 12:00:47 12:02:38 11:55:42 11:45:21 11:39:54 11:46:17 4 12:01:19 12:10:16 12:07:59 11:59:16 11:53:12 11:54:52 12:00:58 12:02:32 11:55:22 11:45:02 11:39:54 11:46:41 5 12:01:46 12:10:21 12:07:46 11:58:59 11:53:07 11:55:02 12:01:09 12:02:26 11:55:02 11:44:44 11:39:56 11:47:06 6 12:02:12 12:10:25 12:07:28 11:58:42 11:53:02 11:55:13 12:01:19 12:02:19 11:54:42 11:44:26 11:39:58 11:47:31 7 12:02:38 12:10:29 12:07:17 11:58:25 11:52:58 11:55:25 12:01:28 12:02:12 11:54:21 11:44:08 11:40:02 11:47:57 8 12:03:03 12:10:31 12:07:02 11:58:09 11:52:55 11:55:36 12:01:37 12:02:04 11:54:01 11:43:51 11:40:06 11:48:23 9 12:03:28 12:10:33 12:06:47 11:57:52 11:52:53 11:55:48 12:01:46 12:01:56 11:53:40 11:43:35 11:40:11 11:48:50

10 12:03:53 12:10:34 12:06:32 11:57:37 11:52:51 11:56:00 12:01:55 12:01:47 11:53:19 11:43:19 11:40:17 11:49:17




THANK

YOU

11 12:04:17 12:10:35 12:06:16 11:57:21 11:52:49 11:56:12 12:02:03 12:01:37 11:52:58 11:43:03 11:40:23 11:49:45 12 12:04:40 12:10:34 12:06:00 11:57:06 11:52:48 11:56:24 12:02:10 12:01:27 11:52:37 11:42:48 11:40:31 11:50:12 13 12:05:02 12:10:33 12:05:44 11:56:51 11:52:48 11:56:37 12:02:17 12:01:16 11:52:15 11:42:33 11:40:39 11:50:41 14 12:05:24 12:10:31 12:05:27 11:56:36 11:52:48 11:56:50 12:02:24 12:01:05 11:51:54 11:42:19 11:40:49 11:51:09 15 12:05:46 12:10:28 12:05:10 11:56:22 11:52:49 11:57:03 12:02:30 12:00:53 11:51:33 11:42:05 11:40:59 11:51:38 16 12:06:07 12:10:25 12:04:53 11:56:08 11:52:50 11:57:16 12:02:35 12:00:40 11:51:11 11:41:52 11:41:10 11:52:07 17 12:06:27 12:10:20 12:04:36 11:55:54 11:52:52 11:57:29 12:02:41 12:00:27 11:50:50 11:41:40 11:41:22 11:52:36 18 12:06:46 12:10:16 12:04:19 11:55:41 11:52:54 11:57:42 12:02:45 12:00:14 11:50:28 11:41:28 11:41:34 11:53:06 19 12:07:04 12:10:10 12:04:01 11:55:28 11:52:57 11:57:55 12:02:49 12:00:00 11:50:07 11:41:17 11:41:48 11:53:35 20 12:07:22 12:10:04 12:03:44 11:55:18 11:53:01 11:58:08 12:02:52 11:59:46 11:49:45 11:41:06 11:42:02 11:54:05 21 12:07:39 12:09:57 12:03:26 11:55:03 11:53:05 11:58:21 12:02:55 11:59:31 11:49:24 11:40:56 11:42:17 11:54:34 22 12:07:56 12:09:49 12:03:08 11:54:52 11:53:09 11:58:34 12:02:57 11:59:21 11:49:03 11:40:47 11:42:33 11:55:04 23 12:08:11 12:09:41 12:02:50 11:54:41 11:53:15 11:58:47 12:02:59 11:59:00 11:48:42 11:40:38 11:42:50 11:55:34 24 12:08:26 12:09:32 12:02:32 11:54:30 11:53:20 11:59:00 12:03:00 11:58:44 11:48:21 11:40:30 11:43:07 11:56:03 25 12:08:40 12:09:23 12:02:14 11:54:20 11:53:26 11:59:12 12:03:01 11:58:27 11:48:00 11:40:23 11:43:26 11:56:33 26 12:08:54 12:09:13 12:01:56 11:54:10 11:53:33 11:59:25 12:03:01 11:58:10 11:47:39 11:40:17 11:43:45 11:57:03 27 12:09:06 12:09:03 12:01:38 11:54:01 11:53:40 11:59:37 12:03:00 11:57:53 11:47:19 11:40:11 11:44:04 11:57:32 28 12:09:18 12:08:52 12:01:20 11:53:52 11:53:47 11:59:50 12:02:59 11:57:35 11:46:58 11:40:06 11:44:25 11:58:01 29 12:09:28 12:08:44 12:01:03 11:53:44 11:53:55 12:00:02 12:02:57 11:57:17 11:46:38 11:40:02 11:44:46 11:58:30 30 12:09:38 12:00:44 11:53:37 11:54:04 12:00:14 12:02:54 11:56:59 11:46:18 11:39:59 11:45:08 11:58:59 31 12:09:47 12:00:26 11:54:13 12:02:51 11:56:40 11:39:56 11:59:28


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Evacuated Closed Loop Solar Water Heater

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