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– Manufacturing processes for extruded polymer ICS systems must be developed, building on techniques of extrusion and manifold welding that are well proven for similar polymer pool collectors (more than one million collectors have been made by U.S. manufacturers). – A 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. Cold-Climate SWH. Analyzing the cold-climate reference system led to identifying TIOs to overcome barriers related to cost, performance, O&M, and reliability. Figure 3.3.6-1 shows the TIOs at two high levels, starting at Tier 1 and further divided in Tier 2. The estimated impact of the Tier 2 TIOs on the performance metrics is also shown in Fig. 3.3.6-1. Fig. 3.3.6-1 Solar water-heating TIOs. Shading indicates degree of impact each TIO has on each metric: red (dark) is high; yellow (light) is medium; no shading is low. The impacts of different TIOs on overall cost of avoided energy were analyzed, in some cases at additional levels of detail. For example, in FY 2004, analysis using the systems-driven approach was conducted to determine the most effective cost-reduction opportunities for three types of SWH systems in cold climates. Table 3.3.6-1 shows the results for the cost of saved energy (COSE). The highest priority was determined to be replacing conventional pressurized solar storage tanks and metal heat exchangers with unpressurized polymer tanks with immersed polymer heat exchangers. In fact, BOS and storage improvements were shown to be of higher priority than collector improvements. The table lists the percentage reduction in COSE for some of the opportunities that were investigated, as well as the estimated R&D risk and the estimated R&D cost. 87PDF Image | Concentrating Solar Power
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