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procedures for qualification and rating of polymer-based systems. • Manufacturing. Design and implementation of manufacturing will be funded mostly by industry partners. Assistance will be provided for those aspects that are novel and necessary to achieve the low-cost goals. For rotomolded PICS, manufacturing support is minimal. For the extruded PICS, assistance will be provided for developing the tank manifold welding and fabricating the heat exchanger. Cold-Climate SWH and CHC Tasks. As with SWH systems for warm climates, the Stage Gate technology development approach for cold climates involves four phases: moving from initial concepts through prototype and engineering development to final product testing and manufacturing development. Descriptions of specific technical issues and tasks follow. Approaches proven successful in the polymer systems for warm-climate work will lower development costs. Unit-area system cost should be reduced at least 50% for cold-climate SWH and at least 80% for CHC (including roofing credits). The tasks are first described for SHW, followed by tasks unique to CHC. Similarly, the task tables are first laid out for SWH (Table 3.3.8-1), followed by tasks unique to CHC (Table 3.3.8-2). Cold-Climate SWH Tasks Collector Tier-1 TIO 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 strength is reduced 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 ensure reliability while minimizing materials. • Glazings. UV degradation testing of coated polycarbonate sheets has been ongoing. Thin-film glazings (e.g., fluorocarbons such as 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. Due to low thermal conductivity (3 orders of magnitude below 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 polymer ICS systems 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 polymer ICS system development indicates that if the collector bottom is corrugated, roof drying is adequate when mounting the collector flat on the roof. This simplifies the mounting procedure. Storage Tier-1 TIO • For active systems with storage separate from collector, storage is a major cost component. Storage cost can be significantly reduced 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 (rotomolded 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, materials tested, prototypes built, and manufacturing optimized. 93PDF Image | Concentrating Solar Power
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