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UNDERTAKING REGARDING ANTI-PLAGIARISM
I, hereby, declare that the material/content presented in the dissertation is free from plagiarism
and is properly cited and written in my own words. In case, plagiarism is detected at any stage, I
shall be solely responsible for it.
Signature of Student
Kashika Baranwal
04902082013
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CERTIFICATE
I hereby declare that the work presented here in the report has been carried out by me towards
the partial fulfillment of the requirements for the award of MASTER OF TECHNOLOGY in
Robotics and Automation at Indira Gandhi Delhi Technical University for Women, Delhi. The
material taken from other sources has been acknowledged. The results presented in this report
have not been submitted in part or full to any other university or institute for the award of any
degree.
(Kashika Baranwal)
04902082013
Date: 12.06.2015
This is to certify that project report entitled "Simultaneous Electricity Generation and
Hydrogen Production Using an Automatically Guided Solar System" being submitted by
Ms. Kashika Baranwal (04902082013) to the Department of Mechanical and Automation
Engineering, Indira Gandhi Delhi Technical University for Women, Delhi in partial fulfillment
of the requirements for the award of MASTER OF TECHNOLOGY in Robotics and Automation
is a record of the Dissertation work carried out by her under my guidance and supervision.
(Dr. O.K Singh)
Assistant Professor
Department of Mechanical & Automation Engineering,
Indira Gandhi Delhi Technical University for Women,
Kashmere Gate,
Delhi - 110006
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ACKNOWLEDGEMENTS
It has been a great pleasure working with the faculty, staff, and students at Indira Gandhi Delhi
Technical University for Women, Delhi, during my dissertation work. I would like to thank Head
of the Department, Dr. Nathiram Chauhan and various faculty members of the university who
helped me creating this project. I would also like to thank my supervisor Dr. O. K. Singh whose
supervision and suggestions helped me in making this project success. It has been an honor to
work under his guidance. He taught me the meaning of research and experimentation. I
appreciate all his contributions of ideas, dedication and time to make my experience productive.
Furthermore, I would like to thank my uncle and friends for their continuous support and
everlasting help throughout this project work.
KASHIKA BARANWAL
04902082013
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ABSTRACT
This project develops a methodology for the cogeneration system that employs solar energy for
electricity and hydrogen production. It deals with the design and construction of a small PV
system for hydrogen production equipped with a dual axis solar tracker system. The photovoltaic
module is connected to the hydrogen electrolyzer and its direction is controlled with the help of a
dual axis solar tracker. The amount of gas produced from electrolyzer unit is evaluated and the
performance of solar tracker is also inspected. The experimental setup raises good results for the
hydrogen production when PV is operated with dual axis solar tracker instead of connected
directly.
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LIST OF FIGURES
Figure 1.1 Global growth rate of electricity consumption in India..................................................1
Figure 1.2 Carbon emissions from conventional power generation................................................2
Figure 1.3 Solar radiation spectrum.................................................................................................4
Figure 1.4 Azimuth and Altitude angle............................................................................................6
Figure 1.5 Zenith angle....................................................................................................................7
Figure 1.6 Air mass of the atmosphere............................................................................................7
Figure 1.7 Phenomenon causing losses in irradiance......................................................................9
Figure 1.8 Revolution in solar-PV technology..............................................................................12
Figure 1.9 Global electricity generation from solar-PV from 2004 to 2013.................................12
Figure 1.10 Solar Water Heater.....................................................................................................14
Figure 2.1 An active solar tracker..................................................................................................18
Figure 2.2 A passive solar tracker..................................................................................................19
Figure 2.3 Single axis solar tracking..............................................................................................20
Figure 2.4 Dual axis solar tracking................................................................................................21
Figure 3.1 Block diagram of proposed design...............................................................................28
Figure 3.2 Work flow of proposed design ....................................................................................30
Figure 4.1 Mechanical structure for tracker...................................................................................32
Figure 4.2 Developed model of mechanical structure...................................................................33
Figure 4.3 SolidWorks model of mechanical structure in X, Y, Z-coordinates............................34
Figure 4.4 Rotated view of mechanical structure in solidworks....................................................34
Figure 4.5 Front view of mechanical structure in solidworks.......................................................35
Figure 4.6 Counter load used in mechanical structure...................................................................39
Figure 4.7 Counter Weight Calculations.......................................................................................40
Figure 5.1 Electrolysis Unit...........................................................................................................43
Figure 5.2 Block diagram of PV-Electrolysis................................................................................44
Figure 5.3 Fuel Cell.......................................................................................................................49
Figure 5.4 Proposed design for electrolyzer..................................................................................52
Figure 5.5 Actual Experimental setup of electrolyzer...................................................................53
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Figure 5.6 Actual Graphit Electrode..............................................................................................58
Figure 5.7 Graphite electrodes placed at the base of container.....................................................58
Figure 5.8 Pressure Gauge.............................................................................................................59
Figure 6.1 Proposed Circuit Diagram of solar tracker...................................................................61
Figure 6.2 Circuit diagram of solar tracker in Proteus...................................................................61
Figure 6.3 DC gear motor..............................................................................................................63
Figure 6.4 Equivalent circuit diagram of DC motor.....................................................................64
Figure 6.5 Torque Speed curve of DC motor..............................................................................67
Figure 6.6 Light dependent resistor...............................................................................................68
Figure 6.7 Comparator IC-LM339.................................................................................................69
Figure 6.8 Pin Description of LM 339...........................................................................................69
Figure 6.9 Relays...........................................................................................................................71
Figure 6.10 Pin diagram of relay...................................................................................................71
Figure 6.11 Resistor.......................................................................................................................72
Figure 6.12 Transistor....................................................................................................................72
Figure 6.13 Pin diagram of diode..................................................................................................73
Figure 6.14 7805 Voltage Regulator..............................................................................................74
Figure 6.15 Buck Converter IC.....................................................................................................75
Figure 6.16 Operation of Buck Converter in On state...................................................................76
Figure 6.17 Operation of Buck Converter in Off state..................................................................77
Figure 6.18 Graph showing output of Buck Converter..................................................................78
Figure 6.19 Dotted and Layout PCB..............................................................................................80
Figure 6.20 Storage Battery...........................................................................................................81
Figure 6.21 Charge controller........................................................................................................83
Figure 6.22 Stages of charging in a controller...............................................................................83
Figure 6.23 Ammeter and Voltmeter connection with load..........................................................85
Figure 6.24 Connection of charge controller with battery and load..............................................88
Figure 7.1 Cross section of a solar cell..........................................................................................92
Figure 7.2 Equivalent Diagram of a solar cell...............................................................................95
Figure 7.3 I-V characteristic of solar cell......................................................................................97
Figure 7.4 Fill Factor comparison of two solar cells.....................................................................99
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Figure 7.5 Operation of solar cell in different region of P-V curve............................................100
Figure 7.6 Effect of temperature on I-V characteristic of solar cell............................................104
Figure 7.7 Steps for installing a solar-PV system at home..........................................................107
Figure 8.1 Experimental setup of the developed model..............................................................110
Figure 8.2 Signal flow in the developed model...........................................................................111
Figure 8.3 Monthly line graph of GHI in New Delhi..................................................................114
Figure 8.4 Monthly line graph of DNI in New Delhi..................................................................115
Figure 8.5 Monthly line graph of DHI in New Delhi..................................................................116
Figure 8.6 Monthly step line graphs of GHI, DNI, DHI in New Delhi.......................................117
Figure 8.7 Duration curve of GHI in New Delhi.........................................................................118
Figure 8.8 Duration curve of GHI, DNI, DHI in New Delhi.......................................................119
Figure 8.9 Monthly weather profiles in New Delhi showing GHI, DNI, DHI............................120
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LIST OF TABLES
Table 1.1 Technical data for weather of New Delhi using IMD-MNRE database........................09
Table 1.2 Monthly Data of Average GHI and DNI for New Delhi...............................................10
Table 1.3 Examples of solar power applications......................................................................10-11
Table 4.1 Components used in Mechanical Structure with Specifications..............................36-37
Table 5.1 Material used in Electrolyzer with Specifications.........................................................57
Table 6.1 Operating Principle of Solar Tracker.............................................................................60
Table 6.2 Speed and Power calculations of motors.......................................................................67
Table 6.3 Pin Description of LM 339............................................................................................70
Table 6.4 Technical data of solar panel at STC.............................................................................80
Table 6.5 Depth of Discharge for a 12 Volt Battery......................................................................82
Table 6.6 Recorded Data for Power Consumption........................................................................85
Table 6.7 Data for 60lculation of energy requirement...................................................................86
Table 6.8 Optimal Rule for Tilt Angle Selection...........................................................................90
Table 7.1 Residential Solar PV Installation Cost.........................................................................108
Table 9.1 Bill of Material for the model......................................................................................122
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NOMENCLATURE
PV Photovoltaic
AM Air Mass
GHI Global Horizontal Irradiance
DNI Direct Normal Irradiance
DHI Diffuse Horizontal Irradiance
DC Direct Current
w1 Weight of solar panel (Kg)
w2 Weight of counter load (Kg)
d1 Distance of panel from pivot (cm)
d2 Distance of counter weight from pivot (cm)
T1 Torque for panel (N-m)
T2 Torque for counter weight (N-m)
H2 Hydrogen gas
O2 Oxygen gas
H2O Water molecule
R Electrical Resistance of Electrolyzer ()
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l distance between two electrodes (cm)
Ae Area of cylindrical electrode (m2)
p Developed pressure of gas (Pa)
V Volume of gas produced (m3)
x height of the topf of the container above water level (m)
Ac Area of aluminium container (m2)
m mass of gas produced (Kg)
U Universal/molar gas constant
R Characteristic gas constant
T Temperature of gas (K)
LDR Light Dependent Resistor
V1 Voltage developed by LDR-1 (Volts)
V2 Voltage developed by LDR-2 (Volts)
V3 Voltage developed by LDR-3 (Volts)
V4 Voltage developed by LDR-4 (Volts)
PCB Printed Circuit Board
GND Ground
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NO Normally Open
NC Normally Closed
COM Common
Pg Effective Mechanical Torque of d.c. motor
RPM Rotations per minute
N Speed of d.c. motor (RPM)
Tg Genarated torque in d.c. motor
w Speed of d.c. motor (radian/sec)
E Supply Voltage for d.c. motor
Eb Back emf developed in d.c. motor
Ia Armature current of d.c. motor
Ra Armature resistance of d.c. motor
Pn No. of poles
Z Numer of conductors
Ap Number of parallel paths
ka D.C. motor constant
Vi Input voltage for buck converter
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Vo Output voltage for buck converter
Vl Inductor voltage in buck converter
T One complete cycle period
TON On state of buck converter
TOFF Off state of buck converter
Imx Maximum charging current of inductor
Imn Minimum charging current of inductor
Iav average charging current of inductor
t time
Rs Series resistance of solar panel
Rsh Shunt resistance of solar panel
MPP Maximum power point
Pm Maximum power point of solar panel
ID Diode current in solar cell
VD Diode voltage in solar cell
Im Maximum current at MPP (Amps)
Vm Maximum voltage at MPP (Volts)
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Iph Current due to photovoltaic action (Amps)
IL Load current of solar pane (Amps)
VL Load voltage of solar panel (Volts)
Voc Open circuit voltage of solar panel (Volts)
Isc Short circuit current of solar panel (Amps)
FF Form factor of solar panel
Pin Power input from sun (Watts)
E Input light to solar cell (Watts/m2)
Ac Effective surface area of solar cell (m2)
STC Standard test conditions
PWM Pulse width modulation
Greek letters
1 Angle of orientation of panel
2 Angle of orientation of counter weight
Azimuth Angle
Resistivity of electrolyte solution
Flux per pole
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Duty cycle
Efficiency of of solar panel (%)
Pi (3.14)
Subscripts
g For gas
l For liquid
aq For aqueous solution
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CONTENTS
Under Taking Regarding Anti-Pla giarism i
Certificate ii
Acknowledgements iii
Abstract iv
List of Figures v-vii
List of Tables viii
Nomenclature ix-xiv
CHAPTER 1 INTRODUCTION 1-16
1.1 Solar Energy 1
1.2 Solar Irradiance 5
1.3 Solar Energy Applications 10
1.3.1 Solar PV Systems 11
1.3.1.1 Industrial Applications 13
1.3.1.2 Social Applications 13
1.3.1.3 Consumer Applications 13
1.3.2 Solar Thermal Systems 13
1.3.2.1 Solar Thermal Power Plants 14
1.3.2.2 Solar Water Heating 14
1.3.2.3 Solar Drying 15
1.3.2.4 Solar Cooling 15
1.4 Solar Cogeneration 16
CHAPTER 2 LITERATURE REVIEW 17-26
2.1 Solar Tracker 17
2.2 Overview of Tracking Techniques 17
2.2.1 Types of Tracker Actuator Driver 17
2.2.1.1 Active Tracker 18
2.2.1.2 Passive Tracker 18
2.2.2 Types of Solar Tracker Axis 19
2.2.2.1 Single Axis Tracker 19
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2.2.2.2 Dual Axis Tracker 20
2.3 Research Methodologies of Various Researchers 21
2.4 Problem Formulation & Aim of the Project 25
CHAPTER 3 PROPOSED METHODOLOGY 27-30
3.1 Block diagram 27
3.2 Thesis Outline 29
3.3 Work Flow 30
CHAPTER 4 STRUCTURAL DESIGN 31-41
4.1 SolidWorks 31
4.2 Mechanical Structure 31
4.2.1 Selection of Hollow Shaft over Solid Shaft 35
4.3 Materials & Components Used 36
4.3.1 Galvanized Iron 37
4.3.2 Mild Steel 38
4.3.3 Clamps 38
4.3.4 Bearings 38
4.4 Concept of Counter Load 39
CHAPTER 5 HYDROGEN & OXYGEN PRODUCTION 42-59
5.1 Electrolysis of Water 42
5.1.1 PV-Electrolysis 43
5.2 Factors Affecting Efficiency of the Electrolyzer 44
5.2.1 Electrolytic Selection 45
5.2.2 Temperature 45
5.2.3 Electrical Resistance of the Electrolyte 46
5.2.4 Space between the Electrodes 46
5.2.5 Size & Alignment of the Electrodes 47
5.2.6 Electrode Material 47
5.3 The Hydrogen 47
5.3.1 Research Challenges 48
5.3.2 Safety 48
5.3.3 Markets for Hydrogen 48
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5.3.3.1 Power Generation 49
5.3.3.2 Transportation 51
5.3.3.3 Others 51
5.4 The Oxygen 52
5.5 Experimental Setup 53
5.5.1 Mass Calculation for H2 & O2 57
5.5.2 Materials Used 58
5.2.1.1 Electrode 58
5.2.1.2 Electrolyte 59
5.2.1.3 Pressure Gauge 59
CHAPTER 6 CONTROL & INSTRUMENTATION 60-190
6.1 Principle of Operation 60
6.2 Circuit Diagram of the Tracker 61
6.3 Components Used 63
6.3.1 DC Motor & Motor Driver 63
6.3.2 Sensors 68
6.3.3 LM339 Comparator IC 69
6.3.4 Relays 70
6.3.5 Resistor 71
6.3.6 Transistor 72
6.3.7 Diode (IN4001) 73
6.3.8 Buck Converter 73
6.3.9 PCB Design 74
6.3.10 Solar panel 79
6.3.11 Storage Battery 80
6.3.12 Charge Controller 81
6.4 Panel Selection 82
6.4.1 Calculation of Power Consumption of Solar
Tracker & Electrolysis Unit
84
6.4.2 Battery Selection 84
6.4.2.1 Calculation of Daily Energy Use 86
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6.4.2.2 Days of Autonomy 86
6.4.2.3 Battery Bank Capacity 87
6.4.2.4 How to connect Solar Panel, Battery
and Charge Controller
88
6.4.3 PV Selection 88
6.4.3.1 PV Sizing 89
6.4.3.2 PV Orientation 89
CHAPTER 7 SOLAR PANEL/CELL 91-108
7.1 Solar Panel 91
7.2 Photovoltaic Cell 91
7.3 Principle of Operation 92
7.4 Equivalent Circuit of PV Cell 94
7.5 I-V Characteristics 96
7.6 Fill Factor of Solar Panel 98
7.7 MPPT Tracking 99
7.8 Efficiency of the Solar Cell/ Panel 101
7.9 Factors Affecting the Characteristics of Panel 103
7.9.1 Light Intensity 103
7.9.2 Temperature 103
7.9.3 Series and Shunt Resistance 104
7.9.4 Shading 105
7.10 Solar Photovoltaic Technologies 106
7.10.1 Crystalline Technology 106
7.10.2 Thin Film Technology 106
7.11 Solar Photovoltaic for Home 107
CHAPTER 8 EXPERIMENTATION, RESULTS & DISCUSSIONS 109-121
8.1 Experimental Setup 109
8.1.1 Experiment 112
8.2 Results 112
8.2.1 Solar Irradiance Curve by system Advisor Model,
2014.1.14
112
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8.3 Discussions 121
CHAPTER 9 CONCLUSION & FUTURE WORK 122-124
9.1 Bill of Material 109
9.2 Conclusion 112
9.2.1 Solar Tracker Model 112
9.2.2 Electrolyzer Model 112
9.3 Recommendations & Future Work 121
REFERENCES 125-128