team tidewater virginia integrated solar thermal system (2)

canopyhouse.org

BEMIS LABORATORIES HAMPTON UNIVERSITY HAMPTON, VA

23669

(T) 757.727.5442 (E) [email protected]

2013

Taylor McLemore & Horace Woolard

Team Tidewater Virginia

7/16/2013

Team Tidewater Virginia Integrated Solar Thermal System

HAMPTON UNIVERSITY &

OLD DOMINION UNIVERSITY

canopyhouse.org BEMIS LABORATORIES HAMPTON UNIVERSITY

HAMPTON, VA 23669


Table of Contents

Team Tidewater Virginia Solar Thermal System Proposal .................................................................. 1

Solar Thermal System Line Diagram ............................................................................................................. 5

Solar Thermal System Description ................................................................................................................ 6

PureTemp 53 Technical Data Sheet .............................................................................................................. 7

PureTemp 53 Safety Data Sheet ...................................................................................................................... 8

PureTemp PCM Sphere Analysis .................................................................................................................. 12

Solar Thermal System Simulation ................................................................................................................ 19

SunDrum Technical Data Sheet ..................................................................................................................... 25

Bosch WST 50 Technical Data Sheet ........................................................................................................... 27

Buderus Hot Water Tank Technical Data Sheet ...................................................................................... 31

Bosch KS Pump Station Technical Data Sheet ......................................................................................... 34

Bosch SBU Technical Data Sheet ................................................................................................................... 40

Grundfos Alpha 15-55SF Technical Data Sheet ...................................................................................... 43

REHAU PRO_BALANCE Mixing Module ...................................................................................................... 45

Bosch Logalux Membrane Expansion Tank Technical Data Sheet .................................................. 46

Resources ............................................................................................................................................................... 48

ble of Contents

No table of contents entries found.

Integrated Solar Thermal System HAMPTON UNIVERSITY & OLD

DOMINION UNIVERSITY

TEAM TIDEWATER

By Taylor McLemore and Horace Woolard


HAMPTON, VA 23669


TEAM TIDEWATER

HAMPTON UNIVERSITY & OLD DOMINION

UNIVERSITY

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Team Tidewater Virginia Solar Thermal System Proposal

The U.S. Department of Energy, Solar Decathlon, challenges university teams to design,

build, and operate solar-powered houses that are affordable, energy-efficient, and attractive. The

winner of the competition is the team that best blends cost-effectiveness, consumer appeal, and

design excellence with optimal energy production and maximum efficiency. The Solar Decathlon

2013 competition will take place October 3-13, 2013 in Irvine, California. Old Dominion and

Hampton University have joined together in this competition to form Team Tidewater Virginia.

For the 2013 Department of Energy Solar Decathlon, Team Tidewater Virginia has designed

built the Canopy House. Just as the canopy of a tree is a protective, sunlight-filled haven, the Canopy

House is a safe, universally designed, solar-powered dwelling. The Canopy House's smart home

technology allows its owners to live an independent lifestyle and age-in-place. The Canopy House

harmonizes two of Team Tidewater’s most important values: design in response to the

environment and design for all. Drawing from the principles of Universal Design, the Canopy House

strives to make sustainable living accessible to all people, regardless of physical impairments and

limitations. The design harnesses the power of the sun, both as an energy-efficient method for

providing heat and electricity, and as an integral foundation for the home’s innovative

technology. Through this technology, the house aims to instruct the user about living sustainably as

well as to provide the tools to lead a safe and independent lifestyle.

The competition requires each team to produce energy, using photovoltaic systems that will

sustain “net zero” or better energy consumption, maintain comfortable and healthy indoor

environmental conditions, supply energy to household appliances for cooking, cleaning, and

entertainment, and provide adequate hot water while complying with the Solar Decathlons strict

rules and regulations. By integrating and testing numerous combinations of proposed sub-systems,

http://www.canopyhouse.org/


http://www.canopyhouse.org/concept.html


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Team Tidewater expects to perform optimally. One of the major engineering innovations of the

team is the use of an Integrated Solar Thermal System. By using the sun to heat water, the Canopy

House is able to use significantly less energy when compared to using electricity to heat water.

The main component of our schematic system will be a hybrid photovoltaic-solar thermal

collector, the solar thermal component manufactured by SunDrum. This system will not only cool

our PV panels for improved efficiency but it will also allow us to integrate a large amount of thermal

energy into our hot water system design. The sustainable thermal energy will be directed to a

storage tank enclosed with PureTemp’s renewable based phase change material, or PCM. This PCM

is made from a “green” technology, converting vegetable based feedstock into PCM through a

patented and proprietary manufacturing process. This specific heat sink will then be our primary

source for our domestic hot water. To insure that an adequate temperature is met, Team Tidewater

will have an electrical water heater in case of emergency. It is expected that a sufficient amount of

thermal energy will be produced by incorporating 8 SunDrum collectors, allowing Team

Tidewater’s engineer’s schematic design to incorporate radiant floor heating as an additional

source for excess thermal energy. This final addition will optimize the use of SunDrum’s thermal

energy by heating the house. The design of Canopy House

includes a hybrid photovoltaic-solar thermal collector

manufactured by SunDrum® (SunDrum Solar, LLC, Hudson,

MA) as shown in Figure 1. The SunDrum system was selected

over conventional thermal collectors because provides “free”

thermal energy. However, it does not decrease the amount of

area available for photovoltaic panels.

Figure 1. SunDrum Solar

Collector


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Figure 2. SunDrum Total Energy Advantage

A second benefit of the SunDrum system is that it improves the efficiency of the attached

solar panels by cooling them. As seen in Figure 2, by flowing cooler water through the SunDrum’s,

the efficiency of the solar panels is increased due to the cooling from the SunDrum’s. Though

several other companies produce similar products, Team Tidewater elected to use SunDrum due to

various cost constraints.


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1 Therms = 29.3 kWh or 105,480,400 J

Competition duration during the month of

October

17 therms =1.793 GJ

8 SunDrum units

8*1.793 GJ =14.344 GJ / (31 days in October) =

462.753 MJ average thermal energy per day

produced by 8 SunDrum units.

Several theoretical calculations were generated in order to estimate the thermal energy

production of 8 SunDrum panels. Table 1 shows the amount of thermal energy SunDrum Solar

indicates they will produce during optimal conditions.

SunDrum Calculations

Month Energy Production (Therms)

1 13

2 13

3 18

4 20

5 20

6 20

7 22

8 23

9 19

10 17

11 15

12 13

Table 1 SunDrum Thermal Production


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BOSCH SBU BOSCH WST 50 GRUNDFOS PUMP

LOGALUX SM300 (PCM TANK) RADIANT FLOOR PUMP

1.) TO PCM TANK BOTTOM COIL

2.) FROM PCM TANK BOTTOM COIL

3.) TO WST 50 COIL

4.) FROM WST 50 COIL

5.) FROM BOSCH SBU 6.) TO PUMP/ PCM

TANK 7.) TO BOSCH SBU 8.) COLD WATER

INLET/ FROM PCM TANK

9.) DOMESTIC HOT WATER OUTLET

10.) FROM WST 50 COIL

11.) TO PCM TANK TOP COIL

12.) FROM RADIANT FLOOR PUMP

13.) TO BOSCH SBU 14.) FROM BOSCH SBU 15.) FROM PUMP/DOMESTIC

COLD WATER 16.) TO BOSCH WST 50 17.) TO RADIANT FLOOR PUMP

18.) FROM PCM TANK

19.) TO PCM TANK

Solar Thermal System Line Diagram


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Solar Thermal System Description

For this description, I will be using Team Tidewater Virginia’s Solar Thermal System

Line Diagram which is shown on page 5 of this document. Below is a step-by-step

description of how the system works along with the installation of the PCM (phase change

material) within the system.

To start the overall system, the water from the sundrum panels, shown on the top of

the line diagram, will pass through the KS Pump Station directly to the SBU. The SBU will

choose which direction the hot water from the panels will go. The water will either go

through the bottom of the SBU to the hot water tank, Bosch WST 50, or through the left side

of the SBU to the PCM Tank, Logalux SM300. For each tank, the hot water from the

sundrum will flow through a coil that will heat the water inside the tank. For the PCM Tank,

the bottom coil will be used to heat the water from the sundrum panels. The radiant floor

system will be heated with the PCM tank by pumping in the cooler water in the bottom and

taking the warmer water from the top. The top coil of the PCM Tank will be used to transfer

the heat within the tank to the WST 50. This system can work in one of two ways. The first

way includes supplying the PCM tank top coil with domestic cold water which will be pre-

heated and then added into the WST 50. The second way is to pump water from the WST

50 through the top coil of the PCM Tank to be heated and then inserted back into the WST

50. Using a coil to transfer the heat from the PCM Tank to the WST 50 creates a safety

barrier between the PCM and the potable water.

For the installation of the PCM into the PCM Tank, we will first remove the front

access panel of the PCM Tank. We will then put PCM filled spheres that are 4” in diameter

in the tank which will float to the top when the tank is filled with water. The spheres are

made of HDPE, high-density polyethylene, which serves as the containment of the PCM

from the water. The PCM is inserted into the spheres in liquid form. The sealing of the plug

occurs after the PCM has solidified in order to prevent the sphere from breaking when the

PCM expands or contracts. The sealant is polyethylene and therefore can withstand

identical conditions experienced by the sphere. The HDPE spheres are chemical resistant

and do not absorb any liquid. For the PCM, we will be using Puretemp 53 from Entropy

Solutions. Puretemp currently has a trade secret on the composition of Puretemp 53. The

data sheet, safety data sheet, and PCM analysis are included in this document for further

information.


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PureTemp 53 Technical Data Sheet


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PureTemp PCM Sphere Analysis Intro: This analysis is provided to ensure that the PCM balls contained within the secondary hot water tank will be safe during operation. In order for the PCM balls to be considered safe during operation we must conclude that the yield stress of the PCM ball is greater than the stress the ball will undergo at the system’s most extreme operating conditions. Information: The PCM is encapsulated in a ball of high density polyethylene (HDPE). The ball has the following properties (which can be found on the company’s website http://cicball.thomasnet.com/item/hollow-plastic-balls/hdpe-hollow-balls/pn-1140?): Outer Diameter: d_0 = 4 in = 0.1016 m Material Thickness: t = 1.4 mm = 0.0014 m Max. Operating Temp: T_max = 180 oF = 82 oC The analysis also requires the ultimate stress of HDPE (found in “Foundations of Materials Science and Engineering” 4th Ed, by William F. Smith and Javad Hashemi, Pg. 949) and a couple other key properties of air (found in “Fundamentals of Thermodynamics” SI Version, 7th Ed, by Claus Borgnakke and Richard E. Sonntag, Pg. 686). Ultimate Stress: σ_yield = 16 MPa = 16,000,000 Pa Gas Constant of Air: R = 287 J/kg/K Density of Air at 25 deg C: ρ_a_25 = 1.169 kg/m3

Experiment: In order to properly evaluate the stress the HDPE will undergo we will also require the volume of the PCM during both its liquid and solid states. The mass of PCM contained in each ball is given to be m_PCM = 0.45466 kg. In the experiment we heated the PCM ball in liquid water until all of the PCM was melted. At this point we carefully cut a hole in the ball and emptied the contents into 5 graduated cylinders, measured their volumes, let them cool, and then measured their volumes again. We chose to measure the volume change in 5 different cylinders so we could take the results and find an experimental average in volume change. Below are the results of our experiment.

Liquid PCM Solid PCM % Dif

Graduated Cylinder Volume (ml) Volume (ml)

25 ml (inc = 0.2 ml) 15.3 14.9 2.61438

25 ml (inc = 0.2 ml) 14.4 13.8 4.16667

25 ml (inc = 0.2 ml) 9.9 9.6 3.0303

10 ml (inc = 0.1 ml) 4.65 4.5 3.22581

500 ml (inc = 5.0 ml) 415 400 3.61446

http://cicball.thomasnet.com/item/hollow-plastic-balls/hdpe-hollow-balls/pn-1140


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From the results of the experiment we calculated the following: Total volume of liquid PCM: V_liq = 459.25 ml = 0.00045925 m3

Average % difference from liquid to solid: % dif = 3.330323 %

We are now able to calculate the volume of solid PCM as follows: Total volume of solid PCM: V_sol = (V_liq) – (V_liq) * (% dif) V_sol = 0.000443955 m3

The experiment also revealed a small cylindrical notch inside the sphere. This was discovered when we cut the hole in the sphere. In order for our experiment to be as accurate as possible we also take this small volume into account. The notch was very close to having a cylindrical shape and thus will be approximated as a cylinder with measurements height = 0.0121 meters and diameter = 0.008 meters. Thus the volume of this miscellaneous piece was found to be: V_misc = (0.0121) * (π/4) * (0.008)^2 V_misc = 6.0821*10^-7 m3

Next we find the total volume the PCM and air can occupy within the sphere. To find this we must subtract the thickness of the HDPE from the radius of the sphere and remove the miscellaneous volume occupied by the notch within the sphere:

V_total = {(4/3)* π * ([d_0/2] – t)^3} – (V_misc) V_total = 0.000504366 m3

Assumptions: In this experiment we assume that the sphere was filled with 0.45466 kg of PCM, (which is equivalent to 0.00045925 cubic meters) and then allowed to cool to room temperature, (25 degrees Celsius), before the sphere was sealed. (This was the process that was described to us by Entropy Solutions, however they were not able to provide us with documentation of this). Thus the volume occupied by the solid PCM upon sealing the sphere was V_sol = 0.000443955 cubic meters. We calculate the mass of air that was left to occupy the remaining space within the ball during the sealing process. We assume the air was at a room temperature of 25 degrees Celsius. It is also important to note that the gauge pressure inside the vessel under these conditions will be equal to zero, thus P1 = 0 Pa. V1_air = (V_total) – (V_sol) = (0.000504366 m^3) – (0.000443955 m^3) V1_air = 6.04108*10^-5 m^3 m_air = (ρ_a_25) * (V1_air) = (1.169 kg/m^3) * (6.04108*10^-5 m^3) m_air = 7.06202*10^-5 kg


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Because the ball is sealed at these conditions the mass of the air will remain constant. This allows us to find the volume the air will occupy when the PCM is in its liquid state. V2_air = (V_total) – (V_liq) = (0.000504366 m^3) – (0.00045925 m^3) V2_air = 4.51163*10^-5 m^3 We now calculate the gage pressure inside the ball due to the expansion of the PCM. For this part we will assume that air is an ideal gas and thus use the ideal gas equation (found in “Fundamentals of Thermodynamics” SI Version, 7th Ed, by Claus Borgnakke and Richard E. Sonntag, Pg. 61), with T2 = 82 deg Celsius (the maximum operating temperature of the PCM). We will also assume that PCM (in its liquid state) can be treated as an incompressible fluid. P2 = [(m_air) * (R) * (T2)] / (V2_air)

= [(7.06202*10^-5 kg) * (287 J/kg/K) * (355.15 K)] / (4.51163*10^-5 m^3)

P2 = 159,547.2801 Pa Other Important Details: The PCM balls will be located inside the Buderus hot water tank and submersed in the working fluid of the Rehau panel radiant flooring system. Thus our operating conditions must accommodate all of these products. The maximum temperature of both of these systems is greater than the operating temperature of the PCM (82 degrees Celsius). Thus the maximum operating temperature of the system must be set at this temperature. The maximum operating pressure of the Rehau panel at 82 degrees Celsius is 690 kPa; this increases as temperature is lowered, thus we will use 82 deg C as our standard. It is also important to note that the Buderus tank itself does not need to be pressurized; however the maximum operating pressure of the tank is 1 MPa. Due to the design of our system, the pressure of the Rehau panel directly depends on the pressure inside the Buderus tank and the minimum pressure required to move the working fluid through the 236 feet of PEX tubing (called head loss). The maximum head loss the system will need to overcome (found on page 22 of the Rehau installation guide, using 100% water as the working fluid and a PEX length of 250 ft.) is 31.41 ft. head. We convert this pressure to Pascal’s for convenience: Head (psi) = head (ft.) * (specific gravity) * density of water (lb./ft^3) = (31.41 ft.) * (1) * (62.4 lb./ft^3) / (1 ft. / 12 in)^2 = 13.61 psi = 92.458 kPa

P_headloss = 92.458 kPa


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We now find the maximum pressure of the tank as not to exceed the maximum pressure of the Rehau panel and still enable the additional pressure required by the pump to accommodate the working fluid. P_tank_max = P_Rahue – P_headloss = (690 kPa) – (92.458 kPa) P_tank_max = 597.542 kPa Analysis:

We will model the sphere as a thin-walled pressure vessel, (found in Shigley’s Mechanical Engineering Design” 9th Ed (SI units), by Richard G. Budynas and J. Keith Nisbett, Pg. 114).

σ _actual = (ΔP) * (d_0) / (2 * t) It is important that we understand how this equation works for our analysis. The actual

pressure the PCM ball experiences is the difference between the pressure inside of the sphere and inside of the tank. Thus:

ΔP = P_actual = P_Sphere – P_tank The pressure in the sphere depends on the tank temperature and the state of the phase

change material in the sphere. Thus: P_Sphere = [(m_air) * (R) * (T_tank)] / V_air We analyze the stress on the sphere by varying the operating pressure of the tank at three

different temperatures: T_min, T_max and at the phase change temperature (53 deg C). These temperatures were selected as they represent the extreme conditions of the system and will vary linearly at all points in-between. The phase change temperature will be analyzed twice, once assuming completely liquid PCM and a second assuming completely solid PCM. Thus the general equation we use for analysis will have two different forms depending on the temperature we are analyzing:

T_tank ≤ 53 deg C: σ _actual = {[(m_air) * (R) * (T_tank)] / V1_air) – P_tank} * (d_0) / (2 * t)

T_tank ≥ 53 deg C: σ _actual = {[(m_air) * (R) * (T_tank)] / V2_air) – P_tank} * (d_0) / (2 * t)

Because the tank pressure is an independent variable we will select it last and vary it to see the impact it has on the factor of safety. We first determine if the factor of safety is adequate to withstand the stress at each of these conditions. If it is in fact adequate, we use the tank pressure that yields the highest factor of safety for all conditions. *Note: We avoid selecting a tank pressure which yields a factor of safety that changes from positive to negative in the working temperature


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range. This implies a change from tension to compression within the ball and stands an increased chance of failing due to fatigue. Results:

Tank Pressure = 0 kPa

Air (m^3) Temp (C) P_Sphere (Pa) P_tank (Pa) σ _actual (Pa) Factor of Safety

Solid PCM 6.04E-05 25 0.00E+00 0 0.00 Approach Infinity

6.04E-05 53 9.39E+03 0 340870.93 46.94

Liquid PCM 4.51E-05 53 4.65E+04 0 1686889.71 9.48

4.51E-05 82 5.95E+04 0 2159617.40 7.41



Solid PCM 6.04E-05 25 0.00E+00 5000 -181428.57 -88.19

6.04E-05 53 9.39E+03 5000 159442.35 100.35

Liquid PCM 4.51E-05 53 4.65E+04 5000 1505461.14 10.63

4.51E-05 82 5.95E+04 5000 1978188.82 8.09



Solid PCM 6.04E-05 25 0.00E+00 10000 -362857.14 -44.09

6.04E-05 53 9.39E+03 10000 -21986.22 -727.73

Liquid PCM 4.51E-05 53 4.65E+04 10000 1324032.57 12.08

4.51E-05 82 5.95E+04 10000 1796760.25 8.90



Solid PCM 6.04E-05 25 0.00E+00 50000 -1814285.71 -8.82

6.04E-05 53 9.39E+03 50000 -1473414.79 -10.86

Liquid PCM 4.51E-05 53 4.65E+04 50000 -127396.00 -125.59

4.51E-05 82 5.95E+04 50000 345331.68 46.33



Solid PCM 6.04E-05 25 0.00E+00 60000 -2177142.86 -7.35

6.04E-05 53 9.39E+03 60000 -1836271.93 -8.71

Liquid PCM 4.51E-05 53 4.65E+04 60000 -490253.15 -32.64

4.51E-05 82 5.95E+04 60000 -17525.46 -912.96


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Solid PCM 6.04E-05 25 0.00E+00 100000 -3628571.43 -4.41

6.04E-05 53 9.39E+03 100000 -3287700.50 -4.87

Liquid PCM 4.51E-05 53 4.65E+04 100000 -1941681.72 -8.24

4.51E-05 82 5.95E+04 100000 -1468954.03 -10.89



Solid PCM 6.04E-05 25 0.00E+00 400000 -14514285.71 -1.10

6.04E-05 53 9.39E+03 400000 -14173414.79 -1.13

Liquid PCM 4.51E-05 53 4.65E+04 400000 -12827396.00 -1.25

4.51E-05 82 5.95E+04 400000 -12354668.32 -1.30



Solid PCM 6.04E-05 25 0.00E+00 400000 -14514285.71 -1.10

6.04E-05 53 9.39E+03 400000 -14173414.79 -1.13

Liquid PCM 4.51E-05 53 4.65E+04 400000 -12827396.00 -1.25

4.51E-05 82 5.95E+04 400000 -12354668.32 -1.30

Tank Pressure = 597.542 kPa


Solid PCM 6.04E-05 25 0.00E+00 597542 -21682238.29 -0.74

6.04E-05 53 9.39E+03 597542 -21341367.36 -0.75

Liquid PCM 4.51E-05 53 4.65E+04 597542 -19995348.58 -0.80

4.51E-05 82 5.95E+04 597542 -19522620.89 -0.82


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Discussion: From the chart we are able to quickly eliminate tank pressures of 200, 400, and 597.542 kPa as they all yield very low factor of safeties. A closer look also eliminates tank pressures of 5, 10, and 50 kPa as they each vary from positive to negative factor of safeties which we want to avoid due fatigue. Of the remaining 3 tank pressures (0, 60, and 100 kPa) we eliminate 100 kPa as it has lower factor of safeties for all temperatures than 60 kPa. The remaining two options are both adequate for use as the factor of safeties in both cases are more than sufficient at all temperature ranges. The difference between these two options is the tank pressure of 0 kPa holds the ball in constant tension and the tank pressure of 60 kPa holds the ball in constant compression. Also, a tank pressure of 0 kPa, on average, has higher factor of safeties through the operating temperature range. This selection also does not require the tank to be pressurized. Thus the PCM balls can be used with confidence within the given temperature range of 25oC – 82oC at a tank pressure of 0 kPa.

-1000

-800

-600

-400

-200

0

200

400

600

800

25 53 53 82

Fa

cto

r o

f S

afe

ty

Tank Temperature

PCM Analysis

0 kPa

6 kPa

10 kPa

50 kPa

60 kPa

100 kPa

200 kPa

400 kPa

597.542 kPa


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Solar Thermal System Simulation


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SunDrum Technical Data Sheet


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Bosch WST 50 Technical Data Sheet


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Buderus Hot Water Tank Technical Data Sheet


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Bosch KS Pump Station Technical Data Sheet


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Bosch SBU Technical Data Sheet


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Grundfos Alpha 15-55SF Technical Data Sheet


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REHAU PRO_BALANCE Mixing Module


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Bosch Logalux Membrane Expansion Tank Technical Data Sheet


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Resources:

http://www.solardecathlon.gov/


http://www.sundrumsolar.com/

http://www.puretemp.com/technology.html

http://www.bosch-home.com/us

http://www.bosch-climate.us/products-bosch-thermotechnology/indirect-storage-tanks/

http://www.bosch-climate.us/products-bosch-thermotechnology/solar-thermal-

system/solar-hydraulics/

http://www.buderus.us/residentialhomeowners/products/solarproducts.html

http://www.rehau.com/US_en/Construction/Radiant-Heating-and-

Cooling/Radiant_Heating/

http://us.grundfos.com/products/find-product/alpha.html

http://www.rehau.com/US_en/

http://www.solardecathlon.gov/


http://www.sundrumsolar.com/

http://www.puretemp.com/technology.html

http://www.bosch-home.com/us

http://www.bosch-climate.us/products-bosch-thermotechnology/indirect-storage-tanks/

http://www.bosch-climate.us/products-bosch-thermotechnology/solar-thermal-system/solar-hydraulics/

http://www.bosch-climate.us/products-bosch-thermotechnology/solar-thermal-system/solar-hydraulics/

http://www.buderus.us/residentialhomeowners/products/solarproducts.html

http://www.rehau.com/US_en/Construction/Radiant-Heating-and-Cooling/Radiant_Heating/

http://www.rehau.com/US_en/Construction/Radiant-Heating-and-Cooling/Radiant_Heating/

http://us.grundfos.com/products/find-product/alpha.html

http://www.rehau.com/US_en/

team tidewater virginia integrated solar thermal system (2)

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