Solar thermal collector

Solar thermal collectors are either non-concentrating or concentrating. In non-concentrating collectors, the aperture area (i.e., the area that receives the solar radiation) is roughly the same as the absorber area (i.e., the area absorbing the radiation). A common example of such a system is a metal plate that is painted a dark color to maximize the absorption of sunlight. The energy is then collected by cooling the plate with a working fluid, often water or glycol running in pipes attached to the plate.

Concentrating collectors have a much larger aperture than the absorber area. The aperture is typically in the form of a mirror that is focussed on the absorber, which in most cases are the pipes carrying the working fluid. Since the sun moves through the sky during the day, concentrating collectors often require some form of solar tracking system, and are sometimes referred to as "active" collectors for this reason.

Non-concentrating collectors are typically used in residential, industrial and commercial buildings for space heating, while concentrating collectors in concentrated solar power plants generate electricity by heating a heat-transfer fluid to drive a turbine connected to an electrical generator.

Heating water

Flat-plate and evacuated-tube solar collectors are mainly used to collect heat for space heating, domestic hot water, or cooling with an absorption chiller. In contrast to solar hot water panels, they use a circulating fluid to displace heat to a separated reservoir. The first solar thermal collector designed for building roofs was patented by William H. Goettl and called the "Solar heat collector and radiator for building roof".

Evacuated flat-plate solar collectors are a more recent innovation and can be used for Solar Heat for Industrial Cooling (SHIC) and Solar Air Conditioning (SAC), where temperature in excess of 100 °C (212 °F) are required. These non-concentrating collectors harvest both diffuse and direct light and can make use of steam instead of water as fluid.

Flat plate collectors

Flat-plate collectors are the most common solar thermal technology in Europe. They consist of (1) an enclosure containing (2) a dark-colored absorber plate with fluid circulation passageways, and (3) a transparent cover to allow transmission of solar energy into the enclosure. The sides and back of the enclosure are typically insulated to reduce heat loss to their surroundings. A heat transfer fluid is circulated through the absorber's fluid passageways to remove heat from the solar collector. The circulation fluid in tropical and sub-tropical climates is typically water. In climates where freezing is likely, a heat transfer fluid similar to an automotive antifreeze solution may be used instead of water, or in a mixture with water. If a heat transfer fluid is used, a heat exchanger is typically employed to transfer heat from the solar collector fluid to a hot water storage tank. The most common absorber design consists of copper tubing joined to a high conductivity metal sheet (copper or aluminum). A dark coating is applied to the sun-facing side of the absorber assembly to increase its absorption of solar energy. A common absorber coating is black enamel paint.

In higher performance solar collector designs, the transparent cover is tempered soda-lime glass having reduced iron oxide content same as for photovoltaic solar panels. The glass may also have a stippling pattern and one or two anti-reflective coatings to further enhance transparency. The absorber coating is typically a selective coating, where selective stands for having the special optical property to combine high absorption in the visible part of the electromagnetic spectrum coupled to low emittance in the infrared one. This creates a selective surface, which reduces black body energy emission from the absorber and improves performance. Piping can be laser or ultrasound welded to the absorber sheet to reduce damage to the selective coating, which is typically applied prior to joining to large coils in a roll-to-roll process.

Absorber piping configurations include:

• harp: traditional design with bottom pipe risers and top collection pipe, used in low pressure thermosyphon and pumped systems;
• serpentine: one continuous S-shaped pipe that maximises temperature but not total energy yield in variable flow systems, used in compact solar domestic hot water only systems (no space heating role);
• flooded: consisting of two sheets of metal molded to produce a wide circulation zone that improves heat transfer;
• boundary layer: consisting of several layers of transparent and opaque sheets that enable absorption in a boundary layer. Because the energy is absorbed in the boundary layer, heat conversion may be more efficient than for collectors where absorbed heat is conducted through a material before being accumulated in the circulating liquid.

A flat plate collector making use of a honeycomb structure to reduce heat loss also at the glass side too has also been made available commercially. Most flat plate collectors have a life expectancy of over 25 years..

Evacuated tube collectors

Evacuated tube collectors are the most common solar thermal technology in the world. They make use of a glass tube to surround the absorber with high vacuum and effectively resist atmospheric pressure. The vacuum that surrounds the absorber greatly reduces convection and conduction heat loss, therefore achieving greater energy conversion efficiency. The absorber can be either metallic as in the case of flat plate collectors or being a second concentric glass tube ("Sydney Tube"). Heat transfer fluid can flow in and out of each tube or being in contact with a heat pipe reaching inside the tube. For the latter, heat pipes transfer heat to the fluid in a heat exchanger called a "manifold" placed transversely with respect to the tubes. The manifold is wrapped in insulation (glass wool) and covered by a protective metal or plastic case also used for fixing to supports.

Glass-metal evacuated tubes are made with flat or curved metal absorber sheets same as those of flat plates. These sheets are joined to pipes or heat pipes to make "fins" and placed inside a single borosilicate glass tube. An anti-reflective coating can be deposited on the inner and outer surfaces of such tubes to improve transparency. Both selective and anti-reflective coating (inner tube surface) will not degrade until the vacuum is lost. A high vacuum-tight glass-metal seal is however required at one or both sides of each evacuated tube. This seal is cycled between ambient and fluid temperature each day of collector operation and might lead to failures in time.

Glass-glass evacuated tubes are made with two borosilicate glass tubes fused together at one or both ends (similar a vacuum bottle or dewar flask). The absorber fin is placed inside the inner tube at atmospheric pressure. Glass-glass tubes have a very reliable seal, but the two layers of glass reduce the amount of sunlight that reaches the absorber. The selective coating can be deposited on the inner borosilicate tube (high vacuum side) to avoid this, but heat has then to flow through the poorly conducting glass thickness of the inner tube in this case. Moreover, moisture may enter the non-evacuated area inside the inner tube and cause absorber corrosion in particular when made from dissimilar materials (galvanic corrosion).

A Barium flash getter pump is commonly evaporated inside the high vacuum gap in between tubes to keep the internal pressure stable through time.

The high temperatures that can occur inside evacuated tubes may require special design to prevent thermal shock and overheating. Some evacuated tube collectors work as a thermal one-way valve due to their heat pipes. This gives them an inherent maximum operating temperature that acts as a safety feature. Evacuated tubes collectors can also be provided with low concentrating reflectors at the back of the tubes realising a compound parabolic concentrator (CPC) collector.

Comparisons of flat plate and evacuated tube collectors

A longstanding argument exists between proponents of these two technologies. Some of this can be related to the structure of evacuated tube collectors which have a discontinuous absorbance area. An array of evacuated tubes collectors on a roof has space between the individual tubes and a vacuum gap between each tube and its absorber inside, covering only a fraction of the installation area on a roof. If evacuated tubes are compared with flat-plate collectors on the basis of the area of roof occupied (gross area), a different conclusion might be reached than if the absorber or aperture areas were compared. The recent revision of the ISO 9806 standard states that the efficiency of solar thermal collectors should be measured in terms of gross area and this might favour flat plates in respect to evacuated tube collectors in direct comparisons.

Flat-plate collectors usually lose more heat to the environment than evacuated tubes because there is no insulation at the glass side. Evacuated tube collectors intrinsically have a lower absorber to gross area ratio (typically 60–80% less) than flat plates because tubes have to be spaced apart. Although several European companies manufacture evacuated tube collectors (mainly glass-metal type), the evacuated tube market is dominated by manufacturers in China, with some companies having track records of 15–30 years or more. There is no unambiguous evidence that the two designs differ in long-term reliability. However, evacuated tube technology (especially for newer variants with glass-metal seals and heat pipes) still needs to demonstrate competitive lifetimes. The modularity of evacuated tubes can be advantageous in terms of extensibility and maintenance, for example, if the vacuum in one heat pipe tube is lost it can be easily be replaced with minimal effort.

In most climates, flat plate collectors will generally be more cost-effective than evacuated tubes. However, evacuated tube collectors are well-suited to cold ambient temperatures and work well in situations of low solar irradiance, providing heat more consistently throughout the year. Unglazed flat plate collectors are the preferred devices for heating swimming pool water. Unglazed collectors may be suitable in tropical or subtropical environments if domestic hot water needs to be heated by less than 20 °C (36 °F) over ambient temperature. Evacuated tube collectors have less aerodynamic drag, which may allow for a simpler installation on roofs in windy locations. The gaps between the tubes may allow for snow to fall through the collector, minimizing the loss of production in some snowy conditions, though the lack of radiated heat from the tubes can also prevent effective shedding of accumulated snow. Flat plate collectors might be easier to clean. Other properties, such as appearance and ease of installation are more subjective and difficult to compare.

Evacuated flat plate collectors

Evacuated flat plate solar collectors provide all the advantages of both flat plate and evacuated tube collectors combined. They surround a large area metal sheet absorber with high vacuum inside a flat envelope made of glass and metal. They offer the highest energy conversion efficiency of any non-concentrating solar thermal collector, but require sophisticated technology for manufacturing. They should not be confused with flat plate collectors featuring low vacuum inside. The first collector making use of high vacuum insulation was developed at CERN, while TVP SOLAR SA of Switzerland was the first company to commercialise Solar Keymark certified collectors in 2012.

Evacuated flat plate solar collectors require both a glass-metal seal to join the glass plate to the rest of the metal envelope and an internal structure to support such plate against atmospheric pressure. The absorber has to be segmented or provided with suitable holes to accommodate such structure. Joining of all parts has to be high vacuum-tight and only materials with low vapour pressure can be used to prevent outgassing. Glass-metal seal technology can be based either on metallized glass or vitrified metal and defines the type of collector. Different from evacuated tube collectors, they make use of non-evaporable getter (NEG) pumps to keep the internal pressure stable through time. This getter pump technology has the advantage of providing some regeneration in-situ by exposure to sunlight. Evacuated flat plate solar collectors have been studied for solar air condition and compared to compact solar concentrators.

Polymer flat plate collectors

These collectors are an alternative to metal collectors. These may be wholly polymer, or they may include metal plates in front of freeze-tolerant water channels made of silicone rubber. Polymers are flexible and therefore freeze-tolerant and can employ plain water instead of antifreeze, so that they may be plumbed directly into existing water tanks instead of needing heat exchangers that lower efficiency. By dispensing with a heat exchanger, temperatures need not be quite so high for the circulation system to be switched on, so such direct circulation panels, whether polymer or otherwise, can be more efficient, particularly at low solar irradiance levels. Some early selectively coated polymer collectors suffered from overheating when insulated, as stagnation temperatures can exceed the polymer's melting point. For example, the melting point of polypropylene is 160 °C (320 °F), while the stagnation temperature of insulated thermal collectors can exceed 180 °C (356 °F) if control strategies are not used. For this reason, polypropylene is not often used in glazed selectively coated solar collectors. Increasingly, polymers such as high temperate silicones (which melt at over 250 °C (482 °F)) are being used. Some non polypropylene polymer based glazed solar collectors are matte black coated rather than selectively coated to reduce the stagnation temperature to 150 °C (302 °F) or less.

In areas where freezing is a possibility, freeze-tolerance (the capability to freeze repeatedly without cracking) can be achieved by the use of flexible polymers. Silicone rubber pipes have been used for this purpose in UK since 1999. Conventional metal collectors are vulnerable to damage from freezing, so if they are water filled they must be carefully plumbed so they completely drain using gravity before freezing is expected so that they do not crack. Many metal collectors are installed as part of a sealed heat exchanger system. Rather than having potable water flow directly through the collectors, a mixture of water and antifreeze such as propylene glycol is used. A heat exchange fluid protects against freeze damage down to a locally determined risk temperature that depends on the proportion of propylene glycol in the mixture. The use of glycol lowers the water's heat carrying capacity marginally, while the addition of an extra heat exchanger may lower system performance at low light levels.

A pool or unglazed collector is a simple form of flat-plate collector without a transparent cover. Typically, polypropylene or EPDM rubber or silicone rubber is used as an absorber. Used for pool heating, it can work quite well when the desired output temperature is near the ambient temperature (that is, when it is warm outside). As the ambient temperature gets cooler, these collectors become less effective.

Bowl collectors

A solar bowl is a type of solar thermal collector that operates similarly to a parabolic dish, but instead of using a tracking parabolic mirror with a fixed receiver, it has a fixed spherical mirror with a tracking receiver. This reduces efficiency but makes it cheaper to build and operate. Designers call it a fixed mirror distributed focus solar power system. The main reason for its development was to eliminate the cost of moving a large mirror to track the sun as with parabolic dish systems.

A fixed parabolic mirror creates a variously shaped image of the sun as it moves across the sky. Only when the mirror is pointed directly at the sun does the light focus on one point. That is why parabolic dish systems track the sun. A fixed spherical mirror focuses the light in the same place independent of the sun's position. The light, however, is not directed to one point but is distributed on a line from the surface of the mirror to one half radius (along a line that runs through the sphere center and the sun).

As the sun moves across the sky, the aperture of any fixed collector changes. This causes changes in the amount of captured sunlight, producing what is called the sinus effect of power output. Proponents of the solar bowl design claim the reduction in overall power output compared with tracking parabolic mirrors is offset by lower system costs.

The sunlight concentrated at the focal line of a spherical reflector is collected using a tracking receiver. This receiver is pivoted around the focal line and is usually counterbalanced. The receiver may consist of pipes carrying fluid for thermal transfer or photovoltaic cells for direct conversion of light to electricity.

The solar bowl design resulted from a project of the Electrical Engineering Department of the Texas Technical University, headed by Edwin O'Hair, to develop a 5 MWe power plant. A solar bowl was built for the town of Crosbyton, Texas as a pilot facility. The bowl had a diameter of 65 ft (20 m), tilted at a 15° angle to optimize the cost/yield relation (33° would have maximized yield). The rim of the hemisphere was "trimmed" to 60°, creating a maximum aperture of 3,318 square feet (308.3 m²). This pilot bowl produced electricity at a rate of 10 kW peak.

A 15-metre (49 ft) diameter Auroville solar bowl was developed from an earlier test of a 3.5-metre (11 ft) bowl in 1979–1982 by the Tata Energy Research Institute. That test showed the use of the solar bowl in the production of steam for cooking. The full-scale project to build a solar bowl and kitchen ran from 1996 and was fully operational by 2001.

In locations with average available solar energy, flat plate collectors are sized approximately 1.2 to 2.4 square decimeter per liter of one day's hot water use.

Applications

The main use of this technology is in residential buildings where the demand for hot water has a large impact on energy bills. This generally means a situation with a large family or a situation in which the hot water demand is excessive due to frequent laundry washing. Commercial applications include laundromats, car washes, military laundry facilities and eating establishments. The technology can also be used for space heating if the building is located off-grid or if utility power is subject to frequent outages. Solar water heating systems are most likely to be cost effective for facilities with water heating systems that are expensive to operate, or with operations such as laundries or kitchens that require large quantities of hot water. Unglazed liquid collectors are commonly used to heat water for swimming pools but can also be applied to large-scale water pre-heating. When loads are large relative to the available collector area, the bulk of the water heating can be done at low temperature, lower than swimming pool temperatures where unglazed collectors are well established in the marketplace as the right choice. Because these collectors need not withstand high temperatures, they can use less expensive materials such as plastic or rubber. Many unglazed collectors are made of polypropylene and must be drained fully to avoid freeze damage when air temperatures drop below 44 °F (7 °C) on clear nights. A smaller but growing percentage of unglazed collectors are flexible meaning they can withstand water freezing solid inside their absorber. The freeze concern only needs to be the water-filled piping and collector manifolds in a hard freeze condition. Unglazed solar hot water systems should be installed to "drainback" to a storage tank whenever solar radiation is insufficient. There are no thermal shock concerns with unglazed systems. Commonly used in swimming pool heating since solar energy's early beginnings, unglazed solar collectors heat swimming pool water directly without the need for antifreeze or heat exchangers. Hot water solar systems require heat exchangers due to contamination possibilities and in the case of unglazed collectors, the pressure difference between the solar working fluid (water) and the load (pressurized cold city water). Large-scale unglazed solar hot water heaters, like the one at the Minoru Aquatic Center in Richmond, BC operate at lower temperatures than evacuated tube or boxed and glazed collector systems. Although they require larger, more expensive heat exchangers, all other components including vented storage tanks and uninsulated plastic PVC piping reduce the costs of this alternative dramatically compared to the higher temperature collector types. When heating hot water, we are actually heating cold to warm and warm to hot. We can heat cold to warm as efficiently with unglazed collectors, just as we can heat warm to hot with high-temperature collectors.