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AVESAHEMAD S.N.HUSAINY

2008-2009

UNDER THE GUIDENCE OF

PRINCIPAL.SANJAY A.KHOT


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This is to certify that, the project report entitled

By

AVESAHEMAD S.N.HUSAINY

(T.Y.MECHANICAL)

Is record of their own work carried out by them for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Under my supervision & guidance during academic year 2008-2009

Prof.S.A.Khot Prof.S.A.Khot Prof.S.J.Patil

GUIDE PRINCIPAL H.O.D.

CERTIFICATE


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We the student of third year mechanical are very much grateful to Prof. Sanjay

Khot, who is our project guide and principal of our college, for giving his

guidance and spirit to our project work.

Our thanks are also to:

1) Prof. S.J. Patil.(H.O.D.)

2) Mr .G.M.Chavan(Workshop Head)

Last but not the least we would like to acknowledge the help provided by

our friends from whom we had the benefits of innumerable useful comments &

suggestions.


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SR.N0. PARTICULARS PAGE N01 ABSTRACT OF OUR PROJECT 6

2 INTRODUCTION SOLAR WATER

HEATER

8

3 COMPONENENTS OF SOLAR WATER

SYSTEM

10

4 HOT WATER TANK 11

5 WORKING OF COLLECTOR 12

6 MATERIAL OF COLLECTOR 16

7 PHASE CHANGE MATERIAL 188 ADVANTAGES OF P.C.M. 20

9 MACHINING OPERATION 23

10 TEMPRATURE READINGS 24

11 APPLICATION 28

12 COST ANALYSIS 33

13 CONCLUSION 35


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There are many sources available to heating the water. But the most convenient

method of heating water is solar energy, because of its availability. In ordinary

solar water heater works on the principle of sensible heating but our solar

water heater works on the principle of latent heat storing by Phase Chang

Material(P.C.M.) viz,Paraffin Wax .

Latent heat means, the phase change material can store some amount of heat,

and dissipate whenever system necessary. The main application of our project

is, it is used mainly where the space restriction limit larger thermal storage

units in direct gain or sunspace passive solar system.

Latent heat thermal energy storage is one of the most efficient ways to store

thermal energy for heating water by energy received from sun. This paper

summarizes the investigation and analysis of thermal energy storage

incorporating with and without PCM for use in solar water heaters. It has been

demonstrated that for a better thermal performance of solar water heater a

phase change material with high latent heat and with large surface area for

heat transfer is required.


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Solar heating systems are generally composed of solar

thermal collectors, a fluid system to move the heat from the

collector to its point of usage. The system may use electricity

for pumping the fluid, and have a reservoir or tank for heat

storage and subsequent use. The systems may be used to heat

water for a wide variety of uses, including home, business and

industrial uses. Heating swimming pools, under floor heating
http://en.wikipedia.org/wiki/Solar_heatinghttp://en.wikipedia.org/wiki/Solar_thermal_energyhttp://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Electricityhttp://en.wikipedia.org/wiki/Swimming_poolshttp://en.wikipedia.org/wiki/Underfloor_heatinghttp://en.wikipedia.org/wiki/Solar_heatinghttp://en.wikipedia.org/wiki/Solar_thermal_energyhttp://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Electricityhttp://en.wikipedia.org/wiki/Swimming_poolshttp://en.wikipedia.org/wiki/Underfloor_heating


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or energy input for space heating or cooling are more specific

examples.

Residential solar thermal installations can be subdivided into

two kinds of systems: compact and pumped systems. Both

typically include an auxiliary energy source (electric heating

element or connection to a gas or fuel oil central heating

system) that is activated when the water in the tank falls

below a minimum temperature setting such as 50 C. Hence,

hot water is always available. The combination of solar hot

water heating and using the back-up heat from a wood stove

chimney to heat water can enable a hot water system to work

all year round in cooler climates without the supplemental

heat requirement of a solar hot water system being met with

fossil fuels or electricity.

Among pumped options, there is an important distinction to

be made regarding the sustainability of the design of the

system. This relates to what source of energy powers the

pump and its controls. The type of pumped solar thermal

systems which use mains electricity to pump the fluid through

the panels are called low carbon solar because the pumping
http://en.wikipedia.org/wiki/Space_heatinghttp://en.wikipedia.org/wiki/Solar_coolinghttp://en.wikipedia.org/wiki/Celsiushttp://en.wikipedia.org/wiki/Space_heatinghttp://en.wikipedia.org/wiki/Solar_coolinghttp://en.wikipedia.org/wiki/Celsius


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negates the carbon savings of the solar by about 20%,

according to data in a report called "Side by side testing of

eight solar water heatings" by DTI UK. However, zero-

carbon pumped solar thermal systems use solar electricity

which is generated onsite using photovoltaics to pump the

fluid and to operate its control electronics. This represents a

zero operational carbon footprint and is becoming an

important design goal for innovative solar thermal systems.

1) Tank

2) Collector

3) Phase Change Material,viz(Paraffin Wax)

4) Copper Tubes in Hot Water Tank


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5) Cold Water Tank

The hot water tank is made by using plastic pipe which is

resistant to heat up to 80 degree centigrade. It has length of

1.5feet and diameter 200mm the ends of pipes are sealed by


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placing two caps of same diameter. The cap and pipe is sealed

by using M-seal & solution

Inlet, outlet &collector connections are made at the face of

cap. The tank is insulated from surrounding atmosphere by

cladding process. A thick cladding of three inch is done by

using rock wool material. The rock wool is covered with thin

Aluminum sheet of thickness 26guage. This completes the

tank.


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Flat tube collectors are made of a series of modular tubes,

mounted in parallel, whose number can be added to or

reduced as hot water delivery needs change. This type of

collector consists of rows of parallel transparent glass tubes,

each of which contains an absorber tube (in place of the

absorber plate to which metal tubes are attached in a flat-

plate collector). In some cases, the tubes are covered with a

special light-modulating coating. In an evacuated tube

collector, sunlight passing through an outer glass tube heats

the absorber tube contained within it. The absorber can either

consist of copper (glass-metal) or specially-coated glass tubing

(glass-glass). The glass-metal evacuated tubes are typically

sealed at the manifold end, and the absorber is actually sealed

in the vacuum, thus the fact that the absorber and heat pipe


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are dissimilar metals creates no corrosion problems. Some

systems use foam insulation in the manifold. Soda-lime glass is

used in the higher quality evacuated tubes manufacture.

Lower quality evacuated tube systems use the glass coated

absorber. Due to the extreme temperature difference of the

glass under stagnation temperatures, the glass sometimes

shatters. The glass is a lower quality boron silicate material

and the aluminum absorber and copper heat pipe are slid

down inside the open top end of the tube. Moisture entering

the manifold around the sheet metal casing is eventually

absorbed by the glass fibre insulation and then finds its way

down into the tubes. This leads to corrosion at the

absorber/heat pipe interface area, also freeze ruptures of the

tube itself if the tube fills sufficiently with water.

Two types of tube collectors are distinguished by their heat

transfer method: the simplest pumps a heat transfer fluid

(water or antifreeze) through a U-shaped copper tube placed

in each of the glass collector tubes. The second type uses a

sealed heat pipe that contains a liquid that vapourises as it is
http://en.wikipedia.org/wiki/Antifreezehttp://en.wikipedia.org/wiki/Heat_pipehttp://en.wikipedia.org/wiki/Antifreezehttp://en.wikipedia.org/wiki/Heat_pipe


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heated. The vapour rises to a heat-transfer bulb that is

positioned outside the collector tube in a pipe through which a

second heat transfer liquid (the water or antifreeze) is

pumped. For both types, the heated liquid then circulates

through a heat exchanger and gives off its heat to water that is

stored in a storage tank (which itself may be kept warm

partially by sunlight). Evacuated tube collectors heat to

higher temperatures, with some models providing

considerably more solar yield per square metre than flat

panels. However, they are more expensive and fragile than

flat panels. Evacuated heat tubes perform better than flat

plate collectors in cold climates because they only rely on the

light they receive and not the outside temperature. The high

stagnation temperatures can cause antifreeze to break down,

so careful consideration must be used if selecting this type of

system in temperate climates.Tubes come in different levels of

quality so the different kinds have to be examined as well.

High quality units can efficiently absorb diffuse solar

radiation present in cloudy conditions and are unaffected by


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wind. They also have the same performance in similar light

conditions summer and winter.

For a given absorber area, evacuated tubes can maintain their

efficiency over a wide range of ambient temperatures and

heating requirements. The absorber area only occupied about

50% of the collector panel on early designs, however this has

changed as the technology has advanced to maximize the

absorption area. In extremely hot climates, flat-plate

collectors will generally be a more cost-effective solution than

evacuated tubes. When employed in arrays of 20 to 30 or

more, the efficient but costly evacuated tube collectors have

net benefit in winter and also give real advantage in the

summer months. They are well suited to extremely cold

ambient temperatures and work well in situations of

consistently low-light. They are also used in industrial

applications, where high water temperatures or steam need to

be generated. Properly designed evacuated tubes have a life

expectancy of over 25 years which greatly adds to their value.


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1. Two rolls of 50-foot 20 aluminum flashing

2. Four .060-inch thick 4X8 sheets of Kalwall

from:

3. Twenty 1X4X8 pine with few or no knots

4. Four X4X8 CDX plywood

5. Four 1X4X8 sheet insulation R value 5 or

better

6. Clear silicon caulking

7. Aluminum foil and some felt paper

8. One gallon of roofing tar


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9. One gallon of oil base paint

10. Angle iron for mounting

11. Sixteen X 3 lag bolts, sixteen X 1 inch

machine bolts

12. 1 inch and 2 inch drywall screws

13. One pound of 1 inch galvanized nails with

small heads

14. PLUMBING SUPPLIES

a. Eight 3/8 to adaptors

b. Four inch Ts

c. Two X X Ts

d. One inch T

e. Four inch unions

f. Eight inch elbows

g. One inch street elbow


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h. One sweat to female pipe

i. One pressure relief valve

j. Four sixty foot rolls of 3/8 ID copper tubing

k. - inch rigid copper tubing type L

l. - inch rigid copper tubing type L or M

m. Solder and flux


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A phase change material (PCM) is a substance with a high

heat of fusion which, melting and solidifying at a certain

temperature, is capable of storing and releasing large

amounts of energy. Heat is absorbed or released when the

material changes from solid to liquid and vice versa; thus,

PCMs are classified as latent heat storage (LHS) units.

PCMs latent heat storage can be achieved through solid-solid,

solid-liquid, solid-gas and liquid-gas phase change. However,

the only phase change used for PCMs is the solid-liquid

change. Liquid-gas phase changes are not practical for use as

thermal storage due to the large volumes or high pressures

required to store the materials when in their gas phase.
http://en.wikipedia.org/wiki/Heat_of_fusionhttp://en.wikipedia.org/wiki/Latent_heathttp://en.wikipedia.org/wiki/Heat_of_fusionhttp://en.wikipedia.org/wiki/Latent_heat


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Liquid-gas transitions do have a higher heat of

transformation than solid-liquid transitions. Solid-solid phase

changes are typically very slow and have a rather low heat of

transformation.

Initially, the solid-liquid PCMs behave like sensible heat

storage (SHS) materials; their temperature rises as they

absorb heat. Unlike conventional SHS, however, when PCMs

reach the temperature at which they change phase (their

melting temperature) they absorb large amounts of heat at an

almost constant temperature. The PCM continues to absorb

heat without a significant raise in temperature until all the

material is transformed to the liquid phase. When the

ambient temperature around a liquid material falls, the PCM

solidifies, releasing its stored latent heat. A large number of

PCMs are available in any required temperature range from

-5 up to 190oC .Within the human comfort range of 20 to

30C, some PCMs are very effective. They store 5 to 14 times

more heat per unit volume than conventional storage

materials such as water, masonry, or rock
http://en.wikipedia.org/wiki/Sensible_heathttp://en.wikipedia.org/wiki/Sensible_heat


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1. Availability in a large temperature range

2. Freeze without much super cooling

3. Ability to melt congruently

4. Self nucleating properties

5. Compatibility with conventional material of

construction

6. No segregation

7. Chemically stable


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8. High heat of fusion

9. Safe and non-reactive

10.Recyclable

In chemistry, paraffin is the common name for the alkane

hydrocarbons with the general formula CnH2n+2. Paraffin wax

refers to the solids with n=2040.

The simplest paraffin molecule is that ofmethane, CH4, a gas

at room temperature. Heavier members of the series, such as

that ofoctane C8H18, appear as liquids at room temperature.

The solid forms of paraffin, called paraffin wax, are from the
http://en.wikipedia.org/wiki/Alkanehttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Methanehttp://en.wikipedia.org/wiki/Octanehttp://en.wikipedia.org/wiki/Alkanehttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Methanehttp://en.wikipedia.org/wiki/Octane


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heaviest molecules from C20H42 to C40H82. Paraffin wax was

identified by Carl Reichenbach in 1830.

Paraffin, or paraffin hydrocarbon, is also the technical name

for an alkane in general, but in most cases it refers specifically

to a linear or normal alkane whereas branched, or

isoalkanes are also called isoparaffins. It is distinct from the

fuel known in Ireland, Britain and South Africa as paraffin

oil or just paraffin, which is called kerosene in most of the

U.S., Australia and New Zealand.

The name is derived from the Latin parum (= barely) + affinis

with the meaning here of "lacking affinity", or "lacking

reactivity". This is because alkanes, being non-polar and

lacking in functional groups, are very unreactive.

Paraffin wax (or simply "paraffin", but see alternative name

for kerosene, above) is mostly found as a white, odorless,

tasteless, waxy solid, with a typical melting point between

about 47 C to 64 C ( 116.6F to 147.2F), and having a

density of around 0.9 g/cm3. It is insoluble in water, but

soluble in ether, benzene, and certain esters. Paraffin is
http://en.wikipedia.org/wiki/Carl_Reichenbachhttp://en.wikipedia.org/wiki/South_Africahttp://en.wikipedia.org/wiki/Kerosenehttp://en.wikipedia.org/wiki/Electron_affinityhttp://en.wikipedia.org/wiki/Reactivityhttp://en.wikipedia.org/wiki/Non-polarhttp://en.wikipedia.org/wiki/Functional_groupshttp://en.wikipedia.org/wiki/Waxhttp://en.wikipedia.org/wiki/Diethyl_etherhttp://en.wikipedia.org/wiki/Benzenehttp://en.wikipedia.org/wiki/Esterhttp://en.wikipedia.org/wiki/Carl_Reichenbachhttp://en.wikipedia.org/wiki/South_Africahttp://en.wikipedia.org/wiki/Kerosenehttp://en.wikipedia.org/wiki/Electron_affinityhttp://en.wikipedia.org/wiki/Reactivityhttp://en.wikipedia.org/wiki/Non-polarhttp://en.wikipedia.org/wiki/Functional_groupshttp://en.wikipedia.org/wiki/Waxhttp://en.wikipedia.org/wiki/Diethyl_etherhttp://en.wikipedia.org/wiki/Benzenehttp://en.wikipedia.org/wiki/Ester


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unaffected by most common chemical reagents, but burns

readily.

Pure paraffin wax is an excellent electrical insulator, with an

electrical resistivity of between 1013 and 1017ohm metre. This is

better than nearly all other materials except some plastics

(Notably Teflon). It is an effective neutron moderator and was

used in James Chadwick's 1932 experiments to identify the

neutron
http://en.wikipedia.org/wiki/Reagenthttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electrical_insulationhttp://en.wikipedia.org/wiki/Resistivityhttp://en.wikipedia.org/wiki/Resistivityhttp://en.wikipedia.org/wiki/Polytetrafluoroethylenehttp://en.wikipedia.org/wiki/Neutron_moderatorhttp://en.wikipedia.org/wiki/James_Chadwickhttp://en.wikibooks.org/wiki/A-level_Physics/Forces,_Fields_and_Energy/The_nuclear_atomhttp://en.wikibooks.org/wiki/A-level_Physics/Forces,_Fields_and_Energy/The_nuclear_atomhttp://en.wikipedia.org/wiki/Reagenthttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electrical_insulationhttp://en.wikipedia.org/wiki/Resistivityhttp://en.wikipedia.org/wiki/Resistivityhttp://en.wikipedia.org/wiki/Polytetrafluoroethylenehttp://en.wikipedia.org/wiki/Neutron_moderatorhttp://en.wikipedia.org/wiki/James_Chadwickhttp://en.wikibooks.org/wiki/A-level_Physics/Forces,_Fields_and_Energy/The_nuclear_atomhttp://en.wikibooks.org/wiki/A-level_Physics/Forces,_Fields_and_Energy/The_nuclear_atom


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Sr.

No.

Machine

operation

Name of

machine

Setup

time

In min.

Prod.

Time

In min.

Feed

Hand/power

1 Copper pipecutting

Coppercutter

45 60 Hand

2 Copper pipe

brazing

Burner &

silver rod

15 120 Hand

3 Copper pipe

soldering

Burner 15 120 Hand

4 Aluminum

round plate

turning

lathe 20 30 Power

5 Aluminum

round plate

facing

lathe 15 20 power

6 Aluminum

round plate

drilling

Drilling

machine

10 150 power


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=?


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TEMPERATURE READINGS:

T1 = TEMPERATURE OF WAX

T2 = TEMPERATURE OF COPPER PIPE

T3 = TEMPERATURE OF WATER

T4 = TEMPERATURE OF INLET OF COLLECTOR

T5 = TEMPERATURE OF OUTLET OF COLLECTOR

TIME TEMPERATURE8.00 AM T1 = 30

T2 = 30

T3 = 30

T4 = 30

T5 = 30


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9.00 AM T1 = 40

T2 = 40

T3 = 43

T4 = 44

T5 =40

10.00 AM T1 = 41

T2 = 41

T3 = 46

T4 = 48

T5 =41

11.00 AM T1 = 44

T2 = 42

T3 = 48

T4 = 48

T5 =44

12.00PM T1 = 48

T2 = 46

T3 = 50

T4 = 50

T5 =48

1.00 PM T1 = 52

T2 = 52

T3 = 57

T4 = 54

T5 =54

2.00 PM T1 = 54

T2 = 54

T3 = 58


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T4 = 56

T5 =55

3.00 PM T1 = 55

T2 = 55

T3 = 60

T4 = 57

T5 =56

4.00 PM T1 = 57

T2 = 57

T3 = 63

T4 = 61

T5 =60

5.00 PM T1 = 60

T2 = 60

T3 = 65

T4 = 64

T5 =63

6.00 PM T1 = 60

T2 = 60

T3 = 65

T4 = 64

T5 =63


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1) VOLUME OF TANK = 14137166 sq.mm

2) VOLUME OF CU. PIPES =2895291sq.mm

3) CAPACITY OF TANK = 13 LITRE

4) CAPACITY OF COLLECTOR = LITRE

5) CAPACITY OF COLD WATER TANK=20

LITRE

6) AMOUNT OF WAX USED =40GM PER

CU.PIPE

7) TOTAL WAX USED IN CU. PIPE= 2.5KG

8) MAX. TEMP. ATTAINED = 55 DEGREE.


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1) WEIGHT OF COPPER PIPE = 114 gm

2) WEIGHT OF PVC END CAPS = 748 gm

3)

WEIGHT OF AL. PLATE = 138 gm

4) WEIGHT OF PVC PIPE = 1945 gm

5) WEIGHT OF WAX IN EACH CU. PIPE =43 gm

6) WEIGHT OF TOTAL WAX USED = 2752


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1) Domestic: Flats, Bungalows and Apartments.

2) Commercial: Hotels, Hospitals, Hostels and

Dormitories.

3) Industrial: Process Industries, Preheating boiler

feed water.


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In commercial & industrial sectors, where large

quantity of water is required at fairly high

temperature, ''Our Solar Water Heating Systems'' are

designed to meet the above requirement. Depending

on the distribution pattern of hot water, the system

could be either modular or a big capacity single tank

system.


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Sr.No. Item. Rate in Rs. Qty. Amount in Rs.

1 P.V.C.Pipe 90 1.5ft 135

2 End cap 200 2 400


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3 Copper Pipes 40 120ft 4800

4 Collector 4500 1 4500

5 Cladding 800 1 800

6 Stand 500 1 500

7 Brazing &

Soldering

700 1 700

8 Transportation 5oo - 500

9 Thermocouple 35 8m 280

10 Paraffin Wax 70 3kg 210

11 Other Cost 508 - 508

12 Total Cost - - 13,333Rs


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1) Store latent heat unlike other solar heating system

2) Heat storage capacity is large

3) More hot water is obtained with same capacity

4) Constant hot water at 50 degree Celsius is obtained

5) No much variation in temperature is observed even

when cold water is added

6) It is more efficient than other system

4) It is more advantages where the space restriction

limits larger thermal storage units in direct gain or

sunspace passive solar system.


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PHOTO

GALLERY


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