DESIGN AND DEVELOPMENT OF SOLAR THERMAL EXPANSION PUMP

8/22/2019 DESIGN AND DEVELOPMENT OF SOLAR THERMAL EXPANSION PUMP

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DESIGN AND DEVELOPMENT OF SOLAR THERMAL EXPANSION PUMP

BMIT, Solapur. 1

1.ABSTRACT


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ABSTRACT:-

The conventional fuels sources are getting depleted due to continuous use of

it. The prices of petrol increasing day by day. These fuels emit hazardous pollutants

like CO2, CO. etc. Conventional energy sources are not long lasting .Nowadays

energy is continuously in demand and the world is on the one hand facing problem

with limited availability of conventional energy sources and on the other hand global

warming because of pollutants from fossil fuels.

There is need to use the alternative sources like solar, air and water. The solar

energy source is nonconventional type of energy finding solution for above problem

which can replace conventional fuels for number of applications. For lifting and

raising liquid levels electrical motor coupled pumps can be replaced by solar thermal

expansion pump which basically operates on thermal level difference of thermal

expansion.

The experiments are conducted to measure the performance of a solar thermal

expansion pump. The results obtained are encouraging. The report includes design,

construction and working of solar thermal expansion pump.

Report also contains project expenditure, future modification and scope of

solar thermal expansion pump.


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2. Literature Survey


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LITRATURE SURVEY:-

(http://www.edwardsvacuum.com/uploadedFiles/Resource/Technical_Articles/Recent%20Experience%20of%20Mechanical%20Vacuum%20Pumps.pdf)

Name Of Paper:Recent Experience Of Mechanical Vacuum Pump Replacing

Steam ejectors in vod and vd process.

In the area of ladle refining recent advances in the degassing process

utilizing dry mechanical vacuum systems in place of liquid based water ring

and/or steam ejector systems offer clear savings in running costs, maintenance

costs, and installation space, and also offer increased speed, flexibility, and

overall productivity to steel degassing operations. Large Roots style vacuum

booster pumps designed for high dust tolerance are the major component of

such mechanical vacuum degassing systems, backed by dry mechanical

pumping systems.

(http://www.venturipumps.com/ejector.htm) We studied the working detailsof steam jet ejectors. It is based on ejector venture principle in which nozzle

are provided. It provides controlled expansion of the motive steam to convertpressure in to velocity which creates a vacuum within the body chamber to

draw in and entrain gases or vapours.

(http://www.venturipumps.com/siphon.htm) Steam Jet Siphons operate on thesteam jet principle utilizing the energy of steam under pressure to pump, mix

liquids and handle solids. In operation siphons use the kinetic energy of

motive steam to entrain another liquid or slurry, completely mix the two, and

then discharge the mixture against a head or counter pressure.

(http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=5363205&url=http%3A%2F%2Fieeexplore.ieee.org%2Fstamp%2Fstamp.jsp%3Ftp%3D%26arnum

ber%3D5363205) We also studied thermal expansion pump (TEP) based on a

principle of liquid thermal expansion for capillary high performance liquid

chromatography has been developed.


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3. INTRODUCTION


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INTRODUCTION:-

The fossil fuels reservoirs are getting depleted due to continuous use of it

in automobile, industries and other applications. The prices of petrol and diesel, coal

are increasing day by day. The following table shows the increase in prices of petrol

and diesel from 1990 to 2011.

Table 1:- Prices of petrol and diesel.

(Reference:-http://in.reuters.com/article/2010/07/16/india-fuel-price

idINSGE66F08P20100716, Fri Jun 25, 2010 7:17pm)

There is need to use renewable energy sources like solar, air, water orcombination of these to meet the requirements of transportation, industrial and all

other application. So solar energy one of the best alternative source for electricity, gas

etc.

Existing pumps are either electrical pump or hand pump or foot pump.

Electrically operated pump require electrical energy, hand or foot operated pump

require human efforts. As energy crisis is problem in front of our country, so we are

going to design pump which works on principle of solar thermal expansion and as

compare to hand or foot pump it will reduce human effort.

In the solar thermal expansion pump we use solar thermal energy for

lifting the water. As solar energy is freely available its running cost is very low. The

application of solar thermal expansion pump is not only in thermal industry but also it

is used for the chemical industries, it may be used for domestic applications.

Year Petrol (per lit.) Diesel (per lit.)

1990 9.84 4.08

1996 21.13 9.04

2003 32.70 20.73

2005 40.49 28.45

2010 51.43 40.10

2011 67.87 44.60

2012 72.25 44.80


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Typical comparison:-

Sr no. Water lifting pump For

domestic applications

Initial cost

(approximate)

Running cost

(approximate)

1 0.5 hp motor 1900/- 150 PM

2 1 hp motor 3000/- 200PM

3 Solar thermal expansion

pump

14000/- 0

Table 2:- Comparison of pump on the basis of running cost.

Various pumping techniques:-

The following are the various pumping methods which are available for

lifting the water. For the purpose of lifting the water vacuum creation is very

important and it is created by following methods

1) Vacuum creation by temp difference:-

In this method vacuum is created by maintaining temp difference body

and surrounding.

2) Vacuum creation by pressure difference:-

In this method vacuum is created by maintaining pressure difference

.maintaining pressure difference means reducing pressure of flow with the help of

nozzle. As fluid flows through the nozzle it reduces pressure due to which velocity

increases which results in creation of vacuum.


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Fig 1:- vacuum creation by throttling effect

3) Vacuum creation by stem jet siphon:-

Steam Jet Siphons operate on the steam jet principle utilizing the energy

of steam under pressure to pump, mix liquids and handle solids. In operation siphons

use the kinetic energy of motive steam to entrain another liquid or slurry, completely

mix the two, and then discharge the mixture against a head or counter pressure.

Fig 2:- steam jet siphon


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4) Vacuum creation by solar thermal expansion pump:-

In this process first steam is allow to expand then it is to be cooled.

While cooling the steam get contracted which results in vacuum creation.eg:- Based

on a principle of liquid thermal expansion for capillary high-performance liquid

chromatography has been developed.

3.1Primary advantages of solar thermal expansion pump over othervacuum pumps: -

Low cost. No moving parts Mechanical simplicity. No vibration. As there is no moving part less wear takes place. Low running cost. Corrosion and erosion resistant. Easy to install.

3.2 Applications of solar thermal expansion pump:-

1. Domestic application:- Normally in domestic application hydraulic pumps are used for lifting the water

from lower level and store it in the tank on higher side. For completing this

activity we use electricity.

Instead of using this pump, solar thermal expansion pump is used to lift the waterfrom lower level and store it on higher side. As we using solar energy so no

running cost is required.

2. Industrial application:

In industry it may be used for various application of pumping. It may be also used for supplying hot water. It may be used for lifting muddy water which is difficult to lift by conventional

pumps.


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4. SOLAR THERMAL EXPANSION PUMP


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4.1 SOLAR THERMAL EXPANSION PUMP:-

The whole solar thermal expansion pump is shown in the following figure. It consists

of a tank, solar panel, ball valve, breaded pipe, PVC pipe, supporting base frame,

lower reservoir, reducer, elbow etc.

1. Tank:-Normally in one family 5 members are living and their requirement of

water in one day is nearly 150 liters i.e. each member required 30 liters of

water per day. Therefore we decided to manufacture the tank of 300 liters

which fulfils requirement of minimum 10 members.We selected the material

for manufacturing of the tank is mild steel instead of stainless steel. As the mild

steel is having poor corrosion resistance as compared to stainless steel.

Therefore stainless steel is more effective material for manufacturing of the

tank .But stainless steel is more expensive as compared to mild steel. Therefore

we selected the mild steel because of it is cheap, easy to machine and weld and

having more stiffness. Due to poor corrosion resistance some form coating also

provided on the tank.

Tank is having four ports contains one suction port, discharge port; &

other two ports i.e. inlet & outlet ports which are connected to solar panel ports.

The diameter of tank (D1) is 0.45 meter and length (L1) is 0.80 meter. The

diameter of suction port and discharge port is about 1 inch nearly. The ball port

fitted to the discharge port is also about 1 inch. The capacity of the tank is

about 300 liters. At the suction port of the tank reducer of 1 inch is provided to

fitting of the flexible pipe to the port. The height of suction port from ground is

about 7 feet. The flexible pipe is placed in the bucket which is filled by the

water placed on the ground. The height of the discharge port from the ground is

at about 5.5 feet. The Ball port is attached to the discharge port. Other two

ports i.e. one inlet port of tank is attached to the inlet port of solar panel and

other outlet port is connected to the outlet port of the solar panel.


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Fig 3:- Black coated tank of solar thermal expansion pump

2. Base frame:-The base frame is made of mild steel material. Base frame having 4 angles.

The height of the base frame from the ground is about 3 feet. On this base frame black

coated tank is mounted and with respect to the base frame the solar panel is fitted. The

thickness of 4 angles is about 25mm nearly. The base frame is welded from all sides.

The base frame has following detail

Hst: 2.04 m L2: 0 .94m L3: 0.48m W1: 1.08m W2:0.78m


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Fig 4:- Base frame of solar thermal expansion pump

3. Solar panel:-As capacity of our tank is 300 liters, we select the solar panel having

capacity of heating 300 liters per day. We select flat plate solar collector having 9

tubes inside it. The diameter of each tube is 10mm and that tubes are made up of

copper. We select the flat plate collector because it is efficient than evacuated tube

type solar collector and it can produce better pumping effect even in summer

season. Aluminum insulation is provided on the solar panel. We provide fins on

copper tubes for increasing contacting surface area. The solar panel is placed in

inclined position with respect to the ground. The angle of inclination is about 30

degree .The inlet and outlet valve of the tank is fitted with of flexible pipe.


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Fig 5:- Solar panel of solar thermal expansion pump

4. 1 C PVC pipe:-Solar thermal expansion consists of no of pipes for carrying either water

or steam. It consists of 1 (d2) PVC pipe at the inlet for lifting the water.

Fig 6:- C PVC pipe of solar thermal expansion pump

.


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5. Copper tube:-A copper tube of diameter (d4) upto 3mm is used for producing throttling effect.

Fig 7:- Copper tube of solar thermal expansion pump

4.2 WORKING OF SOLAR THERMAL EXPANSION PUMP:-

The solar thermal expansion pump is a piston less or rotor less pump. This

pump working on solar thermal expansion technique. First of all, some water is filled

in the solar panel from the inlet valve of the panel. After filling water in the panel

inlet valve is closed with the help of clips fitted on the flexible pipe. The main

function of the solar panel is to heat the water with the help of sun radiation without

consuming electricity.

As solar thermal expansion pump is rigid in construction we keep it open to

the atmosphere at that time due to solar energy solar panel covert water into wet

steam. That wet steam is collected in the black coated tank .The tank is black coated

and black body absorbs heat the temperature of steam get increase.

When atmospheric temperature increases the steam inside the tank get

expanded and when atmospheric temperature decreases at that time steam tries to

contract which results in creation of vacuum. At the same time steam enters into the

suction pipe. As steam enters inside the pipe its pressure decreases and velocity

increases which results in creation of vacuum. As vacuum is created the water from

lower reservoir gets lifted upwards.


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5.DESIGN OF SOLAR THERMAL EXPANSIONPUMP


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5.1 SYSTEM DESIGN:-

Following Parameters influencing system design:-

1) System Selection Based on Physical Constraints:-While selecting any Pump it must be checked whether it is going to be

used in a large-scale industry or a small-scale industry. Thermal expansion pump is to

be used by a small-scale industry and it may be used for domestic appliances. So

space is a major constrain. The system is to be very rigid and robust construction and

for its application we require solar energy so that it cannot be adjusted to corner of a

room. It must be kept open to atmosphere.

The mechanical design has direct norms with the system design. Hence

the first job is to control the physical parameters, so that the distinctions obtained after

mechanical design can be well fitted into that.

2) Arrangement of Various Components:-Keeping into view the space restrictions the components should be laid

such it is easy to remove or service. More over every component should be easily

seen none should be hidden. Every possible space is utilized in component

arrangements.

3) Components of System:-As already stated the system is having rigid and robust construction so that

it cannot be accommodated at a corner of a room. It does not contain any moving

part. A rigid and robust system design gives a high weighted structure which is

desired.

4) Man Machine Interaction:-The friendliness of a machine with the operator that is operating is an

important criterion of design, but in this application there is no need of controlling the

system as it is automatically operated. Interaction between man and machine is for

only operating delivery valve.


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5) Chances of Failure:-The loss incurred by owner in case of any failure is an important criterion

of design. In this system if any leakage takes place it directly affects output as losses

takes place. The system should be leak proof and air tight.

6) Servicing Facility:-The layout of components should be such that easy servicing is possible.

Especially those components which require frequent servicing can be easily

disassembled.

7) Scope of Future Improvement:-Arrangement should be provided to expand the scope of work in future.

Such as to make the multicycle operating pump.

8) Weight of Machine:-The total weight depends upon the selection of material components as

well as the dimension of components. A higher weighted machine is difficult in

transportation but if we install pump once there is no need to make change in

installation.


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6.FABRICATION PROCESESS


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FABRICATION PROCESS:-

6.1 Design and manufacturing of tank:-

First of all, we have prepared the design of tank with suitable dimensions. Thenselected the material of mild steel for manufacturing the tank. Because mild steel

is mostly used.

Then by using the plate cutting machine, the plates of mild steel are cut withsuitable sizes.

After cutting the plates are rolled to the required radius with the help of platerolling machine.

Then the sides are beveled with help of proper welding by welding machine.Before doing the welding, the welding procedures are prepared and qualified these

procedures and then the welding is to be carried out.

Then weld lets are installed for fixing the suction, discharge, inlet and outlet ports.In our manufactured tank, the weld lets for fixing the temperature gauges, pressure

gauges are not installed. After that end caps are fitted to the tank. After that we

applied the weld heat treatment for the tank by using weld heat treatment machine.

After these all procedures, the tank is sealed with the black coating powder withoil. However, with an oil, wax, or lacquer, it is possible to achieve excellent

indoor corrosion protection (100+ hrs. in a humidity cabinet). Black oxides onsteel are not suitable for severe outdoor applications or corrosive environments,

but they can provide superior humidity cabinet results with proper supplementary

coating.

In order to determine the appropriate after-finish, first evaluated which after-finish to use. The following factors should be considered:

Length of protection required, desired finished appearance (gloss/matte),

Storage conditions (humidity, vapor, temperature), final application

The coating powder is selected black because black oxide coatings are clean andrinse, also for our project it is essential because it absorb the heat with maximum

rate. Then fitting the ball valve, reducers, and pipes to the suction and discharge

ports which are welded to the tank.


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6.2 Manufacturing of base frame:

In order to manufacture a base frame following processes are followed.

1) MS angle of thickness 25.4mm is selected.2) We have cut down the MS bar as per dimensions on hand cutting machine. We cut

2 bars of 70cm and 2 bars of 40cm.

3) By using Electric arc welding, these bars are being welded to form metallic frameof size (70cm*40cm). Then we cut the bar into 4 pieces of length 110 cm, 2 pieces

of 90cm and 2 pieces of 60cm. These bars are also welded to form a frame of size

(90cm*60cm) by using electric arc welding.

4) The 4 pieces of bars of length 110cm are welded to the 4 corners of smaller frame.Then keeping 20cm distance from the ground, larger frame is welded. Smaller

frame is parallel to larger frame. The inclination of smaller frame to the larger

frame is 10 degree.

5) The manufacturing of the base frame is completed.

Fig 1. Catia model of base frame


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Model of solar thermal expansion pump:

Fig 2 Model of solar thermal expansion pump


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7.Experimental Results


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Experimental Results:-

7.1. Experimental Results With 1 C PVC pipe:-

Procedure:-

We have fitted the CPVC pipe of 1 diameter to the suction port with the help ofreducer. One end of pipe is connected to reducer and other end is kept free to

atmosphere. Solar panel is connected water tank. As at noon time steam is

generated it is to be stored in the tank. Steam gets expand in the tank and excess

steam is released to the atmosphere through suction pipe. At evening steam tries to

get condense due to which vacuum is created and water is lifted and observations

are recorded.

7.2. Experimental Results with 6 mm flexible pipe:-

Procedure:-

Instead of 1 PVC pipe we use flexible pipe of 6mm diameter at the suction portby using reducer and all procedure is repeated.

7.3. Experimental Results with 3 mm cooper tube:-

Procedure:-

For obtaining better result we reduced the diameter of suction pipe upto 3mm.now instead of 6mm flexible pipe we used copper tube of diameter 3mm and

procedure is repeated.


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8.Observations


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OBSERVATIONS:-

Pumping effect is observed as follows:

1) When we use pipe of 1 diameter then 2 liter of water was lifted at the head of7 feet.

2) When we use pipe of 6mm diameter then 4 liters of water was lifted at thehead of 7 feet.

3) When we use pipe of 3mm diameter then 7 liters of water was lifted at thehead of 7 feet.


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9.BILL OF MATERIAL


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9.1 BILL OF MATERIAL:-

Table No 11:- Bill of Material

SR NO. DESCRIPTION QTY MATERIAL

1. TANK 01 CI2. BUSH 01 BRASS3. BALL VALVE 01 CI4. REDUCER CI

5. END CAP 08 -6. REDUCER 02 CI7. TAPELAN TAPE 01 -8. GASKET BOTTLE 01 -9. NAPPLER -10. COUPLER 02 CI11. NIPPLE 01 CI

12.

REDUCER 01 GI

13. 6 MM BREADED PIPE 10FEET STD14. SOCKET 02 CI15. 3/4 PVC PIPE 20 STD


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9.2 COST ESTIMATION:-

1. Raw Material Cost:-

The total raw material cost as per the individual materials and their corresponding

rates is as follows,

Total raw material cost = 800 /-

Fabricating cost = 800 /-

2. Cost of Purchased Parts:-

SR NO. DESCRIPTION QTY COST

1. C PVC PIPE 20 FEET 4002. FLEXIBLE PIPE 10FEET 2803. COPPER PIPE 10FEET 5004. REDEUCER 1 2 1005. BALL VALVE 1 1 506.

OTHER MISCELLANEOUS

MATERIAL

500

Table 12:- cost of purchased parts

The cost of purchase parts = Rs 1830/-.

3. TOTAL COST

Total Cost = Raw Material Cost (800) +Machining Cost (800) + cost of air tight tankl

provided by industry(6000) + cost of Purchased Parts (1830)+ solar panel provided by

industry(8000).

TOTAL COST = Rs 17430/- .


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10. CONCLUSION


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CONCLUSION:-

Small amount of water gets lifted during heating and cooling (day & night) insolar water heaters due to thermal expansions.

This experimental result leads & requires further study of the thermal expansionprocess for purpose of pumping the liquid using solar pumps working on thermal

expansion by using some accessories to lift same or different type of liquids.


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11. FUTURE SCOPE


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FUTURE SCOPE:-

Certain modifications and can be carried out to expand the scope of work in

future. There is huge scope for future work.

We constructed this pump especially for domestic applicationsbut in future wecan utilize it for industrial applications.

In future this pump may be used for lifting the muddy water. In future this pump may be utilized for pumping chemicals in chemical industry. This pump produce pumping effect only once in day but in future we can increase

its efficiency by making multicycle.


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12. REFERENCES


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REFERENCE:-

1. http://www.venturipumps.com/ejector.htm2. http://www.venturipumps.com/syphon.htm3. http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=5363205&url=http%3A%

2F%2Fieeexplore.ieee.org%2Fstamp%2Fstamp.jsp%3Ftp%3D%26arnumber%3D

5363205

4. http://ieeexplore.ieee.org/xpl/articleDetails.jsp?arnumber=5943862&contentType=Conference+Publications

Papers:

1. Author : Dr. Simon Bruce, Vic Cheetham, Graham Legge(http://www.edwardsvacuum.com/uploadedFiles/Resource/Technical_Articles/Rece

nt%20Experience%20of%20Mechanical%20Vacuum%20Pumps.pdf)

Books:

1. R.S.Khurmi, Thermal Engineering- thermosyphon system, S Chand &PVT.LTD (New Delhi - 2008) Page no.602 -603.

2. R.S.Khurmi, Thermal Engineering-steam nozzle, S Chand & PVT.LTD (NewDelhi - 2008) Page no.469 -470.

3. S.K. Hajra choudhury , A.K. Hajra choudhury & Niraj Roy, Elements ofworkshop technology volume-1 Manufacturing Processes, Media promoters&

publishers PVT.LTD (Mumbai - 2005)

Documents

DESIGN AND DEVELOPMENT OF SOLAR THERMAL EXPANSION PUMP