FAÇADE AND ROOF INTEGRATED SOLAR COLLECTORS WITH A COMBINATION OF ELASTOMER TUBES AND METAL FORM SHEET ELEMENTS

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1 FAÇADE AND ROOF INTEGRATED SOLAR COLLECTORS WITH A COMBINATION OF ELASTOMER TUBES AND METAL FORM SHEET ELEMENTS Rainer Tepe Solar Energy Research Center, Högskolan Dalarna, Forskargatan 6, Borlänge, 78188, Sweden Phone Number , Fax Number , rte@du.se Bernd Bartelsen, Gunter Rockendorf Institut für Solarenergieforschung GmbH, Am Ohrberg 1, Emmerthal, 31860, Germany Phone Number , Fax Number , Rockendorf@ISFH.de Norbert Vennemann Fachhochschule Osnabrück, Fb Werkstoffe und Verfahren, Albrechtstr. 30, Osnabrück, 49076, Germany Phone Number , Fax Number , N.Vennemann@fh-osnabrueck.de Gottfried Purkarthofer, Andreas Simetzberger Arbeitsgemeinschaft Erneuerbare Energie, Feldgasse 19, Gleisdorf, 8200, Austria Phone Number , Fax Number , g.purkartshofer@aee.at Abstract The principle of the elastomer-metal-absorber (EMA) is described by the tight connection of elastomer fluid tubes clipped in appropriately shaped metal profiles, acting as solar absorber. The advantages are freeze resistance, operation with corrosive fluids and new possibilities for the installation of the collector. Within an EU-project with partners from Austria, Germany and Sweden this new kind of solar collector has been developed and several prototypes have been built up at different locations. Additional three different heat use concepts have been realised in order to analyse the thermal behaviour of these new collector constructions within real systems. The main aim of the project is the application of the EMA-concept for the transformation of metal roofs and façades into glazed or unglazed collectors using industrial production methods. The development comprises the optimisation of the elastomer material and of the absorber heat transfer capability, the design of production tools for the metal profiles and the construction of different prototypes. The thermal performance of the glazed and unglazed prototypes as well as the reliability have been checked. Furthermore, heat use concepts for this collector have been analysed and developed by TRNSYS simulations and the three most promising concepts have been realised within this project. Although the work is still in progress, the results are promising. 1. INTRODUCTION The idea of a combined absorber with a metal absorber sheet for the absorption of the solar radiation and a flexible elastomer fluid pipe for the transport of the solar heat has been developed (Bartelsen et al., 1996). As shown in figure 1, a round shaped clip profile is integrated into a metal plate that has an absorption layer for solar thermal conversion. In this profile an elastomer tube for the heat removal is clipped in. The application of this elastomer-metal-absorber in solar thermal collectors offers the following advantages and essential possibilities: Due to its expected inherent freeze resistance, operation without an antifreeze additive is possible. System installation without heat exchanger in the solar loop may be discussed. Collector can be operated with corrosive liquids, e.g. direct flow with sea or brackish water. New and simplified techniques for the collector and system installation can be realised. Glas cover (optional) Clip profile Irradiation Metal plate Fig. 1: Principle of the elastomer-metal-absorber Elastomer tube Fluid The most promising application results from the new installation possibilities for the collector and the system. It is intended to integrate this new collector concept into

2 roofs and façades made out of metal form sheet elements. This enables to install the elastomer-metal-absorber in all kinds of solar thermal systems that are common today, as well as a glazed as an unglazed construction. Furthermore, the elastomer-metal-absorber concept seems to be an attractive collector for the solar desalination of brackish and sea water, as the collector may be operated directly with corrosive liquids without cost intensive corrosion protected heat exchangers. The desalination process should be designed to operate on a low temperature level (e.g. around 70 C). 2. APPLICATION AS FAÇADE AND ROOF ELEMENTS Industrially produced roofs and façades often consist of corrugated metal form sheets made out of steel or aluminium. These roof or façade constructions are widely used for industrial, public or residential buildings. The elastomer-metal-absorber concept will transform these metal form sheets into uncovered or transparently covered roof and façade absorbers by integrating an appropriate clip profile into the form sheets during the production process. The elastomer tube can then easily be clipped into these profiles after the installation of the roof or façade. Figure 2 shows the conversion of a typical metal form sheet element into an unglazed or transparently covered solar collector. covers. By this way glazed collectors may be produced, which are specially suited for large systems The idea of this building integrated collector type shows further advantages, which are considered to have the same importance as the expected cost reduction: Metal form sheets are a common and a well proved technology. The transformation into an active solar collector by the elastomer-metal-absorber concept does not affect the reliability of the original roof or façade. The additional effort to transform metal roofs into unglazed absorbers seems to be low, on the other hand, the metal roof and façade elements gain by their additional property as active solar absorbers. The extension to glazed collector roofs for a higher demand temperature is possible. The integration may be performed with a high aesthetic quality and architectural acceptance. Typical examples for a future application of this concept are buildings with a high demand of low temperature heat in the range below 70 C, e.g. hotels, sports halls, hospitals etc. using glazed or unglazed active solar metal roofs. 3. DEVELOPMENT OF THE EMA CONCEPT Within a research and development project that is funded by the European Commission and that is still in progress, investigations to integrate the elastomer-metal-absorber Standard steel or Aluminium plates Form sheets with Integrated clip profiles Form sheets with clip profile and backside insulation Form sheets with integrated elastomer tubes (unglazed collector) Form sheets with elastomer tubes and transparent covers (glazed collector) Fig. 2: Conversion of metalfaçade or roof elements to solar collectors The first step of the conversion is the integration of the clip profile into the metal form sheet during the roll form process. The form sheet is covered with a paint of high solar absorptivity, with or without selective properties. The sheet together with an insulation will be mounted on the roof or façade by normal roofing or metal processing companies. The next step is the integration of the elastomer tubes into the form sheets. The elastomer tubes will be connected via the manifold tubes to the solar system. Thus, an uncovered absorber results, where the technical properties of the metal roof or façade remain unchanged. As an additional option for systems with a higher demand temperature a transparent cover may be added, using single glass panes or transparent plastic in roof and façade metal form sheet elements have been carried out. The main tasks within this project are the improvement of the elastomer material and the absorber construction, the production and installation technology, the long term reliability and thermal performance, heat use concepts and the system integration. Despite the above mentioned institutes and universities the work is supported by several companies from different countries: Bemo Elementbau GmbH, Germany Phoenix AG, Germany Sonnekraft GmbH, Austria Swans Mekaniska Verkstad, Sweden C.H. Swahn AB, Sweden The main aim of the project is to develop solutions for the integration of the EMA concept into ordinary metal roofs with a focus on industrial production methods. During the whole progress of the project different solutions have

3 been realised and evaluated in order to find the best choice for demonstration systems that shall be after this project. In co-operation with the involved companies the project partners have developed different metal sheet elements as well in steel as in aluminium, several elastomer tubes and different solutions for the collector and system techniques. The main criteria for the evaluation of these components are the usability, thermal performance and long-term reliability (Bartelsen et al, 1999). Fig. 3: Aluminium roof and façade form sheet elements At the top: standard roof and façade profile At the bottom: EMA profile Fig. 4: Thermal conductivity and tensile strength of different elastomer mixture and tubes Themal conductivity in W/mK 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 4. DEVELOPMENT OF THE COMPONENTS The department of material technology of the University of Applied Science in Osnabrück has developed an elastomer material based on ethylene-propylene-dienterpolymer (EPDM) for the application in the elastomermetal-absorber. The main part of the development was to increase the low thermal conductivity of typical elastomer material that is in general 0.2 to 0.35 W/mK. At the same time the mechanical properties have to be improved, especially for higher temperatures. (Vennemann et al., 1997) In the beginning of the projects requirements for the elastomer material respectively the tubes were fixed: Thermal conductivity: 0.6 to > 1.0 W/mK Tensile strength: > 8.0 N/mm 2 at 23 C > 4.0 N/mm 2 at 130 C Time to failure > 1500 h at 3 bar and 130 C Elongation at break > 80 % Compression set < 35 % at 22 h and 100 C The temperature durability of EPDM material is limited to about 175 C. Furthermore, it has to be taken into account that with increasing operation temperatures as well the tensile strength as the ageing behaviour are decreasing. Therefore it has to be considered: 1. The stagnation temperature of the absorber should be limited to values of around 160 C during conditions with an irradiation of 1000 W/m 2, an ambient temperature of 30 C and when there is no wind at all. 2. The system design for the EMA enables to avoid high pressure and high temperatures at the same time Tensile strength in N/mm² Mixture D31- KS-4 D14 - KS-6 D32 - KS-15 D33 - KS-150 D36 - V Conductivity Mixture Conductivity Tube Tensile strength Tube

4 Already with the first mixtures of the elastomer material the thermal conductivity has been increased significantly. Furthermore, the mechanical properties were optimised in further steps. Problems occurred when the production process was transferred from the laboratory to the industrial production are nearly under control now. Figure 4 shows the thermal conductivity and tensile strength of different industrial produced samples. For several elastomer mixtures, produced in laboratory or industrial, a thermal conductivity of above 1.0 W/mK could be achieved, however the extruded tubes from the industrial production did not reach these high values. This was surprising in the beginning due to the fact that the tubes from the laboratory production showed the same results. Investigations revealed that the differences are caused by the industrial extrusion process that is around 100 times faster than the process in the laboratory. Further investigations concerning this problem showed that in the industrial extrusion process the graphite particles in the material are orientated in the flow direction of the tubes. It has been observed that the thermal conductivity in this direction is up to three times higher than in perpendicular direction. To avoid or diminish the orientation of the filler particles a novel technique for the production of the elastomer tubes has been applied and although the conductivity could be increased the problem has not been solved completely. At the present stage of the project it can be stated that for an elastomer tubes that fulfils the mechanical properties a thermal conductivity of about 0.7 W/mK could be reached. But although with this value the objective has been achieved, the investigations also have shown that the potential can be much higher and that therefore the industrial production process has to be optimised. Then maybe values above 1.0 W/mK might be realised. For the construction of the metal form sheet elements a theoretical analysis of the internal thermal resistance has been carried out first and the construction parameters have been defined. For the industrial production of appropriate absorber prototypes with three respectively two clip profiles special production tools for aluminium and steel sheets have been developed. The main requests for the production process of the metal form sheets are to be able to integrate the tubes into the profile and at the same time to achieve good heat conduction between the absorber and the fluid. This comprises the following items: A material with high thermal conductivity (copper, aluminium or steel). Direct contact between the metal profile and the tube. A large heat transfer area between the metal profile and the elastomer tube (i.e. a great contact angle). Optimised distance between the fluid tubes of 80 to 110 mm. In addition, some mechanical properties are important during ordinary operation conditions: The profile has to be able to expand during freeze conditions and to contract during thaw conditions without remaining alteration. Mechanical protection of the elastomer tubes. Simplified possibility to insert the elastomer tube into the profile. Furthermore, the industrial roll-form process to produce the metal form sheets as shown in fig. 3 should not lead to remarkable cost increase. Therefore it was necessary to integrate the production steps for the clip profile into the ordinary roll-forming machine. Fig. 5: Cross-section of the advanced clip profile The above mentioned requirements and further boundary conditions from the roll-form production led to the more advanced form of the clip profile as shown in Fig. 5. The usability should be much better with a deeper profile and smooth profile edges. This new form supports the protection of the elastomer tube and leads to a better alteration after the expansion during freeze cycles. Furthermore, it avoids that during the expansion the tubes slide out of the profile. In addition, the integration of the elastomer tubes into the profile is much easier and during operation the contact between the metal plate and the tube is improved. These investigations were supported by numerical calculations that especially took into account the interaction between the metal plate and the tubes. With these calculations it was possible to show that even on very long roofs the different expansion coefficients of metal and EPDM would cause no problems. For the industrial production of the metal form sheets special roll-form tools have been developed and the production process has been adapted. The involved company in Germany was able to realise the clip profile with 12 roll pairs, however the Swedish partner needed 9 steps to integrate the profile in the steel plates but in a much simpler process. The internal thermal resistance of the first prototypes from aluminium and steel plates gave values of 32 respectively 35 W/m 2 K which was much lower than the

5 desired value of 50 W/m 2 K. These lower values were mainly caused by the low thickness of the steel plates and the big distance between the tubes in the aluminium plates. But during the first production of the metal form sheet elements the possibilities to produce the best constructions were limited. In the second production phase of the aluminium profile new roll-form tools have been designed and the whole machine could be adapted in a way that a smaller distance between the fluid channels was possible. The next optimisation step will be to redesign the whole production process that makes it possible to form the metal plates in only one step. Furthermore, the metal sheet elements shall be equipped with 4 clip profiles for the next prototypes and possibilities to integrate the elastomer tubes directly after the forming process shall be analysed. 6. TEST SYSTEMS DESIGN AND OPERATION In autumn 2000 three different test systems representing three different heat use concepts have been installed and put into operation: An unglazed steel absorber with 28 m 2 in combination with a heat pump and a bore hole storage for domestic hot water and space heating at SERC in Sweden. An unglazed aluminium absorber with 20 m 2 for an outdoor swimming pool in Gleisdorf, Austria. A glazed aluminium absorber with 30 m 2 for domestic hot water production in drain-back techniques at ISFH in Germany. The absorber consists of partly selective coated aluminium sheets with a stagnation temperature of around 160 C. Fig. 6: Second steel absorber sheets with backside insulation 5. PROTOTYPES In summer 1999 the first prototypes of industrial produced metal form plates were installed and the collectors were put into operation. At SERC a steel absorber of 9 m 2 has been tested, at ISFH a prototype of aluminium plates with 13 m 2 has been analysed. Fig 7 shows the first unglazed aluminium prototype that has been installed at ISFH. The measurements of the collector efficiency gave the expected results, regarding the low internal thermal resistance. These first experiences lead to an optimisation process for the second production phase. The quantity test gave positive results and after two years of operation the efficiency is still the same. Especially during freezing periods no problems occurred. The second prototype out of aluminium plates gave much better results compared to the first collector. Due to a lower distance of 100 mm between the fluid channels and an advanced elastomer tube the internal thermal resistance increased to 58 W/m 2 K. This also increased the efficiency of the elastomer-metal-absorber and the thermal performance. Fig. 7: First unglazed prototype of aluminium steel plates The main criteria for the evaluation of the test systems are the operational behaviour, the reliability and the thermal performance. Evaluations test of as well glazed as unglazed elastomermetal-absorbers made out of aluminium sheets showed only small differences compared to standard solar collectors. Fig. 8 indicates the only small differences in the characteristic collector curves. The internal thermal resistance of the second aluminium prototype reached values of about 60 W/m 2 K that is in the same range as for standard flat plate collectors. For swimming pool absorber this value is in general higher. The same conclusion can be made if the conversion factors are considered. The heat loss coefficients of unglazed constructions are smaller compared to standard absorber and thereby compensate the lower conversion factors of the EMA.

6 Unglazed collectors Glazed collectors Efficiency Irradiation: 800 W/m² Ambient temp.: 20 C Wind speed: 1,5 m/s Standard Sky temp.: 5 C Pool absorber EMA(α=0,93 ; ε=0,87) EMA(α=0,93 ; ε=0,45) Efficiency Irradiation: 800 W/m² Ambient temp.: 20 C Standard Wind speed: 3,0 m/s sel. flat plate collector EMA(α=0,93 ; ε=0,87) EMA (α=0,93 ; ε=0,45) Mean fluidtemperature in C Fig. 8: Collector efficiency curves for different EMA constructions in comparison to standard flat plate collectors and absorbers The heat loss coefficients of the glazed prototypes are determined by the high emission coefficients of the coating. As a results of the only low selectivity the heat loss coefficients are significantly worst than for standard collectors. Furthermore, the aluminium profiles that hold Mean fluidtemperature in C the glass covers work like a cold bridge. But this should be optimised for the next constructions. Glazed and nonselective elastomer-metal-absorber show nearly the same thermal performance as comparable non-selective flat plate collectors. Fig. 9: Unglazed steel absorber at SERC in Sweden, right: first prototype, left: second prototype; both collectors are connected to the test system.

7 Only some small changes in the flow circuit are recommended in the following demonstration systems. Fig. 9 to 11 show the different elastomer-metal-absorber installed at the different locations. 7. HEAT USE CONCEPTS Fig. 10: First glazed aluminium absorber at ISFH with an area of 30 m 2 So far, the operation experiences with the test systems did not reveal any special problems for the integration of this new kind of collector in different solar thermal systems. The collectors and the system installations are freezeresistant, the on and off switching behaviour is satisfying. The high stagnation temperature of the covered EMA constructions (up to nearly 160 C) caused no problems, even during operation starts of the stagnating collector. The huge variety of different collector construction of the elastomer-metal-absorber - glazed or unglazed, nonselective or partly selective, coatings with different colours - offers several possibilities for the integration of this new collector in different solar thermal systems. Thereby it has to be taken into account that the resistance of the elastomer tubes against oxygen permeation can not be neglected. During the design phase of projects or buildings it is common that roofs are in general totally covered with metal sheet elements. If the elastomer-metal-absorber shall be installed, the design of the system should include the calculation of the roof area that has to be equipped with the clip profile. If the whole roof is covered with the clip profile, the active absorber is determined by those profiles that contain the elastomer tube. Furthermore, for different applications parts or the complete area can be covered with glass. Unglazed EMA constructions seem to be predetermined for outdoor swimming pools if enough roof area is available. Furthermore, combinations with heat pumps and ground storage are possible as well as systems for preheating or industrial applications. Fig. 11: Unglazed aluminium absorber in Gleisdorf

8 Glazed elastomer-metal-absorbers are suitable for all kinds of solar thermal systems that are common today. This includes ordinary domestic hot water systems, socalled combisystems and large solar systems with seasonal storage. For all these standard systems TRNSYS simulations have been carried out with main emphasis on those systems that have been realised at the three locations. These simulations were as well done with different EMA constructions as with characteristic values of standard collectors or absorbers. The simulations for outdoor swimming pools are based on a system with 1050 m 2 water surface and 2100 m 3 water volume. For the comparison of the simulations with different absorbers the area of the system with the elastomer-metal-absorber has been increased as long as the pool temperatures reached nearly the same values during the whole season. In comparison with the reference system that is equipped with 500 m 2 of standard absorbers, for the EMA system 12 % more absorber area is needed to get the same results. Ordinary domestic hot water systems as well as combisystems have been simulated with different glazed collector constructions. As well for these systems the collector area has to be increased when the active EMA roof is used. Depending on the heat use concept the increase of the area varies between 15 and 40 % to reach the same solar fraction. For a domestic hot water system in single family houses with a high solar fraction 7 m 2 of a glazed EMA are needed instead of 5 m 2 of a standard selective flat plate collector. seasonal performance factor significantly. In a system for a single family house that is equipped with very good low temperature heating components the seasonal performance factor could be increased from 3.6 up to 4.7. This corresponds to a reduction of nearly 25 % of the needed electricity. Furthermore, the simulations showed that the mean temperature in the ground is slightly rising during several years of operation, however in ordinary heat pump systems this values is decreasing as well as the seasonal performance factor. It has to be taken into account that this combination might have a big potential in Sweden due to the fact that the systems where direct electricity is needed for space heating shall be replaced in future. In addition, metal plate roofs are very common in single family buildings. The potential to raise the seasonal performance factor in heat pump systems should be much higher in bigger plants for residential areas. Here seasonal effects can be reached if several bore holes are connected together to a big storage volume. This should lead to much higher mean ground temperatures and thereby give a much better performance compared to a system with only one bore hole. These combinations will be investigated in the next months. 8. COST CALCULATIONS First cost calculations have been carried out for unglazed EMA constructions. The costs for the production of the metal form sheet elements could only be estimated, however reliable calculations were possible for the Unglazed rubber absorber Unglazed ripped PP-tubes Unglazed elastomermetal-absorber Collector area in m Solar system costs in EURO 34600, , ,- Specific solar system costs in EURO/m 2 69,20 61,80 40,37 Solar heat costs in EURO/MWh 28,90 27,60 20,10 Table 1: Cost calculation for different outdoor swimming pool systems For bigger system where the collectors are mainly used for preheating this ratio becomes smaller. If the elastomer-metal-absorber is coated with a partly selective colour, the increase of the needed area becomes much smaller. However, in combisystems the difference between a standard collector and a glazed EMA construction rises and the area increase can reach values of 50 % and even higher. The combination of the elastomer-metal-absorber with a heat pump and a bore hole storage enables to raise the elastomer tube and the system technique as well as for the installation of the system. The development of glazed constructions is still in progress and therefore reliable cost calculations are not possible. This will be done when suitable solutions for the installation of the glass covers have been found. A comprehensive cost analysis has been carried out for an outdoor swimming pool system. These calculations included the maintenance costs, an interest rate of 8 % and weighted lifetimes of the components. The elastomer-metal-absorber has been compared with two different standard absorbers. For the EMA only the additional costs that arise when metal sheet elements that

9 contain the clip profiles shall be installed are taken into account. Table 1 summarises the most important values of these cost calculations and shows a remarkable advantage for the elastomer-metal-absorber. thermal conductivity for thermal solar collectors. In Proceedings of the International Rubber Conference, 30 June-3 July, Nürnberg, Germany, CONCLUSIONS AND OUTLOOK With the elastomer-metal-absorber concept different solutions for solar thermal systems have been developed. The idea of the EMA offers new possibilities considering aspects like building integration, freeze protection, corrosive liquids and operation techniques. Roof and façade integrated form sheet elements in aluminium or steel have been developed. Glazed or unglazed constructions as well as absorbers with nonselective or partly selective coatings are possible. Because of the variety of different collector design the EMA can be used in all kinds of solar thermal systems. Further activities shall be focused on demonstration systems for different heat use concepts. The market potential of the elastomer-metal-absorber is based on the following items: A further cost reduction seems to be possible. Building integrated solar collectors seem to be much more interesting for architects. Roof and façade integrated collectors are suitable for all kinds of buildings that have a corresponding heat demand. Finally, it can be stated that the elastomer-metal-absorber offers new and interesting possibilities for the use of solar energy. Acknowledgements The work is partially funded by the European Commission, within the project Façade and roof integrated solar collectors with a combination of elastomer tubes and metal form sheet elements, Contract No. JOR3-CT , organised in the framework of the Non-Nuclear Energy Research and Technological Development Programme JOULE III. REFERENCES Bartelsen B., Rockendorf G. and Vennemann N. (1996). Development of an elastomer-metal-absorber for thermal solar collectors.. In Proceedings of the EuroSun 96, September, Freiburg, Germany, 1996, pp DGS-Sonnenenergie Verlag, München. Bartelsen B., Rockendorf G. and Vennemann N., Tepe R., Lorenz K. and Purkarthofer G. (1999). Elastomer- Metal-Absorber: Development And Application. Solar Energy. Vol. 67. Nos pp Vennemann N., Bökamp K., Wallach I., Bartelsen B. and Rockendorf G. (1997). EPDM compounds with improved

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