Low-Cost Solar Water Heating Research and Development Roadmap K. Hudon, T. Merrigan, J. Burch and J. Maguire National Renewable Energy Laboratory NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC. Technical Report NREL/TP-5500-54793 August 2012 Contract No. DE-AC36-08GO28308 Low-Cost Solar Water Heating Research and Development Roadmap K. Hudon, T. Merrigan, J. Burch and J. Maguire National Renewable Energy Laboratory Prepared under Task No. SHX1.1001 NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC. National Renewable Energy Laboratory Technical Report 15013 Denver West Parkway NREL/TP-5500-54793 Golden, Colorado 80401 August 2012 303-275-3000 • www.nrel.gov Contract No. DE-AC36-08GO28308 NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. 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Table of Contents List of Figures .............................................................................................................................................. v List of Tables ............................................................................................................................................. viii Executive Summary ................................................................................................................................... ix Nomenclature .......................................................................................................................................... xviii 1 Introduction ........................................................................................................................................... 1 1.1 U.S. Department of Energy Goals .......................................................................................2 1.1.1 Office of Energy Efficiency and Renewable Energy ...............................................2 1.1.2 Building Technologies Program ..............................................................................3 1.1.3 Low-Cost Solar Water Heating R&D Goals ............................................................3 1.2 Roadmap Objective ..............................................................................................................4 1.3 Roadmap Development Process ..........................................................................................4 2 Technology and Market Status ............................................................................................................ 5 2.1 Solar Water Heating Technology.........................................................................................5 2.2 Performance and Economics................................................................................................7 2.2.1 Performance Comparisons .......................................................................................7 2.2.2 Solar Water Heater Economics ..............................................................................13 2.3 Domestic Solar Thermal Market ........................................................................................15 2.3.1 Solar Water Heating Accomplishments .................................................................19 2.3.2 Competing Technologies .......................................................................................20 2.3.3 Global Solar Thermal Market ................................................................................21 2.3.4 Opportunities and Market Growth Potential for Low-Cost Systems .....................24 2.4 Low-Cost Solar Systems ....................................................................................................26 3 Materials, Manufacturing, and Labor Resource Status ................................................................... 30 3.1 Material Requirements .......................................................................................................30 3.1.1 Collectors ...............................................................................................................30 3.1.2 Storage ...................................................................................................................31 3.1.3 Balance of Systems ................................................................................................31 3.2 Manufacturing Capabilities ................................................................................................31 3.3 Labor Resources.................................................................................................................35 3.3.1 Manufacturing ........................................................................................................36 3.3.2 Design and Installation ..........................................................................................36 3.3.3 Operations and Maintenance ..................................................................................36 4 Technology Improvements and Research Needs ............................................................................ 37 4.1 Pathway Option 1—Polymers............................................................................................39 4.1.1 Solar Collectors ......................................................................................................45 4.1.1.1 Absorbers ................................................................................................46 4.1.1.2 Glazings ..................................................................................................47 4.1.2 Thermal Storage .....................................................................................................49 4.1.2.1 Membrane Tanks ....................................................................................50 4.1.2.2 Rotomolded Rigid Tanks ........................................................................50 4.1.3 Balance of System and Controls ............................................................................51 4.1.3.1 Low-Cost Heat Exchangers ....................................................................51 4.1.3.2 Piping ......................................................................................................51 4.1.4 System Engineering and Integration ......................................................................52 4.2 Pathway Option 2—Cold Climate Thermosiphon .............................................................53 4.2.1 Polymer Film Thermosiphon .................................................................................55 iii 4.2.2 Evacuated Tube Thermosiphon .............................................................................55 4.2.3 Freeze Concern for Cold Climate Thermosiphons ................................................56 4.3 Research and Development Priorities ................................................................................57 4.3.1 Materials Testing: Priority 1 ..................................................................................58 4.3.2 Polymer Components: Priorities 1 and 2 ...............................................................58 4.3.2.1 Polymer Heat Exchangers: Priority 1 .....................................................58 4.3.2.2 Polymer Tank: Priority 1 ........................................................................58 4.3.2.3 Polymer Piping: Priority 2 ......................................................................58 4.3.3 Other Component Research: Priorities 2 and 3 ......................................................59 4.3.3.1 Integrated Valving Package: Priority 2 ...................................................59 4.3.3.2 Mounting Methods: Priority 3 ................................................................59 4.3.3.3 Installation