Adsorption Refrigeration Research at Warwick Prof. R.E ...
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1st TECCS meeting, 26th April 2007
Adsorption Refrigeration Research at Warwick
Prof. R.E. Critoph
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Contents:
1. Background2. Previous research projects3. Current projects and future plans
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We are focussed on adsorption cycles for:
Heat pumpsRefrigeratorsAir conditioning
Driven by heat from:Fossil fuelsBio fuelsWaste heatSolar thermal energy
Background:
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These machines adsorb refrigerant into a solid as the basis of a refrigeration cycle.
It all started with Faraday in 1821…
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Adsorption refrigerators and heat pumps
These machines ADsorb the refrigerant into a solid rather than ABsorbing it into a liquid. It is a discontinuous (batch) process
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Mycom Silica-gel water adsorption chiller
One of the few commercial machines in production :
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Background
• Adsorption refrigeration research at Warwick began in 1986
• We prefer to utilise ammonia as a refrigerant
• We have investigated zeolites and salts but still tend to prefer active carbons
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The reasons for our use of ammonia:
• High pressure, so permeability of sorbent is not critical, pressure drops not a problem
• Can be easier to engineer than sub-atmospheric systems
• Good latent heat (although not as good as water)
• With regenerative cycles, the COP can be satisfactory
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Challenges common to all our research:
1.Improving heat transfer in the adsorbent bed, both to reduce the cycle time / size and to use regenerative cycles.
2.Doing it with zero cost and zero mass!
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Facilities:
1.Porosimetry.
2.Thermal conductivity measurement.
3.Permeability measurement.
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Rubotherm magnetic suspension balance
Test vessel
Liquid reservoir
Temperature control
Basket and sample
Porosity measurement equipment
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PROJECTS AT WARWICK :1.Convective Thermal Wave
2.Monolithic carbon generators
3.Multiple-Bed regenerative cycle
4.Plate heat exchanger bonded to thin layers of adsorbent.A patented cycle using granular carbon and requiring an ammonia gas circulator. Good heat transfer is obtained by forcing the refrigerant gas through the granular bed.
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“Proof of concept” machine [prototype #1]
Heater
Condenser
Circulating pump
Inert bed
Cooler
Active bed
Receiver /evaporator
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Performance of the proof of concept forced convection adsorption machine [#1]
• Generating temperature 225° C• Heat rejection temperature 40 ° C• Condensing temperature 35° C• Evaporating temperature -2 ° C• Cooling COP 0.8
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Characteristics of #2 prototype machine
1.5 m
• Cooling power 12 kW• Heating power 17 kW• Cooling C.O.P = 0.9 • Heating COP = 1.8• Driving temperature 175° – 225°C• Parasitic pumping power 200 W
+200 W ancillaries• Ammonia charge 4 kg• Projected cost €400-600 / kW ??
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Rotor and stator of ammonia circulator
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Assembled prototype #2, May 2003
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• Already proven in laboratory
• High efficiency
Advantages
Disadvantages• Mechanically complicated
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• Gas circulator successful
• Design problems (soluble) lead to poor performance
• There is another prototype [#3] being built in a Carbon Trust project
Results of #2 DTER / Industry project
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PROJECTS AT WARWICK :1. Convective Thermal Wave
2. Monolithic carbon generators
3. Multiple-Bed regenerative cycle
4. Plate heat exchanger bonded to thin layers of adsorbent.
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GRANULAR CARBON
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MONOLITHIC CARBON
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Sample ρ
kg m-3
λWm-1K-1
hE
Wm-2K-1
Xmax
(kg kg-1)
Cmax
J kg-1K-1
Kr
m2x 10-14
Br
m-1x 108
LM127 750 0.60 350 0.36 8000 36 0.44
LM128 715 0.38 800 0.33 8000 1.3 5.42
Granular 500 0.16 50 0.29 8000 - -
Monolithic carbon properties
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Carbon- Aluminium Laminate
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Carbon- Aluminium Laminate
Typical conductivity of monolithic carbon : 0.5 W/mK
Typical radial conductivity of new carbon - aluminium laminate: 20 W/mK
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Junction of steel shell and aluminium fin
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Schematic of monolithic carbon refrigerator
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Overall view of first test rig
Generators
Steam boiler
Evaporator
Ammonia condenser
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Typical test results
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1. The carbon - aluminium monolith has good heat transfer.
2. The design computer modelwas validated.
3. COP obtained = 0.44, Power = 500 Watts
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Unfortunately, the manufacturing process for making this design of laminate is too labour intensive and therefore too costly – we are not continuing with this work at present, but have moved on to lower cost solutions...
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PROJECTS AT WARWICK :1. Convective Thermal Wave
2. Monolithic carbon plate-type generator
3. Multiple-Bed regenerative cycle
4. Plate heat exchanger bonded to thin layers of adsorbent.
A patented cycle based on modular generators lined with monolithic carbon
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12.7 mm
4.0 mm 0.9 mm
Initial carbon-lined tube
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Double sorption module
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Sliding vane assembly
Evaporator and condenser section
Adsorption and desorptionsection
Ambient air to adsorber
Air heated by adsorber
Air heated by heat source
Air heats desorber
Warm air rejected
Ambient air to condenser
Warm air from condenser
Cold air from evaporator
Ambient air to evaporator
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Performance of optimised design
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Rig under construction – Drum and ducts visible
Condenser fan
Sorption section fan
Evaporator fan
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Complete machine –Outer cladding in place
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The realisation that the mechanical complexity outweighed the benefits of the ‘counterflow’ design, lead us to a low-cost ‘cross-flow’ concept…
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VARIATIONS ON MODULE DESIGNS:
Advanced module (separate condenser and evaporator)
Fixed beds – Being used on ‘SOCOOL’ tri-generation project
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Module with separate evaporator, receiver and condenser
Evaporator
Condenser
Generator
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FIXED MODULAR BED CONFIGURATION
Evaporation
Condensation
Phase 1
DesorptionAdsorption
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FIXED MODULAR BED CONFIGURATION
Evaporation
Condensation
Phase 2
Desorption Adsorption
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Advantages :
• Sealed modules are low-cost and safe
• No ammonia valves or controls
• Only moving parts are the fans
Disavantages :
• More modules needed than for rotating system
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Parameters:• Number of tubes in row• Mass flow rate of oil• Cycle time / row
Performance Indicators:• COP• Cooling power / kg carbon
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Sorption Machine,COP (cooling) 0.6COP (heating) 1.6[illustrative]
Engine
+
Generator
+
Waste
Heat
Recovery
100 kW Fuel
30 kW electricity
30 kW exhaust
30 kW cooling jacket
30 kW cooling
96 kW heating
OR
Ambient energy or cooling load
SOCOOL TRIGENERATION PROJECT - illustrative energy flows
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Single module under test, January 2005
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5 kW SOCOOL prototype before delivery to Italy
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THE COMPLETE UW SOCOOL MACHINE INSTALLED AT CRF
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‘Spinner’ project using the fixed bed design
The advantages are those of simplicity –the only moving parts are fans.
A 1–2 kW air conditioner for laboratory demonstration has been built in early 2006 and is being commissioned.
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‘Spinner’ project
Generator section
Condenser section
Receiver section
Evaporator section
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‘Spinner’ project
Assembled prototype without fans
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PROJECTS AT WARWICK :1. Convective Thermal Wave
2. Monolithic carbon generators
3. Multiple-Bed regenerative cycle
4. Plate heat exchanger bonded to thin layers of adsorbent.
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Has been investigated in a group project during 2003/4
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Inlet Temperature 200C
Condensing temperature 30 C
Evaporating temperature 15 C
Carbon thickness 1mm
Wall thickness 0.1mm
Fluid channel thickness 0.25mm
h=1080 W/m2 K 10 20 30 40 50 60 70 80 90 100
0.15
0.2
0.25
0.3
0.35
3
3.5
4
4.5
5
5.5
6.
6.5
Specific cooling power (kW/kg)
Refrigeration C.O.P.
Total cycle time (s)
This is two orders of magnitude more compact than commercially available adsorption refrigerators
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• VERY compact
• Low ammonia mass
Advantages
Disadvantages• Not yet demonstrated – some
technical risks (seals, thermal shock)
• Liquid-liquid heat transfer may not suit all applications
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In 2003, a student group project worked on a version of this concept, simply to demonstrate the principle.Because of cost constraints they had to use O-ring seals rather than nickel-brazed plates, but still managed to achieve useful results.
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1 kW sorption generator, based on plate heat exchanger
Generator internal structure
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This lead to an EU-funded project, ‘TOPMACS’, aimed at heat operated car/truck air conditioning.
It is coordinated by CRF and started in March 2005.
We are collaborating with Chemviron Carbon and Bodycote to work on a novel brazed plate generator design.
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Two applications:
• C-Class car (2 -3 kW)
• Long distance truck
The initial generator design was manufactured in January 2007. Two such generators are needed per system.
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Engine,cabinheatermatrix
andauxiliaryburner
Rad
iato
r
Sorption Generator
G1
Sorption Generator
G2
Evap
orat
or
Cabin coolermatrix
Coo
ler
Con
dens
er
AmmoniaEngine cooling loop
Cabin chillerloop
Ambient air
Intercoolingloop
V1
V2
V3
V5
V11V6V7 V8 V9
V10P1
P2
P3HEX1
HEX2HEX3
HEX4
FAN2
FAN1
AdsorberCooling loop
V4
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1st TECCS meeting, 26th April 2007
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1st TECCS meeting, 26th April 2007
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1st TECCS meeting, 26th April 2007
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1st TECCS meeting, 26th April 2007
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1st TECCS meeting, 26th April 2007
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1st TECCS meeting, 26th April 2007
Preliminary test: carbon and heating/cooling water temperatures
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1st TECCS meeting, 26th April 2007
Preliminary test pressure swing
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1st TECCS meeting, 26th April 2007
We hope to have a 2-bed system working in the laboratory within three months.
If successful a test-bed system will be installed in a car in 2008.
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1st TECCS meeting, 26th April 2007
EPSRC Domestic Gas-Fired Heat Pump Project
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1st TECCS meeting, 26th April 2007
UK Energy Consumption
In the UK, Space Heating and Hot Water Represents:
82% of Domestic Energy Consumption64% of Industrial Energy Consumption39% of UK Energy Consumption Used For Space Heating and Hot Water
Improvements in the efficiency of space heating and hot water production could dramatically reduce carbon emissions and energy usage
EPSRC Domestic Gas-Fired Heat Pump Project - Background
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1st TECCS meeting, 26th April 2007
•• Replacement for a Domestic Gas Combination Replacement for a Domestic Gas Combination BoilerBoiler
•• Air Source (Ease of Installation)Air Source (Ease of Installation)
•• Heating Output of 7kWHeating Output of 7kW
•• Hot Water Output of 10 l minHot Water Output of 10 l min--11 @ 30@ 30°°C C Temperature Rise (~21 kW)Temperature Rise (~21 kW)
•• Eventual Packaged System Volume Eventual Packaged System Volume ≤≤22××Volume Volume Conventional Gas BoilerConventional Gas Boiler
EPSRC Domestic Gas-Fired Heat Pump Project - Specification
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1st TECCS meeting, 26th April 2007
Two Main Heat Recovery Methods for Adsorption Cycles:
– Thermal Wave (Performance envelope in Red Below)– Multiple-Bed (Four-Bed In Green, Two-Bed In Blue)
00.20.40.60.8
11.21.41.61.8
2
0 500 1000 1500 2000 2500
SCP (W kg-1)
CO
P
2-Bed4-BedModular
Performance Envelopes
EPSRC Domestic Gas-Fired Heat Pump Project – Cycle selection
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1st TECCS meeting, 26th April 2007
• Adsorption Cycle Carbon-Ammonia Heat Pump
• Four-Bed Heat Recovery With Mass Recovery
• Gas Fired by a Regenerative Gas Burner
EPSRC Domestic Gas-Fired Heat Pump Project - System
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1st TECCS meeting, 26th April 2007
System Schematic – Heat Pump
Bed 1 Bed 2
Bed 3 Bed 4
Hot Oil From Burner
Oil Return To Burner
Oil-to-Water Heat Exchanger
Condenser
EvaporatorAmbient Air to Evaporator
Cooled Air From Evaporator
Heating Water Inlet
Heating Water Outlet
(Internal Connections Removed For
Clarity)
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1st TECCS meeting, 26th April 2007
Sorption Generator Design
Plate Heat Exchanger Sorption GeneratorDesigned for the EU TOPMACS Mobile Air Conditioning ProjectGives a High Power Density
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1st TECCS meeting, 26th April 2007
Hot Water Flow Rate - Efficiency
1.4
1.45
1.5
1.55
1.6
1.65
1.7
1.75
5 6 7 8 9 10 11 12
Hot Water Flow Rate (l min-1)
CO
P
WaterTemp=50C
WaterTemp=40C
•Air Source Temperature: 10°C•Hot Water Inlet Temperature: 20°C
EPSRC Domestic Gas-Fired Heat Pump Project -System Performance – Water Heating
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1st TECCS meeting, 26th April 2007
System Can Match a Combination Boiler:• 10 l min-1 flow rate @ 30°C Temperature Rise• 21 kW Output
Including an Assumed Burner Efficiency of 0.8:• @ 50°C Hot Water Temperature: Overall COP ≅1.2• @ 40°C Hot Water Temperature: Overall COP ≅1.32
Typical Condensing Combination Boiler Efficiency 0.88
Gas Fired Heat Pump: • 33% More Efficient• 1.5 Times Lower Gas Consumption
EPSRC Domestic Gas-Fired Heat Pump Project -System Performance – Water Heating
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1st TECCS meeting, 26th April 2007
Heating COP
1.5
1.55
1.6
1.65
1.7
1.75
1.8
1.85
-10 -5 0 5 10 15
Ambient Air Temperature (oC)
CO
P
Heating Water Supply Temperature: 35°C(i.e. Underfloor Heating)
EPSRC Domestic Gas-Fired Heat Pump Project -System Performance – Space Heating
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1st TECCS meeting, 26th April 2007
Seasonal Heating COP: 1.69 (Typical UK Midlands Heating Season)
Seasonal Heating COP Including Burner Efficiency: 1.35
Condensing Boiler Efficiency: 0.88 (source: SEDBUK)
1.5 Times Reduction in Gas Usage
EPSRC Domestic Gas-Fired Heat Pump Project -System Performance – Space Heating
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1st TECCS meeting, 26th April 2007
1.92.2
2.72.2
2.9 2.9
00.5
11.5
22.5
3
Penc
e pe
r kW
h
40 55
Heating Water Delivery Temperature (oC)
Heating Cost
Gas Fired HeatPumpElectric Air SourceHeat PumpCondensing Boiler
Gas Price: 2.55p per kWhElectricity Price: 8.4p per kWhSource: British Gas Prices From 1st March 2006Condensing Boiler Efficiency: 95% and 88%
EPSRC Domestic Gas-Fired Heat Pump Project -System Performance – Space Heating
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1st TECCS meeting, 26th April 2007
0.14 0.14
0.20
0.160.19
0.22
0
0.05
0.1
0.15
0.2
0.25
kg C
O2
per k
Wh
40 55
Heating Water Delivery Temperature (oC)
CO2 Emmisions
Gas Fired HeatPump
Electric AirSource HeatPumpCondensingBoiler
Assumptions:0.19 kg CO2 per kWh of Natural Gas Consumed0.54 kg CO2 per kWh of UK Grid Electricity ConsumedCondensing Boiler Efficiency 95% and 88%
EPSRC Domestic Gas-Fired Heat Pump Project -System Performance – Space Heating
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1st TECCS meeting, 26th April 2007
• Design for a Gas Fired Adsorption Heat Pump Completed
• Shown to Compare Favourably to Alternative Technologies
• Significant Fuel Cost and Carbon Emissions Reductions
• Prototype Undergoing Manufacture Prior to Testing
EPSRC Domestic Gas-Fired Heat Pump Project –Current Status
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1st TECCS meeting, 26th April 2007
Future Projects
1. EU FP7 – Solar Powered Air Conditioning, 5 – 10 kW cooling
2. Solar powered cold store, 2 kW cooling3. Ice-maker for use in Indian villages in
conjunction with a biomass fuelled engine.4. Further development of the gas-fired heat pump
– seeking venture capital or manufacturing investment.
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1st TECCS meeting, 26th April 2007
• Feasibility studies carried out on the use of solar collectors to drive adsorption cycle air conditioners.
• Evacuated tube collectors proved more cost effective than flat plate collectors.
Evacuated Tube Collector Cost: €785/m2.Flat Plate Collector Cost: €500/m2.
Solar Air Conditioning
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1st TECCS meeting, 26th April 2007
Solar Air Conditioning
Performance CalculationsConditions:Evacuated tube collector driving a four bed adsorption cycle with mass recovery and plate type generators.High porosity ‘Maxsorb’ carbon.Hottest day of the year in Seville, Spain: Peak ambient temperature 40°C.Results:Optimum of 2.5 m2 of collector per kg of carbon adsorbent.9.8 MJ of cooling per m2 collector per day.
Equivalent to 0.34 kW m-2 of collector over an 8 hour cooling period.
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1st TECCS meeting, 26th April 2007
Solar Air Conditioning
Typical room air conditioner: ~3 kW
Would require approximately:9 m2 of collector at a cost of €7000.3.6 kg of carbon (total generator volume ~7 litres).
Cost will be dominated by the collector:Important to achieve maximum efficiency from the adsorption air conditioner.
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1st TECCS meeting, 26th April 2007
Future Projects
1. EU FP7 – Solar Powered Air Conditioning, 5 – 10 kW cooling
2. Solar powered cold store, 2 kW cooling3. Ice-maker for use in Indian villages in
conjunction with a biomass fuelled engine.4. Further development of the gas-fired heat pump
– seeking venture capital or manufacturing investment.
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1st TECCS meeting, 26th April 2007
Future Projects
Solar powered cold store, 2 kW cooling
A 1-year project, expected to start in May 2007 is to build a walk-in container for food preservation, which will be field tested. It will use evacuated tube solar collectors with ammonia-carbon plate heat exchangers.
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1st TECCS meeting, 26th April 2007
Future Projects
1. EU FP7 – Solar Powered Air Conditioning, 5 – 10 kW cooling
2. Solar powered cold store, 2 kW cooling3. Ice-maker for use in Indian villages in
conjunction with a biomass fuelled engine.4. Further development of the gas-fired heat pump
– seeking venture capital or manufacturing investment.
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1st TECCS meeting, 26th April 2007
Future Projects
Ice-maker for use in Indian villages in conjunction with a biomass fuelled engine.
A three year project funded by EPSRC, with partners in Aston, Bristol, Leeds and IIT Delhi seeks to establish a complete village energy infrastructure based on biofuels. We have the task of building an ice-maker driven by the waste heat of an engine.
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1st TECCS meeting, 26th April 2007
Future Projects
1. EU FP7 – Solar Powered Air Conditioning, 5 – 10 kW cooling
2. Solar powered cold store, 2 kW cooling3. Ice-maker for use in Indian villages in
conjunction with a biomass fuelled engine.4. Further development of the gas-fired heat pump
– seeking venture capital or manufacturing investment.