November 2023| Volume 02 | Issue 04 | Pages 17-23

AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages
17-23 Technology
Future
Journal homepage: https://fupubco.com/futech
Open Access Journal

ISSN 2832-0379
https://doi.org/10.55670/fpll.futech.2.4.2

Article

Design, fabrication, and performance assessment of

a novel solar air heater based on recycled materials
Abolfazl Hajizadeh Aghdam*, Parisa Rezaei, Mohammad Baraheni
Department of Mechanical Engineering, Arak University of Technology, Arak, Iran
ARTICLE INFO ABSTRACT

Article history: In this paper, a solar air heater (SAH) is designed using recyclable materials,
Received 20 January 2022 and its performance is analyzed. The device is composed of an absorbing plate
Received in revised form made up of 36 cans of soda and an equal number of tins with bodies covered
21 February 2023 with black color and has resistivity against high temperatures. The laboratory
Accepted 26 February 2023 research revealed that the collector's efficiency is enhanced considerably by
increased airflow speed and the heat transfer coefficient between the absorbing
Keywords: plane and air. In addition, the effects of the radiation intensity and mass flow
Soda cans , Solar air heater, rate on parameters such as the absorbed heat, temperature difference, and
Thermal efficiency, Irreversibility, thermal efficiency are investigated. The derived results for mass flow rates of
Exergetic efficiency 0.0104 (kgs-1) and 0.0078 (kgs-1) indicate that all mentioned parameters
increase the radiation intensity. Furthermore, the thermal efficiency and the
*Corresponding author absorbed heat are increased by increasing the mass flow rate, while a reduced
Email address: mass flow rate increases the temperature difference parameter. Moreover,
abolfazl_hajizade@yahoo.com studying the charts demonstrates that the tins absorb a larger portion of the
sun's radiation and, consequently, enhance thermal transfer compared with the
soda cans. Irreversibility increased with increasing radiation intensity. At 300
DOI: 10.55670/fpll.futech.2.4.2 radiation intensity, the highest thermal and exergetic efficiencies occurred.

1. Introduction on the mode. The warm air is generated in diverse sections in

Renewable energy is one of the alternative resources for passive solar air heaters and transferred for final use. On the
non-renewable ones, which can be economical in fossil fuels other hand, passive SAHs are commonly used during the day
prices. Solar energy is also called green energy, so they are [5]. The SAH can be categorized into one-pass and two-pass
clean energy resources, and their technological effects on the with or without heat storage based on the number of airflow
environment are much lower than conventional energy passes [6]. The primary drawback of the SAHs is the low heat
technology. Nowadays, the utilization of solar energy transfer coefficient among the absorbing plate and airflow,
conversion for generating heat and electricity has publicized leading to reduced thermal efficiency. Nevertheless,
the development of thermal conversion energy results from a numerous corrections can be applied to improve the heat
large number of requests for energy. Researchers concentrate transfer coefficient between the absorbing plate and air. In
on thermal collector studies to improve thermal efficiency this regard, the influential parameters are the collector
cause they have an ordinary structure and are widely used in length, type of absorbing plate, glass covering sheet, wind
life from space heating to agricultural drying [1]. Solar Air speed, etc. Increasing the absorption surface culminates in
Heaters (SAH) are usually used as heat exchangers in solar increased heat transfer to the flowing air. On the other hand,
cell applications [2]. Air heating is one of the primary it increases the pressure drop in the collector, leading to
applications of solar heating, which is utilized for heating the raised electricity power consumption for air suction into the
environment and the processes in heating systems such as collector [7]. one of the solutions for this improvement is the
laundry, desalination, drying products, and other drying absorbing surface shape. This parameter plays an important
processes. The common use of energy in procedures leads to role in the designing of solar air heaters. Till now, various
raised costs and also environmental contaminations. Utilizing kinds of SAHs have been developed and investigated
solar energy to heat the air reduces the system’s operation experimentally. It's obvious that material and construction
cost and regular energy consumption [3]. Tyagi et al. [4] have many effects on the collector's efficiency [8]. Metwally et
classified solar air heaters according to their tracing, energy al. [9] stated the results of experimental investigations on
storage, wide surface, and number of coverages. The SAHs are advanced corrugated duct solar collectors. The constituent
divided into three groups: active, passive, and hybrid, based structure of the collector was a corrugated surface exactly

17
 AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages 17-23

identical with those used for heat exchangers, in which in the figures below, the SAH has made from a wooden box in
corrugations got the airflow normally. Öztürk and Demirel some tins, and soda cans (in equal numbers ) are arranged in
[10] showed an investigation experimentally from the and separated by a wooden partition, in which each part has
thermal efficiency of a SAH that its flow channel is covered its own fan. The box has covered by plexiglass, and two
with raschig rings. They conducted that by increasing the projectors were used as sun simulators. The system is laid out
outlet temperature of heat transfer fluid, the energy and in the degree of 45 for having the best performance.
exergy efficiencies of this channel increase too. Benli [8]
conducted an investigation based on energy and exergy
analysis of five types of solar air absorbers (corrugated,
reverse corrugated, trapeze, reverse trapeze, and flat plate).
The results showed that the shape of the absorbers’ surface
has a linear relation with the pressure drop and thermal
coefficient. Four obstacle shapes and three various
configurations in SAHs were numerically tested by Kulkarni
and Kim [11]; the highest efficiency goes to a pentagonal
obstacle that shows the effect of the shape and arrangement
of an obstacle on Nu number. Karsli [12] studies were about
the first and second laws of efficiencies of four kinds of flat
plate SAHs. The experimental results can be derived that solar
radiation and construction are the effective parameters on
the performance of SAHs. Özgen et al. [7] studied three types
of double-flow SAHs with aluminum cans experimentally and
presented that obstacles or cans create a good airflow and
turbulence on the absorber plate and diminish the dead zone Figure 1. A schematic of the device
in the heater. By Concentrating on PVT modules, the total
efficiency of a device can be improved if researchers start to
use tracking devices, concentrate reflectors, or even use
electric and thermal powers in PVT concurrently.
Concentrating PVT (CPVT) modules can be used only on
greater scales, so the components that constitute the system
have significant dimensions. Usually, solar towers, parabolic
trough concentrators (PTCs), compound parabolic
concentrators (CPCs), and parabolic dish concentrators
(PDCs) can be in this category [13].
There are many ways to operate energy for buildings in
the middle east region. The most beneficial one is using
BIPVT-DSF. Double skin façade (DSF) can be a good solution.
The usage of building-integrated photovoltaic thermal
(BIPVT) is such an interesting offer for saving measures
because it considers both energy efficiency and renewable
energy. To endorse this system, some advantages can be Figure 2. Solar air heater
explained: a) the photovoltaic module efficiency boosts due to
the natural or mechanical ventilation, and b) it has substantial 2. Experimental setup
effects on the potential for thermal and/or cooling for the A solar air heater includes the following components:
entire system [14]. Thus, the best system for rejecting, • Main body: the main body of the device is made of wood
absorbing, and reutilizing solar heat is Solar façades. The with dimensions of 120×66 and a thickness of 0.5cm.
main heat sources in BIPV are PV panels. Usually, these Wooden material is selected due to its low price and
systems are designed with the consideration of supplying thermal insulation property. A wooden board is also
ventilation through the solar chimney principle integrated installed as a partition wall between tins and soda cans.
with a DSF design concept [15]. According to previous studies, • Absorbing plate: this plate is the essential element in a
the use of recycled materials in solar systems is limited. In the solar heater that gathers the solar energy together locally
case of solar air heaters, the use of soda cans has been in a thermal form and delivers it to the air. In this case,
reviewed in a limited number of articles. However, in this the rise of the heat transfer is achieved by forced
paper, the performance of a solar air heater with two types of convection and turbulence of the airflow. This surface is
soda cans and tins was studied and compared. Therefore, the made of black-colored aluminium with a thickness of
innovation of this experiment is that the experimental 3mm and connected to the main body.
analysis of solar air heaters has been done with two types of • Input and output duct: these ducts are used to receive
recycled materials, and the performance of SAH has been cold air and take out warm air. The ducts with similar
compared using these two. In addition, exergy and energy diameters are implemented to have equal input flow
analysis has been performed for these two materials. The rates. The output ducts are insulated to prevent thermal
novelty of this experiment is the comparison of soda cans and loss.
tins in one system. The results for tins were better than soda • Transparent glass cover: this cover is made of Plexiglass
cans. The objective of the fabrication of this device is to with a thickness of 4mm. The solar energy passes
compare the output of warm air from two tins and soda can through this glass cover and is absorbed by the absorbing
sections. The schematic and figure of the system are plate. The generated heat is then transferred into the
represented in Figures 1 and Figure 2, respectively. As shown collector.

18
 AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages 17-23

• Tins and soda cans: 36 soda cans and equally 36 tins are overall heat transfer coefficient between the environment
used as fins that are stuck to the absorbing plate in 4 and the heater.
columns and 9 rows. The top and bottom of the
aluminium cans are opened, and their internal and
external surfaces are decontaminated. Moreover, they
are covered with black color to have a higher absorption
coefficient. The soda cans are made of aluminium, and
the tins are tinned-plated.
• Fan: two 220 V, 15W fans are utilized on the other side of
the cans for airflow suction (Wfan=15 W).
• Projector: The existing projector with the power of
1000W in the workshop acted as the sun in a way its
radiation intensity was adjustable using an implemented
dimmer on it.
The equipment used to measure the radiation intensity and
the ambient and output temperatures are described in what
follows:
Radiometer: this equipment (Figure 3) used to measure
the radiation intensity is TES 132 solar power meter (data
Figure 4. Measure the outlet temperature of the device with
logging) with the accuracy of, whichever is greater in sunlight.
a thermometer
As represented in the figure, the attached sensor to the
equipment is placed over the glass cover. The radiation Also, the first and second phrases of equation (1) are defined
intensity is measured twice, once at the bottom of the plate as useful heat absorbed (Qs) and the value of energy increased
for the bottom projector and once at the upper part of the (∆U), respectively. The heaters' thermal efficiency is defined
plate for the upper projector. as follows [16]:
𝑚̇𝑎 𝐶𝑎𝑖𝑟 (𝑇𝑜𝑢𝑡 −𝑇𝑖𝑛 )−𝑤̇𝑓𝑎𝑛
𝜂= (2)
𝐼𝐴𝑐

The total amount of heat transmitted to the fluid is described

as:
• •
𝑄𝑢 = 𝑚𝑎 𝐶𝑝,𝑎 (𝑇𝑜𝑢𝑡 − 𝑇𝑖𝑛 ) (3)
Heat is transported from the absorber plate to the air via
convection and is calculated as:
•
𝑄𝑢
𝛼= (4)
𝐴𝐶 (𝑇𝑝,𝑎𝑣𝑒 −𝑇𝑎,𝑎𝑣𝑒 )

The mass flow rate of air is computed as follows:

•
𝑚 = 𝜌𝐴ℎ 𝑉 (5)
Figure 3. Radiation intensity measurement by model Thermophysical properties of air are determined according
radiometer TES to the average air temperature between entrances and exits
Thermometer: this equipment (as shown in Figure 4) is of the heater. The velocity of air flowing through the duct is
lotron HT-3007SD with accuracy 0.8 C and 1.5F for calculated from the knowledge of the mass flow rate and
measuring temperature. By using this thermometer, the cross-sectional area of the duct. The mean air velocity V is
ambient and output temperatures are measured from hose calculated as Vmax for the flat surface heater with the following
ducts in a way that the thermometer is placed in the middle of equation:
the hose ducts for 10 seconds, and the final temperature is 𝑚
•

recorded. If the test is to be performed in 6 minutes, the 𝑉𝑚𝑎𝑥 = (6)

𝜌𝐴𝑝𝑒𝑟
𝑚𝑎𝑥
temperature should be recorded every 2 minutes, and the
thermometer must be placed in the environment to reach its Vmax indicates the maximum velocity, and Aper is the area
periphery temperature and then start the new test. perpendicular to the flow direction between the two
3. Energy Analysis obstacles. As a result, the Reynolds number of the flat
The law of conservation of heat energy is defined as absorber plate heaters is computed. The air duct is 150 mm
follows: high (H) by 900 mm wide (W). The blockage ratio (BR) is the
ratio of the area of the conical components to the cross-
𝑑𝑇𝑝,𝑎𝑣𝑒 .
𝛼0 𝐼𝐴𝑐 = 𝑀𝑃 𝐶𝑃,𝐶 [ ] + 𝑚𝑎 𝐶𝑝,𝑎 (𝑇𝑜𝑢𝑡 − 𝑇𝑖𝑛 ) + sectional area of the air channel [16].
𝑑𝑡
𝑈𝐶 𝐴𝐶 (𝑇𝑝.𝑎𝑣𝑒 − 𝑇𝑒 ) (1) 3.1 Uncertainty analysis
Test equipment selection, accuracy, specification,
Where α denotes the proportion of solar radiation absorbed observation, reading, and ambient circumstances may all
by the absorber plate and represents the optical yield. Heat contribute to test uncertainty. Surface-fluid temperatures,
losses from the heater are represented by UC, which is the pressure loss, air velocity, and global solar radiation were all
measured in the heaters using appropriate instruments. The

19
 AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages 17-23

following equation (Holman equation) was used to estimate

relative uncertainty. The thermal efficiency and air flow rate
uncertainties are 1.05% and 2.4%, respectively [16].
1
𝑊 = [(𝑋1 )2 + (𝑋2 )2 +. . . (𝑋𝑛 )2 ]2 (7)

4. Results and discussion

Some charts are derived using the achieved results of the
tests, and the comparisons of the mentioned parameters with
some of these charts are illustrated.
4.1 Investigation of the effect of radiation intensity on
the temperature difference
As is evident (Figure 5), the temperature is raised by
increased radiation intensity and also through time. In
addition, more temperature increase occurs in the tins. By
comparison of two Figures 5 and Figure 6, it can define that
the lower mass flow rate cause more temperature differences;
in fact, the lower mass flow rate causes more time to heat the
fluid.

Figure 6. temperature-time difference in terms of radiation

.
intensity for 𝑚=0.0078kgs-1 with 80% dimmer a) Soda cans
b) tins

Figure 5. temperature difference – time in terms of radiation

intensity for =0.0104kgs-1 with 100% dimmer a) Soda cans
b) tins

4.2 Investigation of the effect of radiation intensity on

the useful heat absorbed
As it is demonstrated in Figure 7, the absorbed heat is
increased by increasing the radiation intensity and through
time. The maximum value of heat absorption occurs at the
radiation intensity of 300. The absorbed heat in the tins is
greater compared to the soda cans. It can be due to the
difference in material and metal thickness of tins and sodas.
As shown in Figure 8, the efficiency is improved by increasing Figure 7. Absorbed
.
heat-time diagram in terms of radiation
the irradiance intensity and peaks at 300 radiation intensity. intensity for 𝑚=0.0078kgs-1 with 80% dimer a) soda cans b)
Furthermore, the thermal efficiency of the tins is more than tins
soda cans.

20
 AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages 17-23

demonstrates the surface temperature of tins and soda cans

that match with ∆T results.

Figure
.
8. Efficiency-time in terms of radiation intensity for
𝑚=0.0104kgs-1 with 100% dimmer a) soda cans b) tins Figure 9. Efficiency-time in terms of radiation intensity for
.
4.3 Investigation of the effect of radiation intensity on 𝑚=0.0078kgs-1 with 80% dimmer a) soda cans b) tins
thermal efficiency
Figures 9 (a and b) show the effect of radiation intensity
on the thermal efficiency of the SAH made by soda cans and
tins. It indicated that the thermal efficiency increases with an
increase in radiation intensity while SAH made by tins has
better performance than the one made by soda cans.
4.4 Investigation of the effect of radiation intensity on
given heat
Figure 10 shows the effect of radiation intensity on the
given heat of the SAH made by soda cans and tins. It indicated
that tins have better performance than soda cans. The given
heat is increased by raising the radiation intensity with equal
heat transfer cross sections. This value is equal for both tins
and soda cans.
Figure 10. Given Heat-intensity variation, blue) soda cans,
4.5 Investigation of the effect of mass flow on thermal red) tins
efficiency with increasing radiation intensity
Figure 11 shows the effect of mass flow rate on the
thermal efficiency of the SAH made by soda cans and tins. It
can be seen that by increasing the mass flow rate, the thermal
efficiency is increased.
4.6 Investigation of a thermography camera
The following images are captured using the model
Testo672 thermography camera, which represents the
radiated heat from the heater by radiation intensities
mentioned above. Hot surfaces are recognized by red, orange,
and yellow color spectrums, and cold surfaces are
represented by violet, blue, and green colors. Figures 12 and
Figure 13 show temperature profiles on SAH with two
different radiation intensities. The pictures are recorded in 6-
minute intervals like the previous results, and the units are
set in the SI system. As time passes, during photography, the
thermography camera shows the temperature contour, which

21
 AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages 17-23

tins. However, this absorbed heat still has a larger value in

the case of tins, about 5%.
• With equal heat transfer cross-sections, the delivered
heat increases by raising the radiation intensity and is
similar for both cans and tins cases.
• By reducing the mass flow rate from 0.0104 to 0.0078
kg/s over time, the temperature difference increased
about 4%. This increase also depends on the rise in
radiation intensity.
• The thermal efficiency is enhanced by raising the mass
flow rate and radiation intensity. this enhancement for
100 w/m2 and 0.0104 kgs-1 for soda cans is about 20% and
Figure 11. Thermal efficiency-time diagram for two different for 500 w/m2 and 0.0104 kgs-1 is about 15%. the greater
flow rates a) soda cans b) tins enhancement could be observed for tins at 100 w/m2 and
0.0104 kgs-1 about 40% . Also, at 500 w/m2 and 0.0104
kgs-1 the increment of 25% is recognizable.
Ethical issue
The authors are aware of and comply with best practices in
publication ethics, specifically with regard to authorship
(avoidance of guest authorship), dual submission,
manipulation of figures, competing interests, and compliance
with policies on research ethics. The authors adhere to
publication requirements that the submitted work is original
and has not been published elsewhere.
Data availability statement
Datasets analyzed during the current study are available and
can be given following a reasonable request from the
corresponding author.
Conflict of interest
The authors declare no potential conflict of interest.
Figure 12. Thermal images of radiation intensity 100(w/m2)
References
[1] Mauthner F, Weiss W, Spörk-Dür M) 2016( Solar heat
worldwide: markets and contribution to the energy
supply 2014. IEA Sol Heat Cool Program .doi:
10.18777/ieashc-shw-2016-0001
[2] Hussain A, Arif SM, Aslam M ) 2017( Emerging
renewable and sustainable energy technologies: State
of the art. Renewable and Sustainable Energy Reviews,
71:12-28.doi: 10.1016/j.rser.2016.12.033
[3] Rajaseenivasan T, Srinivasan S, Srithar K) 2015(
Comprehensive study on solar air heater with circular
and V-type turbulators attached on absorber plate.
Energy, 88:863-873.doi:
10.1016/j.energy.2015.07.020
[4] Tyagi V, Panwar N, Rahim N, Kothari R) 2012( Review
on solar air heating system with and without thermal
Figure 13. Thermal images of radiation intensity 500(w/m2)
energy storage system. Renewable and Sustainable
Energy Reviews, 16:2289-2303. doi:
5. Conclusion 10.1016/j.rser.2011.12.005
By analyzing the derived results, the following could be [5] Alkilani MM, Sopian K, Alghoul M ) 2011( Sohif M,
realized: Ruslan M: Review of solar air collectors with thermal
• The absorption heat is improved by increased irradiance storage units. Renewable and Sustainable Energy
intensity from 100 to 500 w/m2 through the specific time Reviews, 15:1476-1490. doi:
(6 minutes); its maximum occurs at the irradiance 10.1016/j.rser.2010.10.019
intensity of 300. The absorbed heat in tins is about 0.01 [6] Chamoli S, Chauhan R, Thakur N, Saini J ) 2012( A
Kw greater compared with soda cans. review of the performance of double pass solar air
• Since the sucked air has a low velocity as a consequence heater. Renewable and Sustainable Energy Reviews,
of reduced fan velocity, it has more opportunity to get 16:481-492. doi: 10.1016/j.rser.2011.08.012
warmer, and more heat is absorbed by the soda cans and

22
 AH. Aghdam et al. /Future Technology November 2023| Volume 02 | Issue 04 | Pages 17-23

[7] Ozgen F, Esen M, Esen H ) 2009( Experimental [13] Shakouri, Mahdi, Hossein Ebadi, and Shiva Gorjian )
investigation of thermal performance of a double-flow 2020( "Solar photovoltaic thermal (PVT) module
solar air heater having aluminium cans. Renewable technologies." Photovoltaic Solar Energy Conversion.
Energy, 34:2391-239. doi: Academic Press,. 79-116. doi:
10.1016/j.renene.2009.03.029 https://doi.org/10.1016/B978-0-12-819610-6.00004-
[8] Benli H ) 2013( Experimentally derived efficiency and 1
exergy analysis of a new solar air heater having [14] Shakouri, M, Hossein G, and Alireza N. (2020)"Quasi-
different surface shapes. Renewable Energy, 50:58-67. dynamic energy performance analysis of building
doi: 10.1016/j.renene.2012.06.022 integrated photovoltaic thermal double skin façade for
[9] Metwally M, Abou-Ziyan H, El-Leathy A ) 1997( middle eastern climate case." Applied Thermal
Performance of advanced corrugated-duct solar air Engineering 179: 115724.doi:
collector compared with five conventional designs. https://doi.org/10.1016/j.applthermaleng.2020.1157
Renewable Energy, 10:519-537 .doi: 10.1016/S0960- 24
1481(96)00043-2 [15] Shakouri, M, Alireza N, and Hossein G.
[10] Öztürk HH, Demirel Y ) 2004( Exergy‐based (2020)"Quantification of Thermal Energy Performance
performance analysis of packed‐bed solar air heaters. Improvement for Building Integrated Photovoltaic
International journal of energy research, 28:423- Double-Skin Façade Using Analytical Method." Journal
432.doi: 10.1002/er.974 of Renewable Energy and Environment 7.3: 56-66. doi:
[11] Kulkarni K, Kim K-Y ) 2016( Comparative study of 10.30501/JREE.2020.228559.1105
solar air heater performance with various shapes and [16] Abuşka, M. (2018)"Energy and exergy analysis of solar
configurations of obstacles. Heat and Mass Transfer, air heater having new design absorber plate with
52:2795-2811 .doi: 10.1007/s00231-016-1788-3 conical surface." Applied Thermal Engineering 131:
[12] Karsli S ) 2007( Performance analysis of new-design 115-124. doi:
solar air collectors for drying applications. Renewable https://doi.org/10.1016/j.applthermaleng.2017.11.12
Energy, 32:1645-1660.doi: 9
10.1016/j.renene.2006.08.005

23