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Hot Water tank stratification

03 Jun 09 | Solar Hot Water

There are many considerations to ensure that a solar domestic hot water system will perform at it’s optimum. The collectors should be facing south, tilted to latitude, unshaded,  etc.  One consideration that is usually not thought about or understood is the storage tank.  Like any energy storage system, there are some physics that accompany a hot water storage tank.

Stratification simply means to divide into layers.  Heated water rises because it is less dense than cold water.  The warmest water will be found in the layer right at the top of the tank, hence, most tanks have their hot water outlet at the very top of the tank.

When pumping water out of a solar storage tank, through a heat exchanger and back again, it is very important not to completely mix the water in the tank.  In most SDHW systems, the temperature sensor for the storage tank is at the very bottom of the unit.  If the tanks gets mixed, chances are the collector temperature and the tank temperature will reach equilibrium and the system will shut off.

If the solar storage tank water is pumped slowly, so that the tank stays stratified, the system will net much more heat.  This works especially well in a two tank system where tank number one is the solar tank which pre-heats the water going into tank number two, which is the back up heating system.  If done correctly, both tanks will  have a thermocline about 1/3 up from the bottom of the tank.

There are two good ways to accomplish water side heat exchanger pumping without breaking the solar tank stratification.

  1. Use a small ac pump, such as a TACO 003B and throttle the output side of the pump with a ball valve.  This pump uses very little electricity (rated for 42 watts, 115 VAC) and therefore is pretty efficient.  Restricting the flow slightly with a ball valve will not hurt it.  The water going into the heat exchanger from the solar tank should be about 5 – 10 degrees (Δt = 5-10° F) cooler than the water coming out.
  2. Use a PV powered DC pump.  There are two DC pumps that run directly from a 12 volt PV panel, the Liang D5 series and El Sid.  These can also be throttled on the output side for temperature rise of 10 degrees from input to output.    The advantage of this system is that the pump speed will adjust to the available sunlight (thus available heat) making the system more efficient.  The disadvantage is it is more expensive.

Experience shows that a good rule of thumb is 0.0125 gallons per minute per gallon of storage.  Therefore, for an 80 gallon storage tank, optimum flow rate on the storage tank side of the heat exchanger would be 80 gallons x 0.0125 = 1 GPM.  For a 120 gallon tank, 1.5 GPM and for a 240 gallon tank, 3 GPM.  This will generally give a 10 degree temperature difference between the top and bottom of a vertical tank.

Tank stratification is an important design factor that is often not thought of when a dual pumped internal or external heat exchanger system is installed.

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03 Jun 09 | Solar Hot Water
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