Case Studies in Thermal Engineering 14 (2019) 100440

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Case Studies in Thermal Engineering

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An experimental investigation of performance of a double pass

T
solar air heater with foam aluminum thermal storage medium
Wajahat Baig, Hafiz Muhammad Ali∗
Mechanical Engineering Department, University of Engineering and Technology, Taxila, 47050, Pakistan

ARTICLE INFO ABSTRACT

Keywords: The enactment of a double pass solar air heater was experimentally probed using four different
Paraffin wax formations. The scope of present study encompasses the use of Thermal Storage Medium (paraffin
Foam aluminum wax) integrated with porous/foam metal (aluminum) during the winter season. In the first phase
Thermal storage medium of experimentation, first formation consisted of flat plate whereas foam aluminum embedded
Data acquisition system.
with paraffin wax was placed inside two copper ducts in the second configuration. In the third
configuration, four copper ducts were used. During the second phase of experiment, similar
configurations were used as in the first phase but with pre-heat. No melting of wax was ac-
complished when the outside air temperature ranged between 12 and 24 °C, however increased
thermal conductivity was attained for configuration two and three. Melting of wax was achieved
when the outside air temperature ranged between 15 and 29 °C, using pre-heat. The increase in
thermal conductivity was achieved using foam aluminum but at the expense of slight decrease in
storage capacity of the paraffin wax. In the last configuration no fan was used during the day
time, and melting of wax achieved under similar conditions. Fourth configuration provided
beneficial heat for 2.5 h after the sunset while the second and third configurations provided
expedient heat for 1.5 h after the sunset.

1. Introduction

Ali et al. [1] analyzed the performance of a double pass solar air heater experimentally using four different formations. In the first
formation flat plate was used whereas paraffin wax encapsulated in copper tubes were used in the second formation. In the third and
fourth formations, Al and SS rods were used at the center of copper tubes with paraffin wax throughout their periphery. He showed
that beneficial heat was obtained for 2 h after the sunset for configuration three with maximum efficiency of 96%. Kant and Saini [2]
showed that a double pass solar air heater with staggered ribs on both side of absorber plates was more efficient with slight penalty of
frictional losses. Kant [3] in a review of performance of a double pass solar air heater showed that double pass solar air heaters were
comparatively better than conventional single pass heaters with improved efficiencies. Using various heat augmentation techniques
and deploying corrugated absorber plate showed increased heat transfer rates.
Alam and Kim [4] in a review paper concluded that performance of parallel and counter flow double pass solar air heater was
superior than a single pass solar air heater. Absorber plates with extended surfaces and packed bed showed substantial improvement
in thermal performance of a double pass SAH. They further concluded that DPSAHs with porous matrix on lower passage increased
the heat transfer rates. Hassan et al. [5] studied the effect of DPSAHs using pin finned, corrugated finned absorber plate and cor-
rugated-perforated finned absorber plate. They showed that maximum efficiency of 83% was observed for the corrugated-perforated

∗
Corresponding author.
E-mail address: h.m.ali@uettaxila.edu.pk (H.M. Ali).

https://doi.org/10.1016/j.csite.2019.100440
Received 20 February 2019; Received in revised form 28 March 2019; Accepted 28 March 2019
Available online 01 April 2019
2214-157X/ © 2019 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license
(http://creativecommons.org/licenses/BY/4.0/).
W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

finned absorber plate `and the outlet air temperatures were also maximum for the same configuration. Singh et al. [6] experimentally
investigated the DPSAH with baffled ducts and showed that efficiency of the system was 16–21 %higher than the conventional SAHs.
Bayrak and Oztop [7] analyzed performance of SAHs with Aluminum foam obstacles on absorber plate and found that efficiency was
considerably increased by increasing the surface area of absorber plate and mass flow rate of the air. Jin et al. [8] studied the effect of
foam metal infiltrated with paraffin wax and showed that foam metal with less porosity showed better melting rate.
Chen et al. [9] in an extensive review of performance of metal foam embedded with thermal storage medium concluded that the
higher thermal conductivity was achieved in metal foams rooted with TSMs. Due to higher thermal conductivity, surface area volume
ratio, sponginess and complicated three dimensional setups, metal foams increased the effective thermal conductivity of the PCMs. Li
et al. [10] showed experimentally that microencapsulated PCMS with metal foam showed more thermal conductivity as compared to
Organic PCMS. Khadraoui et al. [11] carried out comparative study on SAHs with phase change material. He conducted an ex-
perimental study using aluminum array with cavity filled with Paraffin Wax (PW) as latent storage unit. He concluded that during
night the PCM cavity increased the outlet air temperature in between 4 and 7 °C when compared to SAH without PCM. Ho et al. [12]
carried out experimental investigation on double pass solar air heater with wire screen mesh as packed bed and under recycling
conditions. He concluded that efficiency of packed bed solar air heater was increased by mixing of inlet and outlet air and correlated
his analytical model with experimental results.
Chang et al. [13] investigated both theoretically and experimentally the performance of SAHs with finned absorbers and con-
cluded that installation angle of fin showed little effect on efficiency. He further showed that by increasing mass flow rate from
0.01 kg/sec to 0.09 kg/sec, efficiency of collector improved from 41.4% to 78.6%. Rajaseenivasan et al. [14] experimentally in-
vestigated the performance of flat plate SAHs using circular and V-shaped tabulators. They concluded that maximum heat transfer
occurs using concave shaped V type tabulators as compared to circular one. Kabeel et al. [15] experimentally analyzed the efficiency
of flat and v-corrugated SAHs with PCM as thermal storage and concluded that daily mean efficiency of v-corrugated SAH was
15–21.3% higher than Flat plate SAH without PCM. Zhang et al. [16] investigated the thermal conductivity of foam metal/paraffin
with four different porosities and concluded that effective thermal conductivity was 25% better than pure paraffin.
Omojaro and Aldabbagh [17] investigated experimentally the performance of single and double pass SAH with fins and steel wire
mesh as absorber and concluded that the air heater with steel wire mesh as an absorber plate showed considerable improvement in
efficiency in comparison to conventional one. Naphon [18] developed a mathematical model to envisage the heat transfer char-
acteristics, performance and entropy generation of a double pass solar air heater with fins and concluded that efficiency of the system
increased with the increase in fins height and number whereas the entropy generation was found to be in inverse relation with height
and number of fins. Sebaii et al. [19] studied the performance of a double pass solar air heater with v-corrugated absorber plate and
finned absorber plate and found that v-corrugated absorber plate was 9–11% more efficient than finned plate.
Ramani et al. [20] envisaged experimentally the performance of a DPSAH with and without porous media and concluded that
heaters with porous mediums were 20–30% more efficient than heater with non-porous mediums. Jain and Jain [21] experimentally
probed the performance of a tilted, multi-pass solar air heater for drying purposes using thermal storage medium within the heater
and concluded that grain temperature increases with an increase in collector length and thermal storage medium provided useful heat
for drying purpose after sunset. Mohamad [22] identified the major losses in SAHs and suggested an improved efficient version by
placing a double collector over absorber plate. This subsequently pre-heated the air in the second pass and reduced the thermal losses
due to convection. Satcunanathan and Deonarine [23] presented an improved version of DPSAH using double glass collector and
concluded that an extra glass cover provided space for the air to act as an insulator and reduced the convective losses between the
metal collector and the air without increasing the cost of the unit. Aldabbagh et al. [24] experimentally compared the performance of
DPSAH using wire mesh as packing bed during summer season and concluded that DPSAHs were more efficient as compared to
SPSAH. The mass flow rate showed significant effect on the outlet air temperature. Increasing the mass flow rate up to 0.05 kg/sec
increased the thermal efficiency. But after a particular limit, mass flow rate had no significant effect on outlet air temperature.
Tolga Taner [25] in an extensive study of optimization process of drying plant calculated the discount rate on the basis of net
present value method using David Cantrell's Approximation solution method. He also calculated simple payback period by calculating
energy saving and maintenance costs of the drying plant. Techno-economic analysis was based on the operational and capital costs as
explained by tanner and helped in calculating the payback period of the whole project. Taner [26] also discussed the energy and
exergy analysis of proton exchange membrane of fuel cell and elucidated that optimization can be achieved by reducing the water
flow rate i.e. both exergy and energy efficiencies would increase as a result of reduced water production. Taner and Dalkilic [27] in a
feasibility study of solar energy-techno economic analysis considered the available energy in the form of radiation and by calculating
the depreciation time, payback period and net annual profit of the solar plant showed that the requisite plant could be constructed on
the subject site. Huseyin Topal et al. [28] carried out exergy and energy analysis of a trigeneration system (power, heating and
cooling) and concluded that it is feasible to use poultry waste and coal as a fuel to operate the TG system with slight reduced energy
and exergy efficiencies but with additional advantage of cooling. Using maximum PW share and minimum coal share, CO2 emissions
were least. Huseyin Topal et al. [29] carried out exergy destruction analysis of circulating fluidized bed power plant co-firing with
olive pits and found out that most of energy that could be used otherwise, was destroyed in the boiler (86.05%).
They showed that there were some disadvantages of the system. Fluidized bed combustors had high maintenance cost and
increased pressure drop. T. Taner et al. [30] carried out techno-economic analysis of an efficient hydrogen generation system pro-
totype. They aimed to develop a new technology to improve the performance and efficiency of PEM. They also carried out the techno-
economic analysis if prototype and calculated the simple payback period to be 2.32 years.
It is clear from the literature assessment that efforts have been made in one way or another to improve the effective thermal
conductivity of the solar air heater. The effect of artificial roughness on absorber plate augments the heat transfer rate. The use of v-

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

shaped corrugated ducts and obstacles for absorber plates have shown better results. Similarly, the use of thermal storage medium has
attracted the researchers to obtain useful heat in the absence of solar flux. The literature review mentioned from Refs. [25–30]
emphasizes on certain critical aspects of research work. It accentuates on optimization and techno-economic analysis which de-
termine the actual worth of any scientific work.
The aim of this study is to evaluate the performance of a solar air heater with PCM/foam metal in winter season during which
outside air temperature falls below 15 °C. The present work was carried out in the month of November at Energy Engineering
Department, UET Taxila, Pakistan.

2. Experimental setup

A DPSAH was constructed using mild steel having dimensions of 750 × 500 × 200 mm3 (Fig. 1a). Fig. 2a shows the schematic of
the experimental setup. The 2 mm thick aluminum absorber plate was coated black to engross maximum radiation incident upon. In
order to prevent heat losses, the bottom and sideways of the heater were cloistered using glass wool insulation. A 5 mm glass was
placed at the top of the heater to capture maximum irradiance and to reduce convection losses. To incorporate the concept of thermal
storage medium, four rectangular copper ducts having dimensions of 510 × 51 × 32 mm3 were filled with molten paraffin wax (PW)
and placed above the absorber plate. In order to enhance the thermal conductivity of PW, four foam aluminum rectangular pieces
having dimensions of 500 × 50 × 30 mm3 (Fig. 1b) were placed inside the ducts. The heater was fitted out with conical inlet and
outlet and an exhaust fan was connected at the outlet to provide the required mass flow rate. In order to measure the solar flux, the
TBQ type pyranometer having sensitivity of 7–14 μV/Wm2 spectral range of 0.3–3 μm was used. The pyranometer was connected
with a data logger having a range of 0–2000 W/m2 and resolution of 1W/m2 though a cable. The pyranometer was placed at an angle
of 34°, the local latitude of Taxila, Pakistan. The data acquisition system consisted of two modules, thermocouples and digital
temperature sensors. Temperatures recorded by eight temperature sensors mounted on various locations at absorber plate, inlet/
outlet and glass were fed to the controller 1 and displayed on the LCD. Similarly, temperature of wax was measured using three
thermocouples at depth of 15 mm, 25 mm and 35 mm. For monitoring of foam aluminum temperature, a thermocouple was placed at
its center. The temperatures thus recorded from these thermocouples were fed to controller 2 and displayed on LCD. Experiments
were carried out on DPSAH for four different configurations in two phases. The readings were taken from 9 a.m. to 7 p.m. in the
evening. The heater was tilted to 34° fronting south to receive maximum solar flux. In the first phase, outside air temperature ranged
between 15 and 24 °C whereas solar flux varied between 350 and 450 W/m2. First configuration consisted of a simple flat plate
(Fig. 2b). In second configuration, foam rectangular aluminum pieces were placed inside two copper ducts (Fig. 2c). The foam
aluminum pieces were then filled with molten paraffin wax. In the third configuration four ducts were used (2d). In the second phase
of experimentation, similar configurations were used but with pre-heat. The position of thermocouples is shown in Fig. 2e. The
outside air temperature ranged between 6 and 20 °C whereas solar flux ranged in between 450 and 105 W/m2. In the last formation,
no fan was used using four copper ducts embedded with paraffin wax and foam aluminum. Mass flow rate of the air was determined
first by measuring the air velocity induced by the exhaust fan by anemometer and then multiplying it with the cross sectional area of
the pipe and density of the air.
a = R2 (1)
where a is the area of the pipe, R is the radius of pipe, and
M = aV (2)
where M is the mass flow rate of the induced air, ?? is the air density at the inlet temperature and V is the velocity of the air.
The thermal parameters were calculated using the following relations. For configuration 1 without TSM and foam aluminum:
Sin = Ssolar = IA (3)
where Sin is input energy, I is the solar intensity and A is the collector area. For configuration 1,
Gout = mcp T (4)

Where Gout is the output energy, cp is the averaged specific heat capacity of air at inlet and outlet.
Gout
1=
Sin (5)
For configuration 2, second phase with pre-heating the inlet air using foam aluminum and paraffin wax:
Sin = (Ssolar + Gpreheat ) Gstored (6)
whereGstored is the energy stored by the wax and Gpreheat is the additional heat input to the incoming air. Expanding equation (6) yields
the following equation
Sin = (IA + mcp Tinlet ) (Gwax + Gfa ) (7)
where mcp Tinlet is the half hourly heat input rate to the incoming air and Gwax + Gfa is the energy stored by the paraffin wax and
foam aluminum respectively. The heat input to the ambient air was calculated by comparing the inlet temperatures before and after
the preheat for each half hour reading and the increased temperature was then multiplied with the specific heat of the incoming air.

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

Fig. 1. Experimental setup.

The heat stored by the wax and foam aluminum was calculated using the following equations

Twax
Gwax = m wax Cpw
t (8)

Tfa
Gfa = mfa Cfa
t (9)

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

Fig. 2. (a) Schematic of Experimental Setup (b) configuration 1, (c) configuration (2), (d) configuration 3, (e) positions of thermocouples.

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

Fig. 3. Solar Flux Variation for all configurations (a) First Phase, (b) Second Phase.

Gout
2=
Sin (10)

For last configuration using no fan, same equations were used as in second configuration except for equation (7) which can be re-
written as
Sin = (Ssolar ) Gstored (11)

and
Gout
3=
Sin (12)

3. Results and discussions

For each of the configurations, the readings were taken from 9 a.m. in till 7:30 p.m. and are described here for analysis. The
graphs for inlet and outlet air temperatures and efficiency will be discussed for analysis.
Fig. 3 shows the variation of solar flux for first and second phase experimentation. During the first phase, solar flux varied from
350 to 750 W/m2. Particularly dry and polluted air resulted in smog due to which solar flux was considerably decreased. These
factors should be taken on the serious note to maximize the green energy potential. However, during second phase of experi-
mentation, solar flux intensity was normalized and ranged between 400 and 1050 W/m2. For both the configurations, solar flux was
almost zero after 4:30 p.m. There was not much variation of solar flux for all the configurations. During first phase of experi-
mentation, no melting of paraffin wax was achieved even though the outside air temperature was adequate (15–27 °C.). For this
particular outside air temperature, in order to melt paraffin wax, the solar flux should be in the range of 600–1050 W/m2.
Fig. 4 shows the comparison of temperature difference (outlet – inlet) for all three configurations of first phase and second phase
experimental data. During first phase, the ambient air temperature was in the range of 12–28 °C and the solar flux varied from 300 to
750 W/m2. As a result of this, no melting of wax was achieved and only sensible heat contributed in second and third configurations.
Therefore, the temperatures started falling as soon as the flux decreased after 1 p.m. However, it was noticed that for similar flux
conditions, the temperature difference for configuration 2 and 3 were slightly higher than the configuration 1. In configuration 2 and
3, foam aluminum pieces embedded with PW were retained in the copper ducts. The highly porous geometry of foam aluminum in
combination with complex three dimensional cellular network and enhanced surface area, increased the thermal conductivity and
consequently the heat transfer rate of the system [8]. It can be noticed that even during storage process, temperature difference
remained high for configuration 2 and 3. This is due to the fact that the presence of foam metal has increased the surface area of PCM
and as a result more amount of sensible heat has travelled down to the absorber plate due to increased conductivity.
During second experimental phase, the solar flux was considerably increased (400–1050 W/m2), but the outside air temperature
further dropped down and was observed in the range of 6–20 °C. It was expected that at this flux level, melting of wax would easily be
attained but still no melting was achieved. Therefore, inlet air temperature was maintained at 15–29 °C by preheating the incoming
air. Under these circumstances, the melting of wax was achieved. It can be noticed that for configuration 1, maximum temperature
was observed around 12 p.m. as there was no thermal storage medium. However, for configuration 2 and 3, since TSM was used,
maximum temperatures were observed at 2 p.m. This is because the paraffin wax keeps on absorbing the heat input until it fully
melts. The temperature difference for configuration 2 and 3 remained above configuration 1 throughout due to better thermal

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

Fig. 4. Temperature difference (outlet-inlet), (a) First phase, (b) Second phase.

conductivity. As the paraffin wax starts melting, presence of foam aluminum increases the heat transfer rate due to natural con-
vection. Similarly, during solidification process reverse happens and more amount of heat is rejected during the evening. This can be
observed from higher outlet air temperatures for configuration 2 and 3. It can be noticed that this increased thermal conductivity has
slightly decreased the storage capacity of the paraffin wax. The temperature difference was obtained for 1.5 h after the sunset which
is slightly less than the estimated time (2 h).
Fig. 5 shows the thermal efficiency comparison for all configurations during first and second phase of experimentation. Higher
efficiencies for second and third configurations during first phase experimentation were obtained due to better transfer of heat from
the heater to the air. This fact has already been explained in the section for explanation of temperature difference. Generally, the
frequency for all the configuration increased with the passage of time. This is due to the fact that radiation losses are minimum during
the evening. Similar trends were obtained for the efficiencies during second phase experimentation. Maximum efficiency of 96.7%
was obtained for configuration 3, during second phase of experimentation at 1830 h. The thermal efficiencies for configuration 2 and
3 do not vary much and also the storage capacity. This indicates that increasing the mass of both paraffin wax and copper ducts has
not significant effect on the thermal efficiency of the system. Therefore, overall cost of the system can be reduced by using con-
figuration 2 only.
In the last set of experimentation (Fig. 6), melting of paraffin wax was achieved by storing only all of the incident energy during
the day time while utilizing the same after sunset using fan. Since no cold outside air was available for heat transfer, melting of wax
was easily achieved at 2 p.m. Very useful results were obtained during this set of experimentation. In Pakistan, where day time
temperatures range in between 15 and 25 °C even during the winter seasons, this configuration makes it best among the all. All the
energy stored during the day time can efficiently be stored and subsequently used in the evening hours. The useful heat obtained was
for about 2.5 h after the sunset. Similarly, maximum efficiency of 97% was achieved under this configuration. This type of ar-
rangement can replace the hybrid one discussed in second phase experimentation, configuration 3. This can considerably reduce the
overall cost of the equipment.

Fig. 5. Efficiency Comparison for all configurations; (a) First Phase, (b) Second Phase.

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

Fig. 6. Plots for last formation with fan blown after sunset; (a) Absorber Plate Temperatures, (b) Temperature Difference, (c) Energy Released, (d)
Efficiency.

4. Conclusions

A double pass SAH was investigated experimentally during winter season to check its performance at low outside air tempera-
tures. The main scope of the present study is to utilize such solar air heaters for space heating. The present work was carried out in
two phases and four different formations. The important results are as follows:

• While using TSMs during the winter season in which outside air temperature ranges between 6 and 20 °C and solar flux ranges
between 350 and 1050 W/m2 , PCM's melting strongly depends on outside air temperature. Desirable results can also be achieved if
the solar flux ranges between 600 and 1200 W/m2 under similar temperature conditions.
• If the outside air temperature is maintained between 15 and 29 °C, melting of PW is achieved. This can be achieved by using a
hybrid system as discussed in configuration 2 of second phase of experimentation.
• Better heat transfer rates were obtained for configuration 2 and 3 due to increased thermal conductivity. However, increase in
thermal conductivity occurred at an expense of slight decrease in storage capacity of the system.
• Maximum storage time of 2.5 h was observed for last configuration in which no fan was used during the day time. Using the fan
with pre heat, as mentioned in second phase of experimentation, storage time of 1.5 h was achieved.
• Maximum efficiency of 97% was obtained for last configuration, without fan and using four ducts embedded with Foam
Aluminum and PW.
• In order to use TSMs for space heating during winters, either low melting paraffin wax should be used or the air should be
preheated. Also utilizing the fan after sunset makes this system useable during the winter season.
• As discussed in the literature review, further work can be carried out in the area of optimization and techno-economic analysis.

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W. Baig and H.M. Ali Case Studies in Thermal Engineering 14 (2019) 100440

Conflicts of interest

It is declared that all authors have seen the final manuscript which is submitted now and have no objection or conflict of interests.

Nomenclature

A collector area [m−2]

a cross sectional area of pipe [m−2]
Cpw specific heat of paraffin wax [ JKg−1 K−1.]
Cfa specific heat of aluminum foam [ JKg−1 K−1.]
cp specific heat of air [ JKg−1 K−1.]
Sin heat input [Wm−2]
Ssolar solar flux [Wm−2]
Gout heat output [Wm−2]
Gpreheat heat input to the ambient air for preheating [Wm−2]
Gstored - energy stored [Wm−2]
Gwax energy stored by PW [Wm−2]
Gfa energy stored by aluminum foam [Wm−2]
M mass flow rate of air induced [kgs−1]
mwax - total mass of PW [Kg]
mfa total mass of aluminum foam [Kg]
ΔT temperature difference (inlet –outlet) [K]
ΔTwax temperature difference of PW for time t [K]
ΔTfa temperature difference of aluminum foam for time t [K]
t energy storage time [s]
V velocity of air [ms−1]
ɳ thermal efficiency
?? density of air [kgm−3]; Acronyms; TSM – Thermal Storage Medium; DPSAH – Double Pass Solar Air Heater; LHS – Latent
Heat Storage; SHS – Sensible Heat Storage
LCD Liquid Crystal Display
SAH Solar Air Heater

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