As per above designing procedure we have installed 95 solar Flat Plate Collectors and a 8000 ltrs. Hot water storage tank for storing the solar water to supply to the process tanks through the heat Exchangers.

The heat exchanger are designed in such a way that they should occupy minimum space and should be removable for the de-scaling of outer body on which the sludge is deposited during the process. We have used tube type heat exchanger made up of SS 304. The inlet temp of heat exchanger is kept at 75 Deg. C. We have taken the following observations of solollector outlet temp., tank temp. and month wise line chart has been prepared

3.1. Energy Saving Ca	culations
Month	Average Solar Radiation KJ / Sq. Mtr	Actual Heat Gain by Solar System in Kw	Saving of Electricity in Kwh per day ( Rate of Electr. Rs.6 / Kwh)	Saving Per Month in Rs.
October	19559	526	3159	94,790
November	18266	491	2950	88,523
December	17258	464	2787	83,638
January	18112	487	2925	87,777
February	20718	557	3346	1,00,407
March	23212	624	3749	1,12,494

Comparision of Solar Collector Output & Storage Tank Temp.

Comparision betn Solar Collector Outlet Temp. & Storage Tank Temp.

SHAPE * MERGEFORMAT

SHAPE * MERGEFORMAT

Pay Back Calculation ( Without considering depreciation)

Cost of Solar System ( including fabrication of super structure) Rs.13,69,000=00 Cost of Energy Saving per annum (average) Rs. 9,05,668=00

3. Results

The Solar Flat Plate Collector Heating System is generating & fulfilled the heating requirement of pre-treatment process used before powder coating. The payback period of such systems is less than 1 V2 year, which will reduce the cost of production & increases the overall profit. The system has no maintenance except the electrical components & has a life of more than 20 years. The saving is shown in a separate Bar Chart also (Monthly)

4. Conclusions

It is necessary to have Hot Water storage Tank to supply the hot water in the morning as well as in the evening when Solar System is generating hot water below the required temperature.

1. In the month of June, July, August, November, December & January are the critical months & backup-heating system is required (if production is not been completed before 6 O’clock in the evening) to fulfill the gap between the demand & supply.

2. The Solar Flat Plate Collector Heating System is found most feasible and most economical (with compare to electricity) for such application & should be used by the Automobile Industries & Powder coating Plants for the other products also.

5. References

1. Guideline for Solar Flat Plate Collector Testing & Performance ( IS:12933. ) — Bureau of Indian Standards, India.

2. Hand Book of Solar Radiation data of India — By Miss. Anna Mani

3. Testing report of Solar Flat Plate Collector of ANU Solar Flat Plate Collector of 10 fin manufactured by Peenya Alloys Pvt. Ltd — BIS 12933 — by Peenya Alloys Pvt. Ltd. Bangalore

4. Heat Transfer ( A practical Approach ) — By Yunus A. Cengel

5. Seven or Nine Tank Process of Heat Treatment Methods — details provided by — Mr. S. V. Shejwalkar, M/s Chaphekar Suspensions Pvt. Ltd. Pune.