Towards maximum cost-effectiveness: multi-objective design optimisation of insulating glass flat-plate collectors

A significant challenge in the advancement of solar thermal heating systems lies in the unexplored technoeconomic potential of insulating glass flat-plate collectors. These collectors are constructed in accordance with the specifications of standard insulating glass units and have emerged over the past decade as a promising design concept for enhancing the cost-effectiveness of solar thermal systems. However, substantial findings regarding the techno-economic viability of their production are still pending. The aim of this paper is to optimise insulating glass collector designs for solar district heating applications by identifying key design parameters that maximise cost-effectiveness. This study employed a five-stage methodology. It included thermo-hydraulic collector modelling using MATLAB/Simscape and the CARNOT Toolbox. The model was validated against experimental performance tests. A Latin hypercube computational design with 250,000 samples was set up to train supervised machine learning metamodels and perform a multi-objective optimisation using an elitist genetic algorithm. The study identified the argon concentration, collector length, and width as critical parameters influencing efficiency. Larger, thinner collectors demonstrated superior performance due to reduced convective losses and increased aperture-to-surface ratios. The optimisation revealed that the insulating glass collectors could achieve a 7.7 percentage point increase in efficiency, a 19.4 % reduction in material cost, and a 14.5 % decrease in weight compared to market-available flat-plate collectors. However, the direct economic comparison was not considered strong in evidence due to a lack of economic data from technology providers. The most cost-effective designs featured an argon concentration of 99 %, sealing thickness of 31.2 mm, and a glazing thickness of 4.1 mm, and 4.5 mm, while collector length and width varied more significantly. The research findings indicate the technoeconomic potential of insulating glass collectors, demonstrating their ability to outperform conventional flatplate collectors in terms of cost-effectiveness and efficiency. Future studies should focus on producing and testing larger modules and incorporating production costs to fully realise their potential for solar district heating applications. This study provides valuable guidelines for IGU designers and producers aiming to develop costeffective and efficient solar thermal collectors for district heating systems.