Exergy

Thermal Storage Build Log

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2×5 gallon buckets and 20’ of copper tubing make the heart of the thermal storage system The copper tubing is wound in concentric, equidistant circles and zip tied in place The buckets were then fitted atop a modified furniture dolly to make the system portable
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A layer of Mylar was laid on the base of the dolly along with 2 ½” thick slabs of insulating foam The tops of the buckets were then insulated with ½” foam and sealed with duct tape The buckets are then wrapped in several layers of fiberglass insulation
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The entire assembly was then covered with heat reflective Mylar A CPVC plumbing system was configured with a check valves and high temp silicon hose to control coolant flow An aluminum cover was carefully designed and constructed to cover the assembly
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The aluminum cover and a power supply were mounted to the furniture dolly Access ports were drilled to allow connection of the electrical and hydraulic systems The cover was carefully mounted over the insulated thermal storage system
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Quick disconnect coolant and electrical connections mounted to an access cover Rear of the unit with the addition of a radiator and pump system mounted The front of the unit with pump and radiator on and running
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Here the system connected to the computer cooling loop for testing We added a logging watt meter to measure energy consumption Here you can see the watt meter installed
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Addition of fan and temperature control electronics on access plate In this shot you can see the interior mounting of electronics This is a pic of the space under the hood, it’s a tight fit
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The thermal pig ready for the first round of testing After testing at temperatures up to 180f we decided to inspect The high temperature had compromised the tanks
The heat was so high it softened the CPVC piping we had used to construct the loop We chose sealed steel tanks with copper fittings to withstand the heat we would generate Brass fittings and valves should hold up under the heat stress
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The copper coils were fitted with high temperature silicon hoses and reinstalled The completed units were sealed and have a port which attaches to a pressure gauge Reinsulated and ready to reassemble, the hardened tanks are looking good
We added mechanical temperature and pressure gauges while we were at it The tanks regularly see temperatures up to 200f during testing They also withstand up to 15 psi at those high temperatures helping to prevent the coolant from boiling
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The computer mounted and plumbed to the storage tank