DEVELOPMENT OF A SMALL SOLAR THERMAL MECHANICAL
PUMPING SYSTEM
Dennis L. Larson
University of Arizona, USA
Salim Al Rawahy
University of Arizona, USA
ABSTRACT
The University of Arizona is developing a <1kW
sized solar thermal mechanical pumping system
that appears to have great potential for meeting
small pumping requirements (~4000 liters/day with
10 m lift) in locations with adequate solar resource.
This solar pumping system is believed to be
applicable to many remote domestic and irrigation
applications without access to electricity, relying on
diesel power and/or having insufficient wind for
pumping and to be a cost competitive, locally
manufacturable alternative to photovoltaics. The
system consists of solar collector, single piston
diaphragm engine, custom valving, condenser and
return pump. The piston actuates a lever connected
to a lift pump. Testing in Oman is scheduled for
Spring, 2003.
INTRODUCTION
Attempts to convert solar energy to useful
mechanical energy date back at least to the
independent development of engines using thermal
expansion of air and of steam engines by Ericsson
and Mouchot in the 1860s (Kemper,1977). These
developments were followed by ebbs in interest
after the introduction of internal combustion
engines and inexpensive fuels, then by reawakened
activity when fuel supplies were limited.
The latest surge in solar thermal engine
development followed the 1974 oil market turmoil,
activity which again declined as oil became
relatively inexpensive in the 1980s. Spencer
(1989a,b,c) presents a rather comprehensive
summary of the development of solar powered
engines smaller than 100kW. Many of the engines
advanced only to proof-of-concept stage, while
others were commercialized. However, none
continued to evolve and be improved in a manner
similar to the internal combustion engine,
improvements which incorporated new materials
and computerized controls.
Thermal engines are often classified by
thermodynamic cycle (Rankine, Stirling, Brayton),
physical configuration (piston, vane, turbine) and
working medium (gas, steam), but classification by
temperature range may provide better
correspondence with solar collector type (low
temperature for solar ponds and flat plate
collectors, medium temperature, perhaps 100-300C,
for parabolic trough collectors, and high
temperature with parabolic dish collectors) (Tabor,
1962). Higher temperature solar collector output
permits more efficient thermal to mechanical
energy conversion, but also requires greater solar
energy concentration and tracking of the sun,
ranging from no tracking with flat plate collectors
to single axis tracking with parabolic troughs to two
dimensional tracking with parabolic dishes. Only
Rankine cycle engines may be considered with low
to medium temperature inputs.
A number of small (1-25 kW) piston, vane and
turbine engines were developed in the 1970s and
1980s, mostly by independent inventors or
researchers (Halcrow, 1983). Examples of
development by large firms or governmental
agencies include a multi-vane expander by General
Electric (Eckard, 1975), a 10 kW turbine with
Freon as working fluid in Austria (Austria, 1981)
and small (<1 kW) piston engine and larger (~25
kW) turbine by the French firm SOFRETES
(Spencer, 1989b). All of these units were coupled
to solar flat plate collectors. Many of the systems
were developed specifically for pumping (Pytlinski,
1978).
University of Arizona researchers evaluated a ~1
kW single piston, diaphragm engine mechanically
connected to a reciprocating water pump and
powered by a solar flat plate collector two decades
ago, Figure 1 (Larson, Sands & Dutt, 1979).
System efficiency was about 1 % and mechanical
failures eventually interrupted testing. A later
project redesigned the diaphragm engine valving
system, partially resolving the mechanical problems
(Larson & Huaut-Elias, 1989). The redesign and
development of this system to prototype stage is the
subject of this paper.
 OBJECTIVES
To develop a solar thermal powered pumping
system to prototype stage.
To evaluate the performance of the solar pumping
system.
To analyze the economic feasibility of the solar
pumping system.
To develop commercial interest in production of the
solar pumping system.
JUSTIFICATION
Today, electric motors powered by solar
photovoltaic (PV) cells are used to drive pumps,
refrigerators and other mechanical devices in
applications around the world. Many of these
applications require battery storage of energy for
use on demand and conversion of electric power
from DC to AC to interface with user equipment.
PV systems are expensive, manufactured in only a
few places in the world and usually repaired by
component replacement. Reliable, cost effective
solar thermal power systems might more effectively
and appropriately meet many remote mechanical
power demands. These systems could be
manufactured in the users country and repaired by
a local mechanic.
The University of Arizona has been evaluating and
improving the design of a <1kW sized solar thermal
pumping system which appears to have great
potential for meeting small pumping requirements
(~4000 liters/day with 10 m lift) in locations with
adequate solar resource. This solar pumping
system is believed to be applicable to many remote
domestic and irrigation applications in Oman
without access to electricity or relying on diesel
power for pumping. The system consists of a
single piston diaphragm engine, custom made
valves, condenser and return pump. The piston
actuates a lever connected to a lift pump; the
working fluid is an organic fluid commonly used as
a refrigerant, Freon11, Figure 2.
Initial evaluation quantified pumping capability,
but revealed mechanical or operational reliability
problems. One of the principal problems was early
failure of the valves and the difficulty of repairing
the valves (the engine had to be removed from the
collector and taken apart to work on the valves),
Figure 3. A new valve design (Figure 4) may have
resolved valving problems, but requires refinement.
Three other development issues also must be
addressed: assurance of proper start-up on a cold
morning, removal of engine from solar collector to
permit use of commercial collectors and
replacement of Freon11 with a non-ozone
threatening fluid. The University of Arizona
investigator directing past research has agreed to
collaborate on this proposed development project.
PROCEDURES
1. A prototype solar powered pumping system
will be designed and constructed using the
Arizona solar flat plate collector-diaphragm
piston engine model as the starting point.
Design improvements will consider utilization
of a commercially available solar collector and
valving components, valve and engine
maintenance, installation of a cold weather
start-up controller, substitution of a current
refrigerant for Freon11 and other
commercialization issues.
2. The solar powered pumping system will be
tested to determine energy conversion and
pumping performance and evaluate operation,
maintenance and reliability of the system.
3. Solar system capital cost and operating
expenses, lifetime and pumping capability will
be projected and compared with diesel
powered and PV powered alternatives.
4. Results of the project will be documented and
commercialization pursued with assistance of
the University development offices.
EXPECTED OUTCOMES AND THEIR
SIGNIFICANCE
It is expected that this project will produce a design
for a prototype solar thermal powered pumping
systems suitable for commercialization and will
provide performance and cost data which will
promote its commercial use. The system is
believed cost competitive with solar PV and could
be manufactured in developing countries and
repaired locally, and thus be a future source of local
employment.
This solar powered pumping system will provide a
possible means for mechanized pumping of water
in areas lacking power and a more economical,
environmentally acceptable substitute for diesel
powered pumping, yielding benefits to many in
remote locations needing water for domestic and
irrigation requirements.
REFERENCES
Austria (Federal Press Service). 1981. The
Austrian 10kW solar power plant for
developing countries. Final report. Austrian
Federal Press Service, Ministry for Science &
Research, Vienna.
Eckard, S.E. 1975. Multivane expander as
prime mover in low temperature solar or waste
heat application. Paper, 10th IECEC, Univ of
Delaware, Newark.
Halcrow, Sir William and Intermediate
Technology Power Ltd. 1983. Small-scale
solar powered pumping systems: technology,
economics and advancement. The World Bank,
1818 H St, Washington, D.C. 20585.

Kemper, J.S. 1977. Pictorial history of solar

energy use. Sunworld 5:17-32.

Larson, D.L., C.D. Sands II and G.R. Dutt.

1979. Solar and wind powered pumping with
water harvesting. Paper 792574, Winter ASAE
Mtg., New Orleans, LA.

Larson, D.L. and J. Huaut-Elias. 1989. Solar

powered water pump development. Paper
89110 presented 1989 Pacific Region ASAE
Mtg, Sacramento, CA.

Pytlinski, J.T. 1978. Solar energy installations

for pumping irrigation water. Solar Energy
21(4):255-262.

Spencer, L.C. 1989 a,b,c. A comprehensive

review of small solar powered heat engines:
Part I. A history of solar powered devices up to
1950. Solar Energy 43(4)191-196.
Part II. Research since 1950- conventional
engines up to 100kW. Solar Energy 43(4):197-
210.
Part III. Research since 1950-
unconventional engines up to 100kW. Solar
Energy 43(4):211-225.

Tabor, H. 1962. Use of solar energy for

production of mechanical power and electricity
by means of piston engines and turbines. Solar
Energy 6(3):89-93.
 dd

Figure 1. Diaphragm engine mounted in an uncovered flat plate solar collector.

Figure 2. Schematic diagram of the solar thermal mechanical pumping system.

Figure 3. Original mechanical valving system for the diaphragm engine.

Figure 4. Replacement solenoid valves mounted on the diaphragm engine.