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Corrugated tubes as a paradigm shift in solar PV thermal system technologies: Numerical insights into performance

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  • Navegi, Ali
  • Maadi, Seyed Reza
  • Khanjani, Irandokht
  • Kazemian, Arash
  • Xiang, Changying
  • Ma, Tao

Abstract

Corrugated tubes are known for superior heat transfer properties, yet their potential in photovoltaic/thermal (PVT) systems remains underexplored. This study applies three corrugated tube designs—neutral, concave, and convex—in PVT collectors using validated 3D numerical simulations benchmarked against ISO 9806:2017. One design was selected for further analysis. Results show that corrugated tubes enhance heat transfer, reduce thermal stress, and improve system reliability. The concave design achieves the highest efficiency (64.69 %) and largest carbon reduction (338.87 kg CO2/m2). Economic analysis reveals that corrugated tubes lower the Levelized Cost of Energy (LCOE) to 0.036–0.037 USD/kWh, compared to 0.041 USD/kWh for smooth tubes, with a return on investment (ROI) of 908.2 % for the concave design. Payback periods reduce to 2.5 years, confirming financial viability. Parametric analysis indicates that increasing amplitude length (A) from 0.05D to 0.25D improves optical efficiency (η0) by 6.55 % and reduces heat loss (UL) by 32.73 %. Shortening the period length (λ) from 8D to D further improves η0 by 3.66 % and reduces UL by 16.23 %. These findings establish corrugated tubes as a promising solution for enhancing PVT efficiency, reducing costs, and promoting sustainable solar energy applications.

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  • Navegi, Ali & Maadi, Seyed Reza & Khanjani, Irandokht & Kazemian, Arash & Xiang, Changying & Ma, Tao, 2025. "Corrugated tubes as a paradigm shift in solar PV thermal system technologies: Numerical insights into performance," Energy, Elsevier, vol. 327(C).
    • Handle: RePEc:eee:energy:v:327:y:2025:i:c:s0360544225016688
    DOI: 10.1016/j.energy.2025.136026
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