Experimental investigation of enhanced thermal performance of solar air collectors through optimized selection of manufacturing materials: Energy, exergy, economic, and environmental analysis

Abstract The current study aims to experimentally investigate the thermal performance of three identical solar air collectors manufactured from three different metals: aluminum, zinc, and steel. The study conducted environmental and economic analyses of the three proposed solar air collectors over a month. The aluminum solar air collector demonstrated superior performance, achieving a maximum thermal efficiency of 24.46%, while the steel and zinc solar air collectors recorded thermal efficiencies of 21.57% and 18.16%, respectively. The exergy efficiency ranges for aluminum from 0.95% to 13.54%, zinc absorber plate exhibits from 0.63% to 11.89%, and steel from 0.6% to 9.98%. The aluminum solar air collector revealed high monthly cost savings of about $1429.6/month, followed by zinc ($1203.8) and steel ($963.4) solar air collectors. Environmental analysis to showed savings entering the atmosphere per month showed that the aluminum reduced about 19,795 kg CO 2 /month, Zinc solar air heat 16,668 kg CO 2 /month, and the steel solar air collector recorded 13,339 kg CO 2 /month. In this study, the absorber plate made of aluminum was the most efficient material, followed by zinc and steel. That confirms its suitability for designing efficient solar air heating systems in areas with high solar radiation intensity, such as Tunisia, and provides a clear direction for future research and development in manufacturing solar air collectors.