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Solar Assisted Oil Distiller System Design ReviewP15484October 2, 2014
Johnathon Wheaton
Bruno Moraes
Peter Coutts
Nathan Johnson
Benjamin Wolfe
Agenda
Project introductionFunctional DecompositionFunctional ArchitectureMorphological AnalysisPugh MatrixConcept SelectionPreliminary Test PlanUpdated RisksNext Steps
Project Introduction
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http://www.vetivernurseries.co.nz/uploads/images/3%20Months%20growth%202.JPG
Pass Steam Through Plant Material
Contain Steam
Contain Plant Material
Transport Steam from Boiling Water
Design Dependent
Operate Safely
Allow Heat Shutdown at Any
TimeAllow User to Shut
Off
Shut Down Heat Source When
Finished
Regulate Pressure
Protect User from Heat
Other Functions
Boil Water
Supply Water
Supply Heat
Contain WaterProduce Steam
Regulate Pressure and Temperature
Convert Energy
Operate Safely
Pass Steam Through Plant Material
Condense Steam Transfer Heat
Contain Steam/Oil Mixture
Transport Steam Mixture from Plant
Material
Recover Heat (design dependent)Produce Steam
Separate Oil Collect Condensed Mixture
Allow Water and Oil to Separate by
Gravity
Functional Decomposition
Distill OilExtract Oil
Separate Oil
Condense Steam Transfer Heat
Contain Steam/Oil Mixture
Transport Steam Mixture from Plant
Material
Recover Heat (design dependent)
Functional Architecture
Morphological Table
System AlternativesConvert Energy Boil H2O Condenser Direct Steam Separate Oil Insulate Picked This Combination for:
A Reflector + Methane Pressure cooker Coil bath Dry steam, one tube Separatory funnel Spray foam Best OptionsB Evacuated tube Pressure cooker Cool coil Wet-dry steam Floatation separator Pipe foam Next Best OptionsC Photo voltaic battery Heat exchane boiler Air cooled tube Fan directed steam Centrifuge None WorstD Methane burner Pot Flat top Wet-dry steam Turkey baster None CheapestE Lens Gold nano-particles Cool coil dry steam Floatation separator Spray foam Most ExpensiveF Methane Pressure cooker Air cooled Wet-dry steam Separatory funnel Spray foam General OptionG Flat plate Pressure cooker Cone and bowl 2 layered Height drain Foam tape General Option
H Evac Tube + Methane Pot Flat top Wet-dry steam Turkey baster NoneOption D + Evacuated tube (Post 1st Pugh run through)
I Propane / Electricity Chamber / pot air cooled Wet-dry steam Separatory funnel None HomebrewerBen Reflector + Methane Pressure cooker w/drip feed Aircooled Dry steam Separatory funnel Spray foam Ben's option
Peter Evac Tube + Methane Pot w/ drip feed Coil bath Dry steam Separatory funnel Spray foam Peter's pickJohn Reflector + Methane Pressure cooker Water cooled cone Wet-dry steam Separatory funnel Spray foam John's pickNate Flat plate + Methane Pressure cooker Coil bath Wet-dry steam Separatory funnel Spray foam Nate's pickBruno Reflector + Methane Pressure + pot Coil bath Wet-dry steam Seperatory funnel Spray foam Bruno's pick
Alt
erna
tive
s
Pugh Matrix (1st iteration)
Cost to make + + - + - + + +Safe - S S S + S S SOil yield + S + S + S + +Time required to design and build - - - - - - - -Ease of set up - - S S - S S SEase of Operation S - S S + S S SDurability - - - + - S - -Maintainability (cleaning) - S - S S S - -Size/weight - - - + - S - -Sustainability of fuels + + + + + + + +Manufacturability - S - + - S - -Repairable (in Haiti) - S - + - S - -Sum + 's 3 2 2 6 4 2 3 3Sum S's 1 5 3 5 1 9 3 3Sum -'s 8 5 7 1 7 1 6 6Net Score -5 -3 -5 5 -3 1 -3 -3Rank 5 4 5 1 4 2 4 3
Datum
Selection Criteria
A B C D E F G H I
Cost to make + + - + - + + +Ease of set up - - S S - S S SEase of Operation S - S S + S S SDurability - - - + - S - -Sustainability of fuels + + + + + + + +Manufacturability - S - + - S - -Repairable (in Haiti) - S - + - S - -Sum + 's 2 2 1 5 2 2 2 2Sum S's 1 2 2 2 0 5 2 2Sum -'s 4 3 4 0 5 0 3 3Net Score -2 -1 -3 5 -3 2 -1 -1Rank 4 3 5 1 5 2 3 3
F G H IA B C E
Selection Criteria
D
D
Pugh Matrix (2nd iteration)
Cost to make S - - - S S - SSafe - - - S - - S -Oil yield + + S S + + S STime required to design and build S - - S - - - SEase of set up + - + S - - S SEase of Operation - - - S - - S -Durability - S S + - - + +Maintainability (cleaning) S S S S - S S SSize/weight S - - - S S S -Sustainability of fuels - - - - - - S -Manufacturability - - - S - - - +Repairable (in Haiti) S S S S - S - +Sum + 's 2 1 1 1 1 1 1 3Sum 0's 5 3 4 8 2 4 7 5Sum -'s 5 8 7 3 9 7 4 4Net Score -3 -7 -6 -2 -8 -6 -3 -1Rank 3 5 4 2 6 4 3 1
Selection Criteria
Datum
Ben Peter John Nate Bruno A B G H
Cost to make S - - + S S - SEase of set up + - + S - - S SEase of Operation - - - S - - S -Durability - S S + - - + +Sustainability of fuels - - - - - - S -Manufacturability - - - S - - - +Repairable (in Haiti) S S S S - S - +Sum + 's 1 0 1 2 0 0 1 3Sum S's 2 2 2 4 1 2 3 2Sum -'s 4 5 4 1 6 5 3 2Net Score -3 -5 -3 1 -6 -5 -2 1Rank 3 4 3 1 5 4 2 1
Ben Peter John Nate Bruno A B G H
Selection Criteria
D
Pugh Matrix (3rd iteration)
Cost to make S + S + + + + +Safe S - S - - + + SOil yield S - - + S - S -Time required to design and build S S S - - + - +Ease of set up S S S - S + + SEase of Operation - S S - S + + -Durability S S + - S S S +Maintainability (cleaning) S S S - S S S SSize/weight S + S S + + + SSustainability of fuels S S S S S + + SManufacturability S S S - S + + +Repairable (in Haiti) S S S - S S S SSum + 's 0 2 1 2 2 8 7 4Sum 0's 11 8 10 2 8 3 4 6Sum -'s 1 2 1 8 2 1 1 2Net Score -1 0 0 -6 0 7 6 2Rank 5 4 4 6 4 1 2 3
A B G H
Selection Criteria
Ben Peter John
Datum
Nate Bruno
Cost to make S + S + + + + +Ease of set up S S S - S + + SEase of Operation - S S - S + + -Durability S S + - S S S +Sustainability of fuels S S S S S + + SManufacturability S S S - S + + +Repairable (in Haiti) S S S - S S S SSum + 's 0 1 1 1 1 5 5 3Sum S's 6 6 6 1 6 2 2 3Sum -'s 1 0 0 5 0 0 0 1Net Score -1 1 1 -4 1 5 5 2Rank 4 3 3 5 3 1 1 2
D
Bruno A B G H
Selection Criteria
Ben Peter John Nate
Pugh Matrix ConclusionsSub-systems are highly independent
Concepts can be combined with varying degrees
Ex. Photovoltaic & Methane burning
Feasibility was one of the most important deciding factors
Solar heating is the greatest design challenge Must be independently analyzed
Solar Heating Requirements2 gallons of water per distillation process
19.3 MJ (5.36 kWh) required to boil 2 gallons of water (25°C to 100°C boiling)
Inefficiencies can be supplemented by propane (later methane)
Criteria for selection: Initial cost Operating cost Safety Lifespan, durability
Available Solar Energy
Total average daily energy = 8.47 kWh/m2/day
Solar Heating ConceptsCollector
1. Evacuated tubes
2. Flat plate
Concentrators
3. Fresnel Lens
4. Water lens
5. Parabolic reflector
6. Solar trough
Photovoltaic Panels
Solar Thermal CollectorsEvacuated Tubes
http://tgalsolar.com/wp-content/uploads/2011/12/Edson-Heat-Transfer-300x248.jpg
http://www.siliconsolar.com/wp-content/uploads/how-evac-tubes-work.jpg
Solar Thermal CollectorsEvacuated Tubes
http://ecx.images-amazon.com/images/I/51i5tzmlzuL.jpg
Solar Thermal CollectorsFlat Plate Collector
http://www.gunt.de/networks/gunt/sites/s2/mmcontent/img/E3-S-ST-B.jpg
http://www.htproducts.com/images/products/Solar-Flat-Plate-Panels-Installed.jpg
Solar Thermal CollectorsEvacuated tubes x Flat Plates
- Relative costs
- Efficiency
Solar Thermal CollectorsRelative costs (evacuated tubes)
Temperature difference =75ºC
50 100 150 200 250 300 350 4000
200
400
600
800
1000
1200
1400
1600
f(x) = 3.23742205977209 xR² = 0.97049939068447
Slope: 3.24 $/WRelative cost average: 3.56 $/W
Power (w)
Cost (US$)
Solar Thermal CollectorsRelative costs (flat plates)
Temperature difference =75ºC
Slope: 7.34 $/WRelative cost average: 8.20 $/W
80 100 120 140 160 180 2000
200
400
600
800
1000
1200
1400
1600
f(x) = 7.33887149156807 xR² = 0.891753776412852
Power (w)
Cost (US$)
Solar Thermal CollectorsEfficiency
0 20 40 60 80 100 120 1400
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Duda Solar SC5815 Evacuated TubesTitan Power ALDH29 Flat Plate
ΔT
Efficiency
Solar Thermal CollectorsEfficiency
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Photovoltaic Collectors Solar Panels - Converts the suns radiation into electricity Charge Controller – Prevents overcharging of the battery Deep Cycle Battery – Stores energy to offset power fluctuations Electric Heating Coil – Converts electricity into heat
Solar ConcentratorsSolar energy through concentrated light
Fresnel LensWater LensParabolic ReflectorSolar TroughGold Nanoparticles
All require tracking
CalculationsBroke down energy required for processing:
% needed from solar source: (~6 hours of sun) 111 Watts for 48 hours straight 222 Watts for 2 x 12 hour sessions
Remaining % from propane (methane)
Calculated cost of solar source to meet power requirement Benchmarking
Calculated cost savings vs 100% propane
Hypothetical payback period
CalculationsKnown Values & Assumptions:
19.3$6.38
1320.75$
2%1.40$ 88.80
183.12$ 1.170.17
90.00$
Total Energy Req (MJ):Propane Cost per Gallon:
Oil yield:
Distillation cycles per year:
Initial cost of propane:
Labor rate in Haiti ($/hour):
Oil yield per cycle ($):
100% propane annual cost ($):Labor hours for tracking + propane:
Labor hours for just propane:
Energy per gallon of propane (MJ):
Completed Solar Concept Table
Evac Tube
Parabolic Reflector w/
Tracker
Solar Trough w/
Tracker PropanePercent renewable* 100% 25% 25% 25% 25% 25% 0%Percent from propane* 0% 75% 75% 75% 75% 75% 100%Initital cost (not including propane components) 1,200$ 359$ 227$ 99$ 300$ 332$ -$ Gallons of propane/cycle 0.000 0.163 0.163 0.163 0.163 0.163 0.217Labor hours required/cycle 0 0.167 1.167 0.167 0.167 0.167 0Payback period (yrs) 6.49 11.61 NEVER 3.20 9.70 10.74 0.00Payback period (yrs, assuming gas is free) 6.49 2.13 3.28 0.59 1.78 1.97 0.00Annual savings vs propane 183.12$ 29.25$ (69.75)$ 29.25$ 29.25$ 29.25$ (0.00)$
Photovoltaic
48 Hour Continuous Cycle – 111W24 Hour Cycle Over 2, 12 Hour Processes – 222W
Evac Tube
Parabolic Reflector w/
Tracker
Solar Trough w/
Tracker PropanePercent renewable* 100% 50% 25% 50% 50% 50% 0%Percent from propane* 0% 50% 75% 50% 50% 50% 100%Initital cost (not including propane components) 1,500$ 647$ 517$ 395$ 300$ 332$ -$ Gallons of propane/cycle 0.000 0.109 0.163 0.109 0.109 0.109 0.217Labor hours required/cycle 0 0.167 1.167 0.167 0.167 1.167 0Payback period (yrs) 8.12 8.43 NEVER 5.15 3.91 NEVER 0.00
Payback period (yrs, assuming gas is free)8.12$ 3.85$ 7.46$ 2.35$ 1.78$ 4.79$ -$ Annual savings vs propane $ 75.03 $ 75.03 $ (23.97) $ (0.00) $ 183.12
Photovoltaic
Select ConceptCustomer feedbackPrimary plan: solar trough
Novel ideaLow CostSafe
Back-up plan: photovoltaicLess efficientProven concept
http://wims.unice.fr/xiao/solar/collector.html
http://solarknowledge.blogspot.com/2010_12_01_archive.html
All other Sub-systems
Boiler Store bought pressure cooker
Pressure monitor Lid that clamps sealed Steam outlet port
Stainless Steel Stock Pot Simple Cheap Ability to be modified
http://www.morningmystbotanics.com/images/pdf/distillationpdf/df4316.pdf
Wet Wet-Dry Dry
Steam Distillation
Wet Wet-Dry
Steam Distillation Comparison
Cheapest✔ High Simple
0.25%
Middle✔ - Moderate
0.25%
Dry Most Expensive✔ - Complex
0.08%
Cost
Feasible
Fuel Req.
Design
Oil Yield
High
0.08%
http://www.morningmystbotanics.com/images/pdf/distillationpdf/df4316.pdf
Wet-Dry Steam Concepts
CondenserSteam/Oil Mixture must be condensed in order to separate oil from water.
Coil Bath Condenser LengthFlow
Separate Oil
Water must be seperated from oil.Immiscible fluids separate by densityWays to separate include:
Manually drawing out oil using pipetteSeperatory Funnel
System CostsCategory Part Type of Part Cost
Aluminum Pressure Cooker (5.5 gal) $80Vintage Steel (~1970's) (4 gal) $45Stainless Steel (1.5 gal) $65Stainless Steel (2.6 gal) $72Kettle (not pressure) (4 gal) $80Stainless Steel Pot (8 gal) $67Canning Pot (Porcelain on steel) $18Stainless Steel pot (5 gal) $28
Container Plastic water bucket (5 gal) $10Copper Coil (20 feet x 3/8") $21Stainless Steel (25 feet) $58Stainless Steel (25 feet, 3/8in) $33
Collector Stainless bucket (3.25 gal) $207.5 ml Plastic (LDPE) x 50 $73 ml Plastic x 5 $1.39
Plastic Piping (most only are rated to 150 deg F)Copper Pipe 3/4" x 10 ft $18Copper elbow $4
Fiberglass pipe 3/4" diameter, 3 feet $6Spray Foam Spray Foam (1.25 cu feet) $39.95
Total Cost (Low Estimate) $133.39Total Cost (High Estimate) $224.95
Boiler
Condenser
Separator
Piping
Insulation
Pressure Cooker
Coil
Pipette
Metal Piping
Pot
Water Container
Water Flow
Solar Trough
Steam Flow
Plant Matter Container
Condenser
Oil/
Ste
am F
low
Water/Oil Separate by Density
Water/Oil Mixture
Test Plan OutlineTest Related Engineering Requirement
Heating/Boiling S2, S3, S19, S20, S21, S26
Steaming S4, S26
Condensing S26
Collector/Separator S5,S6,S26
Oil Quality S22, S23, S24, S25
Total System S1, S7, S8, S9 S10, S11, S12, S13, S14, S15, S16, S17, S18
Heating/Boiler Time to reach boiling Continuous steam production Total water boiled in 1 day
Steaming Plant material capacity Ensure steam passes through plant
material Check for pressure build up
Condenser Steam flow rate Input/output fluid temp Operation over time
Detailed Test Plan Collector/Separator
Oil recovery rate Oil Quality
Quality of store bought oil Quality of distilled oil
System Processing time Ease of use Area of exposed hot surfaces Set up and repair tools required Size and weight
We Have Vetiver!
6 sterile plantsGoal: have developed roots to test distillation process
Grown in College of Science Greenhouse
Project Management UpdatesAdded risks:
Vetiver diesSolar trough does not provide enough energy
Solar tracking is too fragileLessons Learned:
Meeting plans are essentialConsult customer early onMSD tools & templates may need to be adapted to fit the project
Next Steps (sub-system design)
Assign sub-system design ownersIdentify sub-system interfacesDetermine appropriate dimensionsSelect materialsPrepare for tests
Questions?