Varese, Ville PontiOctober 29, 2013

LIFE HEO

Mid term conference

LIFE PLUS – HEO

Summary Mid Term Conference

2HEECS CONFIDENTIAL

AGENDA

Time Who Affiliation Title

10:30 -- 11:00 D. Gerola Whirlpool HEO Project

11:00 -- 11:30 BREAK & NETWORKING

11:30 -- 11:50 A. Azapagic Manchester University HEO Sustainability11:50 -- 12:05 J.Doyle Whirlpool HEO Coating Material12:05 -- 12:20 J.Doyle Whirlpool/ Lampre HEO Material Application12:20 -- 12:50 M. Daniele Whirlpool/ Scamm HEO Manufacturing12:50 -- 13:05 A. Niro Politecnico Milano HEO Coating Reflectivity13:05 -- 13:20 J. Capablo / N. Garcia Whirlpool HEO Energy Consumption

13:20 – 13:30 WRAP UP

3HEECS CONFIDENTIAL

HIGHLY EFFICIENT OVENS PROJECT

HEO project aims to contribute to the main European environment policies, by addressing the issues of energy-efficiency, over-dependence from fossil fuels, and GHG emissions, chemicals, and waste.

http://www.highefficientoven.eu/ 

4HEECS CONFIDENTIAL

HEO PROJECT SCOPE

• To demonstrate production feasibility of a domestic electric ovens with a stainless steel sol-gel coated cavity that:

• Reduces in-use energy consumption of 30%

• Achieves up to 50% in energy savings in the production process, if compared to state-of the art ovens.

• Eliminates enamel from production process

5HEECS CONFIDENTIAL

HEO PROJECT

LIFE + 11 ENV/IT/103

TOTAL Budget: 1709 kEuroTotal EC funds : 854 Keuro

Partner: Manchester University Start : June 2012End : Nov 2014 Duration: 30 months

6HEECS CONFIDENTIAL

PROJECT BACKGROUND

Steel Enamel Cavity

Stainless Steel Sol Gel Coated

Cavity

3 Heater set up: Grill

Convection RingBake

New Heater Set Up:2 Grill

2 Convection Ring

• Core of the project is the substitution of a steel enamel cavity with a stainless steel cavity (with increased reflectivity)

• To avoid stainless steel deterioration with time, a specially developed sol-gel coating is applied on the material

• Due to change in cavity wall reflectivity typical oven heating system will also be upgraded. New heater set give also an additional energy consumption advantage (applicable also to enamel oven). Details of this study is covered by confidentiality

• Data here presented are obtained with a similar heater set up for an equal foot comparison

7HEECS CONFIDENTIAL

PROJECT ACTIONS AND TIMELINE

A - Preparatory phase WhirlpoolB - Prototype construction and key functionality test Whirlpool (Scamm)C- LCA/LCC impact ManchesterD- Dissemination Activity WhirlpoolE- Management Whirlpool

LIFE+ HEO - Project SchedulingJUN JUL AUG SEP OCT NOV DIC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DIC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DIC

A Preparation of Demonstration & DesignB Construction of prototype pre-production tool and testC Evaluation of Demonstration: Environmental and Market Impact

D Dissemination & Communication

E Management

2012 2013 2014

8HEECS CONFIDENTIAL

Preparatory phase has been done on a US platform• Data were gathered on teflon block matrix to evaluate energy saving (a procedure internally

used to evaluated energy consumption)• It is representative of cooking process on large sheet• Measured an average increase of efficiency of 27%

t h(t)ST h(t)HEO Rh(t)[min] [%] [%] [%]

2 1,15 1,53 2520 12,34 14,97 1850 11,54 15,22 24

t h(t)ST h(t)HEO Rh(t)[min] [%] [%] [%]

2 1,19 2,30 4820 11,46 12,95 1250 11,95 13,98 15

150 °C

180 °C

ACTION A – SUMMARY FOR US PLATFORM

9HEECS CONFIDENTIAL

ACTION A - STAINLESS STEEL COATING

• Coating selection and deposition on selected stainless steel has been investigated • Saving from elimination of enameling process has been evaluated and also

considered in the LCA analysis

Stainless steel coated cavity after ALT with uncoated baffle

Stainless steel coated cavity after accelerated life test (ALT)

Details in :• HEO Coating Material (Doyle)• HEO Material application (Doyle)

10HEECS CONFIDENTIAL

ACTION A - EUROPEAN OVEN

New regulation (to be voted before end Nov). Mandatory 1st Jan 2015 Provision for voluntary use from Jan 14

– A significant change compare to today directive 2002/40/EC)

– Introduction of energy Class above A (today the maximum)

300

400

500

600

700

800

900

1000

50 55 60 65 70 75 80

ENER

GY C

ON

SUM

PTIO

N (W

h)

CAVITY VOLUME (L)

ENERGY vs VOLUME

A

A+

A++

A+++

A (today)

ClassEnergy Target

(kWh)A 0,91A+ 0,70

A++ 0,53A+++ 0,38

11HEECS CONFIDENTIAL

ACTION A - EUROPEAN OVEN

• Action A has been extended to analyze technology potential on an European product application by

modifying the emissivity of enamel cavities (with Aluminum foils) creating an early stainless steel prototype

Details in:• Coating reflectivity (Niro)• HEO Energy Consumption (Capablo/Garcia)

12HEECS CONFIDENTIAL

ACTION A - EUROPEAN OVEN RESULTSBenchmark of HEO versus other WH model and competitors

HEO • Increase in efficiency ranging from 10% to 50% depending on model (also with the more

demanding test with the wet brick)• Meet A+ oven classification

*Efficiency h = Energy to brick/ Energy absorbed Energy to brick 0,159 KWh % Difference= (Cons. X – Cons HEO )/ ½ (Cons. X + Cons HEO)

OVEN Cavity Volume

(liter)

Declared Cons. (kWh)

Measured Cons. (kWh)

Cons. / liter

(Wh/l)

Function Normalised consumption @ 73L (Wh)

% Difference ref. model vs

HEO

Efficiency h %

Competitor 1 74 0,79 0,816 11,03 Forced Air 0,805 23,5 19,8

Competitor 2 51 0,70 0,732 14,35 Forced Air 1,048 48,9 15,2

Competitor 4 67 0,69 0,700 10,45 ECO Forced Air 0,763 18,1 20,8

Competitor 5 67 0,63 0,642 9,58 ECO Forced Air 0,699 9,5 22,7

Whirlpool Conventional 73 0,79 0,762 10,44 Convection bake 0,762 18,0 20,9

HEO 73 TBD 0,636 8,71 ECO Forced Air 0,636 - 25,0

13HEECS CONFIDENTIAL

ACTION B - PRODUCT CONFIGURATION AND TOOLSProduct Design Configurations is Frozen• Dual broil (quartz lamp or tubular)• Dual fan convection• 70 liter cavity volumeReady to launch tooling for prototypes

14

HEO COATING MATERIAL

• The material used to coat the HEO stainless steel cavity—and called CC2—is a truly nanocoating, both in terms of:

1) Material composition (i.e., nano-particles)2) Coating dimensions (i.e., nano-layers)

• The coating material is based on a proprietary sol-gel inorganic chemistry (mainly SiO2)

• The coating is constituted of two transparent nanometric layers applied over a stainless steel substrate, maintaining high IR reflectivity

• The coating is applied through a proprietary roll-on application

• Short curing times and low curing temperatures are required

• The coating presents outstanding properties in terms of:• High-temperature oxidation resistance• Mechanical and Chemical attack resistance• Formability• Durability and food-contact compatibility

OVERVIEW

15

HEO COATING MATERIAL

• The CC2 sol-gel material used to coat stainless steel substrates an be applied according to two proprietary manufacturing application processes:

1. Pre-forming application process2. Post-forming application process

• For the HEO project, CC2 is applied according to a pre-forming roll-on application process• Short curing times and low curing temperatures are possible• Significant energy saving compared to enameling application process is achieved

OVERVIEW

16

DE 1 < DE < 5 5 < DE < 10 10 < DE < 15 DE > > 15

No significative visible change

Very light visible change

Perceivable visible change

Very visible change

Pre-Coated material deep drawing : design guidelinesFormability assessment on bended and stamped samplesTo verify the behavior of the coating during bending and molding of the parts we analyzed the phenomenon in the electron microscope (SEM), determining a relationship between the portion of the coating that is damaged during these operations and the color change (Delta E, or yellowing) resulting from lack of protection after the high temperature cycles.

Bending test description Deep draw test description

Microscope coating analysis Color variation (DE) analysis after 4 cycles at 450°

17

Pre-Coated material deep drawing : design guidelines Cavity formed parts SEM analys

A, B, C Sample

500x vision, the little white areas (coating detachment) are not detectables by human eye

D Sample

Sample presents some yellow spot, this is still acceptable but is the most critical area.

Varese, Ville PontiOctober 29, 2013

LIFE HEO

Mid term conference

COMPARATIVE LIFE CYCLE ENVIRONMENTAL AND ECONOMIC IMPACTS OF CONVENTIONAL AND HIGHLY EFFICIENT OVENS (HEO)David Amienyo and Adisa Azapagic

19

Goal, scope and system boundaries

Raw materials for oven cavity Use

Waste management

Processing – enamelling/sol gel application

Utilities - electricity

o Main goal to estimate the life cycle environmental impacts and costs of conventional and highly efficient ovens from ‘cradle to grave’ with particular focus on the oven cavity

o Functional unit: manufacture and use of 1 domestic oven over a lifetime of 19 years

o Lifetime: 19 years

Data sourceso Primary activity data

o Whirlpool o LCA data

o Ecoinvent (2010)o ELCD and European Steel Association

(2011)o LCC data

o European Energy Portal (2013)o Hogg (2012)

20

Methodology

Goal and Scope Definition

Inventory Analysis

Impact Assessment

Interpretation

o Life Cycle Assessment (LCA) according to ISO 14044 o Life Cycle Costing (LCC) defined in line with ISO 14044

21

Carbon footprint and costs

100%

54%

100%

54%

92%

49%

94%

51%

84%

45%

86%

47%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Carbon footprint kg CO2eq. (19 year lifetime)

Carbon footprint kg CO2eq. (10 year lifetime)

LCC € (19 year lifetime) LCC € (10 year lifetime)

Conventional oven HEO (Hypothesis 1) HEO (Hypothesis 2)

22

Other environmental impacts

AP acidification potential, EP eutrophication potential, ODP ozone depletion potential, POCP photochemical ozone creation potential, HTP human toxicity potential, ADP abiotic depletion potential

92%91%93%91%93%92%

84%83%85%83%83%84%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

AP (kg SO2 eq.) EP (kg PO4 eq.) ODP (kg R-11 eq.) POCP (kg C2H4eq.)

HTP (kg DCB eq.) ADP fossil (MJ)

Conventional oven HEO (Hypothesis 1) HEO (Hypothesis 2)

23

Carbon-Cost intensityCradle to gate

1.181.18

2.08

0.0

0.5

1.0

1.5

2.0

2.5

Conventional oven HEO (Hypothesis 1) HEO (Hypothesis 2)Inte

nsity

ratio

(kg

CO

2 eq

. gen

erat

ed/€

spe

nt)

24

Summary of findings

o The HEO (Hypotheses 1 and 2) has a lower carbon footprint than the conventional oven by 8% and 16%, respectively

o Use of ovens is the main contributor to the carbon footprint (98%) mainly due to electricity

o Linear relationship between increasing energy efficiency and carbon footprint reduction, ranging from 8-30% for the same increase in efficiency

o The HEO (Hypotheses 1 and 2) has lower life cycle costs than the conventional oven by 6% and 16%, respectively

o Use of ovens is the main contributor to the LCC costs (95-97%)

o ‘Cradle to grave’ carbon-cost intensity for the HEO is only 2% lower than the conventional oven

o However, the difference between the two models is 43% from ‘cradle to gate, despite 57% higher manufacturing costs for the HEO relative to the conventional oven

25

Key aspects planned for next phase

o Update of LCA and LCC models taking into account new energy consumption values

o Sensitivity analysis showing impact of pyrolytic cleaning and chemicals used for manual cleaning