Solar Assisted Oil Distiller System Design Review P15484 October 2, 2014 Johnathon Wheaton Bruno Moraes Peter Coutts Nathan Johnson Benjamin Wolfe Agenda Project introduction Functional Decomposition Functional Architecture Morphological Analysis Pugh Matrix Concept Selection Preliminary Test Plan Updated Risks Next Steps Project Introduction http://www.anandaapothecary.com/images3/distillation.gif http://www.vetivernur series.co.nz/uploads/ images/3%20Months %20growth%202.JP G Functional Decomposition Design Dependent Other Functions Extract Oil Distill Oil Operate Safely Protect User from Heat Pass Steam Through Plant Material Allow Heat Transport at Steam Shutdown Any from Boiling Time Water Allow User to Shut Supply OffWater Shut DownPlant Heat Contain Boil Water Transfer Heat Source When Material Finished Contain Water Pass Steam Through Produce Steam Condense Steam Condense Steam Operate Safely Plant Material Produce Steam Separate Oil Oil Recover Heat Regulate Pressure Contain Steam Regulate Pressure (design dependent) and Temperature Contain Steam/Oil Collect Mixture Condensed Mixture Transport Steam Mixture from Plant Allow Water and Oil Material to Separate by Gravity Supply Heat Convert Energy Functional Architecture Morphological Table Alternatives System Alternatives A B C D E F G Convert Energy Reflector + Methane Evacuated tube Photo voltaic battery Methane burner Lens Methane Flat plate Boil H2O Pressure cooker Pressure cooker Heat exchane boiler Pot Gold nano-particles Pressure cooker Pressure cooker Condenser Coil bath Cool coil Air cooled tube Flat top Cool coil Air cooled Cone and bowl Direct Steam Dry steam, one tube Wet-dry steam Fan directed steam Wet-dry steam dry steam Wet-dry steam 2 layered Separate Oil Separatory funnel Floatation separator Centrifuge Turkey baster Floatation separator Separatory funnel Height drain Insulate Spray foam Pipe foam None None Spray foam Spray foam Foam tape H I Ben Peter John Nate Bruno Evac Tube + Methane Propane / Electricity Reflector + Methane Evac Tube + Methane Reflector + Methane Flat plate + Methane Reflector + Methane Pot Chamber / pot Pressure cooker w/drip feed Pot w/ drip feed Pressure cooker Pressure cooker Pressure + pot Flat top air cooled Aircooled Coil bath Water cooled cone Coil bath Coil bath Wet-dry steam Wet-dry steam Dry steam Dry steam Wet-dry steam Wet-dry steam Wet-dry steam Turkey baster Separatory funnel Separatory funnel Separatory funnel Separatory funnel Separatory funnel Seperatory funnel None None Spray foam Spray foam Spray foam Spray foam Spray foam Picked This Combination for: Best Options Next Best Options Worst Cheapest Most Expensive General Option General Option Option D + Evacuated tube (Post 1st Pugh run through) Homebrewer Ben's option Peter's pick John's pick Nate's pick Bruno's pick Pugh Matrix (1st iteration) Selection Criteria Selection Criteria Cost to make Cost to make Safe Ease of set up Oil yield Easerequired of Operation Time to design and build Durability Ease of set up Sustainability of fuels Ease of Operation Durability Manufacturability Maintainability (cleaning) Repairable (in Haiti) Size/weight Sum + 's Sustainability of fuels Sum S's Manufacturability Sum -'s Repairable (in Haiti) Net +Score Sum 's Rank Sum S's Sum -'s Net Score Rank A A B B + S + 2 1 4 -2 4 + + S + 3 1 8 -5 5 + + S S 2 2 3 -1 3 + S S S + S S 2 5 5 -3 4 C C S S + 1 2 4 -3 5 S + S S + 2 3 7 -5 5 D D + S S + + + + 5 2 0 5 1 + S S S S + S + + + + 6 5 1 5 1 E E FF GG HH + + + S + 4 1 7 -3 4 + S SS S SS +S SS SS 2S + 5 S 0S 22 29 + + S S+ S-S +S - - 2+ 2 3-1 3 33 + + S S+ S-S +S --2+ 2 3-13 33 1 1 2 6 -3 4 6 -3 3 + + 2 0 5 -3 5 II + D Datum Pugh Matrix (2nd iteration) Peter John John Nate Nate Bruno Bruno BenBen Peter SelectionCriteria Criteria Selection Cost to to make Cost make Safe Ease of set up Oil yield Ease of Operation Time required to design and build Durability Ease of set up Sustainability of fuels Ease of Operation Durability Manufacturability Maintainability Repairable (cleaning) (in Haiti) Size/weight Sum + 's Sustainability of fuels Sum S's Manufacturability Sum -'s Repairable (in Haiti) Net+Score Sum 's Rank Sum 0's Sum -'s Net Score Rank S + S 1 2 4 -3 3 S + S + S S S 2 5 5 -3 3 S S 0 2 5 -5 4 + S S S 1 3 8 -7 5 + S S 1 2 4 -3 3 S + S S S 1 4 7 -6 4 + S S + S S 2 4 1 1 1 S S S S S + S S S 1 8 3 -2 2 AA SS + - - - - - 0S 16 -6 1 52 SS + ----SS 0S 25 S -51 44 9 -8 6 7 -6 4 BB GG H H D -S S S S+S SS -+ -S 1S 3S 3 -21 27 S S S S S + S -++ S + 32+ 2 + 13 15 4 -3 3 4 -1 1 Datum Pugh Matrix (3rd iteration) Selection Criteria SelectionCriteria make to Cost S Cost to make Safe S Ease of set up Oil yield Ease of Operation Time required to design and build S Durability of set up Ease S of fuels Sustainability of Operation Ease S Manufacturability Durability (cleaning) Maintainability S Haiti) Repairable (in Size/weight Sum + 's Sustainability Sum S's of fuels Manufacturability Sum -'s Repairable (in Haiti) Net Score Sum + 's 4 Rank Sum 0's Sum -'s Net Score Rank S S S S S S S 0S 6S 1S S -1 0 11 1 -1 5 D + S S S S S S Datum 3 + S+ +S S-S + S S S + S S S S S S S + S SSS S S 1 1 1+ S S 1 6 6S S S 50 0 S S -4 1 1 2 1 2 5 3 2 10 8 8 1 2 -6 0 0 6 4 4 + S S S S S S + S S S S S +1 S 6 S 0 S 1 2 3 8 2 0 4 + + + S + + S + + + + + S S +5 +2 +0 S 5 8 1 3 1 7 1 HH G G B B Bruno A A NateBruno John Nate PeterJohn BenBenPeter + + + S + + S + + S + + S S +5 +2 +0 S 5 7 1 4 1 6 2 + S + S + S + S + S + S S3 S3 +1 S 2 4 2 6 2 2 3 Pugh Matrix Conclusions Sub-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 Requirements 2 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 Concepts Collector 1. Evacuated tubes 2. Flat plate Concentrators 3. Fresnel Lens 4. Water lens 5. Parabolic reflector 6. Solar trough Photovoltaic Panels Solar Thermal Collectors Evacuated Tubes http://www.siliconsolar.com/wpcontent/uploads/how-evac-tubes-work.jpg http://tgalsolar.com/wp-content/uploads/2011/12/EdsonHeat-Transfer-300x248.jpg Solar Thermal Collectors Evacuated Tubes http://ecx.images-amazon.com/images/I/51i5tzmlzuL.jpg Solar Thermal Collectors Flat Plate Collector http://www.gunt.de/networks/gunt/sites/s2/mmcontent/img/ E3-S-ST-B.jpg http://www.htproducts.com/images/products/Solar-FlatPlate-Panels-Installed.jpg Solar Thermal Collectors Evacuated tubes x Flat Plates - Relative costs - Efficiency Solar Thermal Collectors Relative costs (evacuated tubes) Temperature difference =75ºC Cost (US$) 1600 1400 1200 y = 3.2374x R² = 0.7967 1000 800 600 400 200 Power (w) 0 0 50 100 150 200 250 300 Slope: 3.24 $/W Relative cost average: 3.56 $/W 350 400 Solar Thermal Collectors Relative costs (flat plates) Temperature difference =75ºC Cost (US$) 1600 y = 7.3389x R² = -0.721 1400 1200 1000 800 600 400 200 Power (w) 0 0 20 40 60 80 100 120 140 160 Slope: 7.34 $/W Relative cost average: 8.20 $/W 180 200 Solar Thermal Collectors Efficiency Efficiency 0.8 Duda Solar SC5815 Evacuated Tubes Titan Power ALDH29 Flat Plate 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 20 40 60 80 100 120 140 ΔT Solar Thermal Collectors Efficiency http://www.solardynamix.com/uploads/6/8/1/0/6810974/611 2205.png?312 http://www.aeodexia.com/Images/UpFile/2008123085 258946.gif 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 Concentrators Solar energy through concentrated light Fresnel Lens Water Lens Parabolic Reflector Solar Trough Gold Nanoparticles All require tracking Calculations Broke 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 Calculations Known Values & Assumptions: Completed Solar Concept Table 24 Over 2, 12 Hour Processes – 222W 48 Hour Cycle Continuous Cycle – 111W Percent Percent renewable* renewable* Percent from Percent from propane* propane* Initital Initital cost cost (not (not including including propane propane components) components) Gallons Gallons of of propane/cycle propane/cycle Labor Labor hours hours required/cycle required/cycle Payback Payback period period (yrs) (yrs) Photovoltaic Photovoltaic 100% 50% 25% 100% 25% 25% 0% 50% 75% 0% 75% 75% Evac Evac Tube Tube 50% 25% 50% 75% $ $ 1,500 1,200 $ $ 647 359 $ $ 517 227 $$ 395 99 0.000 0.109 0.163 0.109 0.000 0.163 0.163 0.163 0 0.167 1.167 0.167 0 0.167 1.167 0.167 8.12 8.43 NEVER 5.15 6.49 11.61 NEVER 3.20 Payback period (yrs, Payback $ 6.49 is 8.12 free)$ 2.13 3.85 assumingperiod gas is (yrs, free)assuming gas Annual $$ 183.12 $ 29.25 Annual savings savings vs vs propane propane Parabolic Solar Parabolic Solar Reflector Reflector w/ w/ Trough Trough w/ w/ Tracker Tracker Tracker Tracker Propane Propane 50% 50% 0% 25% 25% 0% 50% 50% 100% 75% 75% 100% $ $ $ 3.28 7.46 $0.59 2.35 $ 75.03 $ 183.12 $ $ (69.75) $ 29.25 $ 300 332 300 $ $ 332 $ $ -0.109 0.109 0.217 0.163 0.163 0.217 0.167 1.167 0 0.167 0.167 0 3.91 NEVER 0.00 9.70 10.74 0.00 4.79 $ 0.00 1.781.78 $ 1.97 75.03 $$ (23.97) 29.25 29.25 $$ (0.00) (0.00) Select Concept Customer feedback Primary plan: solar trough Novel idea Low Cost Safe http://wims.unice.fr/xiao/solar/collector.html Back-up plan: photovoltaic Less efficient Proven concept 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 Steam Distillation Wet Wet-Dry http://www.morningmystbotanics.com/images/pdf/distillationpdf/df4316.pdf Dry Steam Distillation Comparison Wet Wet-Dry Dry Cost Feasible Fuel Req. Design Cheapest ✔ High High Simple Middle ✔ Moderate Most Expensive ✔ Complex Oil Yield 0.25% 0.25% 0.08% 0.08% http://www.morningmystbotanics.com/images/pdf/distillationpdf/df4316.pdf Wet-Dry Steam Concepts Condenser Steam/Oil Mixture must be condensed in order to separate oil from water. Coil Bath Condenser Length Flow Separate Oil Water must be seperated from oil. Immiscible fluids separate by density Ways to separate include: Manually drawing out oil using pipette Seperatory Funnel System Costs Category Boiler Condenser Separator Piping Insulation Part Type of Part Aluminum Pressure Cooker (5.5 gal) Pressure Vintage Steel (~1970's) (4 gal) Cooker Stainless Steel (1.5 gal) Stainless Steel (2.6 gal) Kettle (not pressure) (4 gal) Stainless Steel Pot (8 gal) Pot Canning Pot (Porcelain on steel) Stainless Steel pot (5 gal) Container Plastic water bucket (5 gal) Copper Coil (20 feet x 3/8") Coil Stainless Steel (25 feet) Stainless Steel (25 feet, 3/8in) Collector Stainless bucket (3.25 gal) 7.5 ml Plastic (LDPE) x 50 Pipette 3 ml Plastic x 5 Plastic Piping (most only are rated to 150 deg F) Copper Pipe 3/4" x 10 ft Metal Piping Copper elbow Fiberglass pipe 3/4" diameter, 3 feet Spray Foam Spray Foam (1.25 cu feet) Total Cost (Low Estimate) Total Cost (High Estimate) Cost $80 $45 $65 $72 $80 $67 $18 $28 $10 $21 $58 $33 $20 $7 $1.39 $18 $4 $6 $39.95 $133.39 $224.95 Water Flow Solar Trough Oil/Steam Flow Water Container Steam Flow Water/Oil Mixture Plant Matter Condenser Container Water/Oil Separate by Density Test Plan Outline Test 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 Detailed Test Plan 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 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 plants Goal: have developed roots to test distillation process Grown in College of Science Greenhouse Project Management Updates Added risks: Vetiver dies Solar trough does not provide enough energy Solar tracking is too fragile Lessons Learned: Meeting plans are essential Consult customer early on MSD tools & templates may need to be adapted to fit the project Next Steps (sub-system design) Assign sub-system design owners Identify sub-system interfaces Determine appropriate dimensions Select materials Prepare for tests Questions?