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?