LIFE HEO
Mid term conference
Varese, Ville Ponti
October 29, 2013
LIFE PLUS – HEO
Summary Mid Term Conference
AGENDA
Time
Who
Affiliation
Title
10:30 -- 11:00
D. Gerola
Whirlpool
HEO Project
11:00 -- 11:30
BREAK & NETWORKING
11:30 -- 11:50
11:50 -- 12:05
12:05 -- 12:20
12:20 -- 12:50
12:50 -- 13:05
13:05 -- 13:20
A. Azapagic
J.Doyle
J.Doyle
M. Daniele
A. Niro
J. Capablo / N. Garcia
Manchester University
Whirlpool
Whirlpool/ Lampre
Whirlpool/ Scamm
Politecnico Milano
Whirlpool
HEO Sustainability
HEO Coating Material
HEO Material Application
HEO Manufacturing
HEO Coating Reflectivity
HEO Energy Consumption
13:20 – 13:30
WRAP UP
HEECS CONFIDENTIAL
1
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/
HEECS CONFIDENTIAL
2
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
HEECS CONFIDENTIAL
3
HEO PROJECT
LIFE + 11 ENV/IT/103
TOTAL Budget: 1709 kEuro
Total EC funds :
854 Keuro
Partner: Manchester University
Start : June 2012
End :
Nov 2014
Duration: 30 months
HEECS CONFIDENTIAL
4
PROJECT BACKGROUND
•
•
•
•
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
Steel Enamel
Cavity
Stainless Steel
Sol Gel Coated
Cavity
3 Heater set up:
New Heater Set Up:
Grill
Convection Ring
Bake
HEECS CONFIDENTIAL
2 Grill
2 Convection Ring
5
PROJECT ACTIONS AND TIMELINE
A - Preparatory phase
B - Prototype construction and key functionality test
C- LCA/LCC impact
D- Dissemination Activity
E- Management
LIFE+ HEO - Project Scheduling
2012
JUN
JUL
AUG
SEP
Whirlpool
Whirlpool (Scamm)
Manchester
Whirlpool
Whirlpool
2013
OCT
NOV
DIC
JAN
FEB
MAR
APR
MAY
JUN
2014
JUL
AUG
SEP
OCT
NOV
DIC
JAN
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DIC
A Preparation of Demonstration & Design
B Construction of prototype preproduction tool and test
C Evaluation of Demonstration:
Environmental and Market Impact
D Dissemination & Communication
E Management
HEECS CONFIDENTIAL
6
ACTION A – SUMMARY FOR US PLATFORM
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%
150 °C
t
[min]
2
20
50
h(t)ST
[%]
1,19
11,46
11,95
h(t)HEO
[%]
2,30
12,95
13,98
Rh(t)
[%]
48
12
15
h(t)ST
[%]
1,15
12,34
11,54
h(t)HEO
[%]
1,53
14,97
15,22
Rh(t)
[%]
25
18
24
180 °C
t
[min]
2
20
50
HEECS CONFIDENTIAL
7
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
accelerated life test (ALT)
Stainless steel coated cavity after ALT
with uncoated baffle
Details in :
•HEO Coating Material (Doyle)
•HEO Material application (Doyle)
HEECS CONFIDENTIAL
8
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)
ENERGY vs VOLUME
1000
ENERGY CONSUMPTION (Wh)
900
800
A
A (today)
Class
700
A+
600
500
A++
400
A+++
300
50
55
60
65
CAVITY VOLUME (L)
HEECS CONFIDENTIAL
70
75
80
A
A+
A++
A+++
Energy Target
(kWh)
0,91
0,70
0,53
0,38
9
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)
HEECS CONFIDENTIAL
 10
ACTION A - EUROPEAN OVEN RESULTS
Benchmark of HEO versus other WH model and competitors
OVEN
Cavity
Volume
(liter)
Declared
Cons.
(kWh)
Measured
Cons.
(kWh)
Cons. /
liter
(Wh/l)
Function
Normalised % Difference
consumption ref. model vs
@ 73L (Wh)
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
*Efficiency h = Energy to brick/ Energy absorbed
Energy to brick 0,159 KWh
% Difference= (Cons. X – Cons HEO )/ ½ (Cons. X + Cons HEO)
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
HEECS CONFIDENTIAL
 11
ACTION B - PRODUCT CONFIGURATION AND TOOLS
Product Design Configurations is Frozen
• Dual broil (quartz lamp or tubular)
• Dual fan convection
• 70 liter cavity volume
Ready to launch tooling for prototypes
HEECS CONFIDENTIAL
 12
HEO COATING MATERIAL
OVERVIEW
•
The material used to coat the HEO stainless steel cavity—and called CC2—is a truly nanocoating,
both in terms of:
1)
2)
Material composition (i.e., nano-particles)
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
 13
HEO COATING MATERIAL
OVERVIEW
•
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 process
2. 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
 14
Pre-Coated material deep drawing : design guidelines
Formability assessment on bended and stamped samples
To 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
Microscope coating analysis
Deep draw test description
Color variation (DE) analysis after 4 cycles at 450°
DE
1 < DE < 5
No significative visible
change
5 < DE < 10
10 < DE < 15
Very light visible
change
Perceivable visible
change
DE > > 15
Very visible
change
 15
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.
 16
LIFE HEO
Mid term conference
Varese, Ville Ponti
October 29, 2013
COMPARATIVE LIFE CYCLE ENVIRONMENTAL AND
ECONOMIC IMPACTS OF CONVENTIONAL AND
HIGHLY EFFICIENT OVENS (HEO)
David Amienyo and Adisa Azapagic
Goal, scope and system boundaries
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 sources
o Primary activity data
Utilities electricity
o Whirlpool
o LCA data
o Ecoinvent (2010)
o ELCD and European Steel Association
(2011)
Raw materials
for oven cavity
Processing –
enamelling/sol
gel application
Use
o LCC data
o European Energy Portal (2013)
o Hogg (2012)
Waste management
 18
Methodology
o Life Cycle Assessment (LCA) according to ISO 14044
o Life Cycle Costing (LCC) defined in line with ISO 14044
Goal and Scope Definition
Inventory Analysis
Interpretation
Impact Assessment
 19
Carbon footprint and costs
Conventional oven
100%
100%
90%
HEO (Hypothesis 1)
HEO (Hypothesis 2)
100%
94%
92%
86%
84%
80%
70%
60%
54%
50%
54%
49%
45%
51%
47%
40%
30%
20%
10%
0%
Carbon footprint kg CO2
eq. (19 year lifetime)
Carbon footprint kg CO2
eq. (10 year lifetime)
LCC € (19 year lifetime)
LCC € (10 year lifetime)
 20
Other environmental impacts
Conventional oven
100%
90%
93%
92%
84%
83%
AP (kg SO2 eq.)
EP (kg PO4 eq.)
91%
83%
93%
85%
HEO (Hypothesis 1)
91%
83%
HEO (Hypothesis 2)
92%
84%
80%
70%
60%
50%
40%
30%
20%
10%
0%
ODP (kg R-11 eq.)
POCP (kg C2H4
eq.)
HTP (kg DCB eq.)
ADP fossil (MJ)
AP acidification potential, EP eutrophication potential, ODP ozone depletion potential, POCP photochemical
ozone creation potential, HTP human toxicity potential, ADP abiotic depletion potential
 21
Carbon-Cost intensity
Intensity ratio (kg CO2 eq. generated/€ spent)
Cradle to gate
2.5
2.08
2.0
1.5
1.18
1.18
HEO (Hypothesis 1)
HEO (Hypothesis 2)
1.0
0.5
0.0
Conventional oven
 22
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
 23
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
 24