Rochester Institute of Technology P17487: KonTiki Kiln Heat Recovery System Design Review October 4, 2016 Eta RIT

Roles and Introductions Student Engineering Major Role Abby Higgins Industrial Project Manager Leah Matczak Mechanical EDGE Admin Eta Santoro Communications Kelsey Thompson Lead Engineer Thane Vollbrecht Simulation Lead Each Individual Customer: Kathleen Draper Advisor: Bill Nowak Additional Support: Sarah Brownell

Agenda Problem Statement Developments Adjustments Functional Decomposition Morphological Table Designs Concept Selection Criteria Pugh Chart Design Selection Benchmarking Design Risks Test Plan Schedule Eta

Problem Issue Goal Heat from the Kon-Tiki kiln is being wasted Create a system that can recover the excess heat Repurpose the heat warm water for showers Bonus – Repurpose the heat to pasteurize water Kelsey

Developments Completed first burn with Kathleen Collected preliminary temperature data Interviewed Dr. Stevens Helped prioritize design concepts Submitted FMS Report Eta

Adjustments – Customer Requirements Group ID Description Priority Purpose CR1 Uses recovered heat for a helpful purpose in a developing country 9 Economics CR2 Costs < $250 to add to the system CR3 Uses local materials and resources 3 Safety CR4 Operated safely by farmer/homeowner CR5 Prevents unintended steam discharge CR6 Operates safely outdoors Ergonomics CR8 Easy to install (minimal steps, lightweight) CR7 Simple to operate by farmer or homeowner Adaptability CR9 Attaches to the existing KonTiki Kiln CR10 Adjustable for different KonTiki models CR12 Adjustable for pit design CR11 Design doesn’t interfere with kiln operations Eta

Adjustments – Engineering Metrics ID Source Description Measure Target Accepted E1 CR4 pH level of shower water (Safe for skin contact) pH 7 ±0.5 E2 CR1 Temperature of flame °C 650-750 600-800 E3 CR1, CR11 Temperature of kiln 450-550 400-600 E4 Temperature of output bathing water 65 45 E5 CR6 Temperature of surrounding environment 10-45 20-40 E6 CR2 Total cost of materials $ < $250 E7 CR11 Average burn time Hours < 2 2 E8 CR7 Hours of Training Required 3 E9 CR9, CR10 Kon Tiki kiln diameter (for multiple models) Meters 1< E10 Time to heat the recovery system Minutes <15 <25 E11 CR1, CR5 Heat recovered from working fluid/hour KJ >8000 >4000 E12 Volume of water collected Liters >5 8 E13 CR8 Setup time to add recovery system <30 <45 E14 Operation Steps # <2 <4 E15 CR3 Travel radius for external materials Miles 10 15 E16 Product lifetime Years >2 5 E17 Maximum weight of heat recovery system kg <20 E18 % of materials by cost available within 100 miles % 100 90 E19 People needed to install system 2 or less E20 CR7, CR9 Loading clearance Cubic meters 1 0.75 E21 CR4, CR5, CR6 Potential unprotected burn hazards Eta

Adjustments – HOQ Eta

Functional Decomposition Main Function: Heat Water Explored Function: Collect Heat Eta

Morphological Chart Kelsey

Designs Kelsey Also looked into Condenser Hood Cookie Sheet Boil Pot Above Coil in Kiln Brick Battery Coils Above Kiln Kelsey Also looked into Condenser Hood Cookie Sheet Syn Gas After Burner Hot Tub Bucket in Fire Coil Syn Gas Hybrid Ring Around the Fire Chem Spinner

Concept Selection Criteria Safety Feasibility (Materials) Feasibility (Technology) Simplicity of Use Does not Obstruct Kiln Use Cost Effectiveness of Heat Collection Size (Weight) Adaptability to Other Models Set-Up Time Interaction Time Lifetime Thane

Original Pugh Continue Worth Keeping Eliminate Coils in the Kiln Thane Continue Coils in the Kiln Hood Collection Hot Tub Worth Keeping Brick Battery Ring Around the Fire Eliminate Syn Gas After Burner Condenser Chem Spinner Bucket in Fire Boil Pot Above Cookie Sheet Coil + Syn Gas Hybrid

Pugh Chart Round 2 When compared to the Hot Tub… Thane When compared to the Hot Tub… None of the main options performed better Coil did the best Both of the side options proved to still be effective

Pugh Chart Round 3 When compared to the Coil… Thane When compared to the Coil… The Hot Tub was the only main option the performed better Both of the side options proved to still be effective

Selected Concept Leah

Selected Concept Leah

Selected Concept Leah

Alternative Concepts Leah

Alternative Concepts Leah

Alternative Concepts Leah

Alternative Concepts Leah

Alternative Concepts Leah

Preliminary Test Plan Test Last Years Gather data Make needed adjustments Create a simulation Attempt to model convection Create Prototype Kelsey

Benchmarking Last Year’s Project Purpose Pasteurize water Dry tea leaves Method Used a conical coil heat exchanger Issues Water temperature was too inconsistent to pasteurize Abby

Benchmarking Solar Water Heater – Costa Rica Purpose Use solar energy to heat water for showers Method Uses gravity to move water from the storage to the heating system Abby

Benchmarking Solar Water Heater – Conduction Loop Purpose Heats water by collecting solar energy Method Moves water with a passive convection loop Abby

Design Risks Abby

Schedule Abby

Questions?