[Sub-System 1 Name] - Rochester Institute of Technology



Critical Sub-System DesignSub-System DesignP15484 – Solar Assisted Essential Oil Distiller October 10, 2014[Sub-System 1 Name]Benchmarked Items Be sure to add to the benchmarking document.Concept Generation“Mini” morph table (concept sketches) for features of the sub-system. Does not need to be extensive just show a few ideas you want to look at. Example: different kinds of fittings that could be used, different shape containment vessel, different fastening methods, and so onFeasibility AnalysisCriteria for selectionQuestions that need to be answeredInformation you need from other sub-system ownersAnalyses for criteria (tables, graphs)Be sure to save your supporting files (files that you copy paste from excel, visio, etc.) to the folder also.Concept SelectionReasons for elimination/Sub-System DesignSketches, rough solid model imagePreliminary BOMLikely based off benchmarked itemsPhotovoltaic SystemBenchmarked Items ?ImageNameCostDescriptionURLPhotovoltaic Panels11430011430000130 Watt Solar Panel by Sundance Solar $329.00 130 Watts59.6" x 26.57" x 1.38"18V7.5A Watt Solar Panel by Suncance Solar$129.95 40 Watts21.1" x 26.2" x 1.38"17.3V2.32V DS-A18-60, 60W 12VDC Solar Panel $124.74 60W27.2" x 26.2" x 1.38"18V7.5APolycrystalline DS-A18-135, 135W Solar Panel $207.90 135 W56.7" x 26.6" x 1.38"18V7.5APolycrstalline Watt 12 Volt Solar Power Kit, SPM130P-KIT $917.97 130W57.7 " x 26 " x 1.97 "Comes with 15 Amp 12 Volt Solar Charge Regulator Adventure Power AP1800S2, 1800 Watt Portable Solar Power System $1,595.00 80 W, 17.5V, 2 x 2.29A solar panel, with 1800W 120VAC PortablePower System Power Station 60 W $871.00 60 WBattery and cables included Off-grid AC Kit 1 $1,290.00 290W Elements90805241300024/48V DC Heating Element$165.83 1"NPT Male Water Heater Element$34.99 600W, 12V1" NPT Male Water Heater Element$39.99 6 in12V, 200, 300, or 600W Gallon Drum Heater?550W, 4in wide115V 50/60Hz50 to 425 F thermostat Kleen 7361Replacement Plug-in Range Element$8.97 6" HeatersVaries? Element Kit$145.00 ? Tone Soldering Type Electric Kettle Heater$8.25 220V, 800W Kettle Heater Replacement Kit$15.67 220V, 3000W (Frontier/Glenray) 1906746 Warmer Element 120V 1250W 9" Dia Tomlinson Frontierglenray Kettle 341519$67.95 120V, 1250W Steel Electric Kettle Tube Heater Element$8.89 220V, 1500W Manufacturing Kettle Heating Element$41.97 120V, 1000W Lead Acid Battery$66.27 12V, 35 Ah - Sealed Lead UPS Replacement Bettery$46.83 6V, 10Ah Lead Acid Battery$32.99 12V, 12Ah Controller4826020066000Renogy Tracer 4210$209.99 Nominal System Voltage: 12V/24V Auto recognitionMax. PV Input Power: 500W (12V), 1000W (24V)Rated Charge Current: 40ARated Discharge Current: 20AMax. Solar Input Voltage: 100VDCSelf-consumption: <10mA (24V)Maximum Battery Voltage: 32VCharge Circuit Voltage Drop: ?0.26VDischarge Circuit Voltage Drop: ?0.15V Tristar TS-45$146.46 45Amp Charge Controller - C40$112.74 40Amp12/24/48V Charge Controller - C35$88.86 35Amp12/24V Generation1234Heat WaterExternally heating the chamberNPT tapped hole in chamberBand HeaterSubmersible HeaterCriteria for selection: Meets engineering requirementsCostRisk to projectFeasibility AnalysisQuestions that need to be answered:Charge controller? – StevensWhat is the minimum (or recommended) thread engagement necessary to prevent leaks?According to CNCexpo a thread length of 1.5 times the diameter of the fastener is a good rule of thumb ().Information other sub-system owners:How deep will the water be?What material is the boiling chamber made of?Stainless steel.Will the chamber have a wall thickness or dimensions that will allow for a 1” NPT hole to be tapped with enough thread engagement to prevent leaks? No – we need to look into modifications. Contact John Bonzo.What volume of water will be present in the chamber?2.16 gallons per process minimumWhat is the diameter of the chamber?Benchmarking shows 10-14 inches.Concept SelectionConcept 1: An external heating element is much less efficient than a submersible heating element and is not substantially cheaper than other heating elements. Concept 2: If the heating element is 0.25” in diameter (smaller than any benchmarked products) then the thread length must be 0.375” (1.5 times diameter rule of thumb). No reasonably priced vessel will have a wall thickness of 0.375”.The wall of the vessel could be modified to provide this thickness but that would require welding and extended design time (high project risk). Instead, the male NPT threads on the heating element could be used to seal and fasten the element to the wall of the vessel.Photovoltaic panel:Photovoltaic panels on the market are most often sold with power specifications in Watts. During the system level design phase of the project the energy required to boil 2 gallons of water was found to be 19.3MJ, or 1.43 MJ for 0.1486 gallons of water. This energy, required each hour, results in a 397 Watt requirement before efficiency loss. The following efficiency losses are assumed:Charge controller – 94%(“Solar…”, 2014)Battery – 85%(“Charging…”, 2014)Accounting for these inefficiencies, the solar panel must be able to produce 496 Watts.397W0.850.94=496WAll benchmarked photovoltaic panels were considered. Dividing the panel cost by Watts produced helped select the lowest cost option. $50 was added to the cost of panels not included in kits to account for additional wiring and fittings that will be required. The Dasol DS-A18-60, 60W 12VDC solar panel meets all sub-system engineering requirements at the lowest cost per Watt of all benchmarked panels. Four of these panels will be needed to produce the minimum power supply.Battery:A battery will be used to maintain power to the heating element during cloud cover. The team has chosen to design the sub-system to provide power for 15 minutes of cloud cover. This requires (as specified in the sub-system requirements flow-down) a battery that can provide at least 125 Wh (Wh are a standard industry measure for batteries). Charge controllers (discussed below) typically require the same voltage for both the photovoltaic panel and battery. Because a 12V panel has been selected meaning the battery must also be 12V. The 12V, 12Ah benchmarked battery is selected because it matches the voltage of the photovoltaic panel and exceeds the necessary power storage. Charge ControllerA charge controller protects the photovoltaic system from overcharging the battery to prolong the life of the battery. The input and output voltages and amps must be specified to select a charge controller.Module Short Circuit Current x Modules in parallel x Safety Factor = Array Short Circuit Current*7.5A x 4 x 1.25 = 37.5A (minimum controller input current)Total DC Connected Watts / DC System Voltage = Max. DC Load Current*500 W / 12 V = 42 Amp (minimum controller output current)The Morningstar Tristar TS-45 is selected because it matches these specifications.* DesignPreliminary BOMDasol DS-A18-135, 135W Solar Panel$207.90X4135 W56.7" x 26.6" x 1.38"18V7.5APolycrstalline Tristar TS-45$146.46 45Amp Lead Acid Battery$32.99 12V, 12Ah Water Heater Element$34.99 600W, 12V1" NPT Male Gas SystemBenchmarked Items ?ImageNameCostDescriptionURLBurner104775952532 Tip Round Nozzle Jet Burner$58.50 10 in diamter150,000 BTU Tip Natural Gas Jet Burner$44.99 100,000 BTU1/2" pipe inletThreaded pilot mount (pilot sold seperately)8 1/2" Dia. X 2 1/2" H Pacific Alpine Cuisine Propane Burner, Ruglator, & Hose$29.81 40,000 BTU13x26x5 Chef Single Burner SHP-RL$60.99 60,000 BTU1 cast iron burnerRemovable revsible legs13"x13" cooking surface 76200104775Bayou Classic Outdoor Patio Burner$49.97 16"x16" cooking surface36" stainless braided hose13" tallAvailable in stainless for $91.00 Cast Iron Burner$51.18 100,000 BTU14.65 x 18.5 x 14.65 Tools Sportsman Series Single Burner$73.50 Cast iron14 x 12 x 12 LP Gas Buner$79.50$144.8935,000 BTU or 70,000 BTUOption 5 ft hose appox $327 in burner diameter8 x 13x 15 or 7.5 x 27 x 13 Propane Tank4.25lb - $77.7911lb - $82.0720lb - $45.1830lb - $77.9140lb - $115.62100lb - $176.071 gal2.6 gal4.7 gal7.1 gal9.4 gal23.6 gal Empty$29.97 20lb Pro Grade Empty4.5lb - $54.9711lb - $56.9730lb - $62.4740lb - $83.47100lb - $1365? Rhino Pre-filled$48.22 15lb Systems15240038100Coleman One-Burner Propane Stove$23.88 10,000 BTU8 in burner bowl, Fittings, Gauges, & Valves19050047625Valves for Propane Tanks20lb - $18.2830lb - $25.0840lb - $28.73100lb - $36.883/4" NPT inlet1 5/16" ACME type 1 and internal female POL 7/8"-14 outlet Tank Refill Indicator Gauge$26.65 1 5/16" female ACME type 1 inlet1 5/16" ACME type 1 and internal female POL 7/8"-14 outlet GenerationDue to project time constraints and the already relatively low cost, parts will be purchased rather than designed and machined.Feasibility AnalysisCriteria for selection: Meets engineering requirementsCostRisk to projectQuestions:How many hours will the operation run off propane? No more than 4 hours per cycle. Dewi et al () indicate a 9 hour distillation process time. The solar trough is being designed to meet energy requirements operating over 2 days, or at least 10 hours of intense sunlight.At what rate should steam be produced?According to Dewi et al, 2kg/hour/kg of dry vetiver root. In accordance with CR6 and S4, at least 1 pound of plant material must be processed. 1 gallon of water=3.7854 Kg→0.2641 gallons of water=1 Kg0.45 Kghour3.7854Kggal=0.1189galhour25% design margin→0.1486galhourHow much power must the burner produce?BTU/HR to boil 0.6604 gallonswater: 8.33 lbs/gal0.1486 gal of water=1.238 lbsThis energy requirement is also dependent on the change in temperature:?T=212°F-65°F=147°FThe BTU’s required to boil 0.1486 gallons of water in one hour is found to be:wΔT+mHv=BTU's1.238lb(147℉+973.63BTUlb)=1387BTUMore power is required to boil that water in less time (10 minutes):BTU/HR to bring 0.1486 gallons to boil in 10 minutes1387BTU10 min60minHR=8,324BTUAnd even more power is required to account for efficiency:With 20% efficiency (“Cooking…”, 2012) 8,324BTU/0.2 = 41,620 BTU?Source: other sub-system owners:What volume of water will be present in the chamber?Using a 20 quart (5 gal) vessel:Upper limit of 2 gallons of water. The exact amount can be determined later and regulated using a float valve.What is the diameter of the chamber? According to benchmarked pots and pressure cookers, the chamber will be 12-14 inches in diameter. A maximum diameter for the burner has been added to the sub-system requirements.Concept SelectionBurnerA burner with integrated vessel resting surface is necessary to disperse flame across a wider area and to prevent the burner from potentially melting the vessel. The prime pacific alpine cuisine is the lowest cost burner benchmarked that meets all requirements.Propane TankA standard 20lb propane tank is the most readily available propane tank in the local area with a low cost.ConnectorsThe burner comes with integrated fittings and tubes.Sub-System DesignPreliminary BOM76200104775Bayou Classic Outdoor Patio Burner$49.97 16"x16" cooking surface36" stainless braided hose13" tallAvailable in stainless for $91.00 Rhino Pre-filled$48.22 15lb Tracker – with a focus on Tracker Sub-System SelectionBenchmarked Items Concept GenerationNot applicable here. The information in this document is for concept selection at this stage.Feasibility AnalysisCriteria for selection: (desired state in parentheses)Cost (low)Design complexity (low)Further design time required (low)Availability of replacement parts in Haiti (high)Difficulty of repairs (low)Video proof of concept (present)Number of electrical components (low)Water resistance (high)Durable (high)Manual labor required (low)Level of torque it can produce (sufficient/high)Reliability under occasional cloud cover (high)Adapting needed for solar trough (low)Questions that needed to be answered:What will our first choice tracking be?What will our backup choice tracking be?Will there be enough money in the budget to support the backup plan?Information you need from other sub-system owners:How heavy will the trough be?Answer: It doesn’t exactly matter if the troughs axis of rotation is also its center of mass, which means very little force will allow the trough to rotateCan we reduce friction between trough axis of rotation and tracking?Concept SelectionOur selected solar tracking concept is the Solar Flower Tracker and if this device fails in some way during the protyping phase (or any phase), we can easily resort to more reliable solar tracking methods (which may cost more and require further purchasing). Specific reasons for selection include:See “Solar Tracking Concept Selection” spreadsheet for:Pugh Matrix iterationsFull pros/ cons list Solar Flower Tracker Selected Because:All Pugh Matrix iterations led to Solar Flower TrackerAlready designedPlans to build availableLow costRisks have low severity Little time spent on designingLow monetary riskParts are mostly ‘up-cycled’ and could potentially be found/replaced in HaitiDoes not require any type of electricityNo electrical maintenance/protection requiredVideo proof of concept revert to a plan “B” if prototyping failsOther tracking devices were not selected because:Pendulum TrackerLots of moving parts that could potentially break and not be available in HaitiNot dependent on sun to control (ie: passive tracking)Unknown cost (lots of components to find/ purchase)Build intensiveSolar Battery TrackerRequires a solar batteryNot as resistant to weather (electrical components)Photodiode Battery TrackerRequires a battery that needs to be chargedNot as resistant to weather (electrical components)Solar Cell TrackerNot as resistant to weather (electrical components)Solar cells may be hard to find in Haiti to replaceSecondary Fluid with Mass TransferUses either anti-freeze or butane as the secondary fluid- could be hard to replace in Haiti and both are potentially dangerousOnly very crude designs availableDrawbacks of Solar Flower Tracker to keep in mind:High complexityMay be hard for Haitian farmers to fix if it breaksRequires secondary working fluid: ethanol or other alcohol based fluidAdds in another level of difficultyMaintaining fluid levelsReusabilityReliabilityAlthough some of the other methods are more widely used and tested in solar tracking than the Solar Flower method, they are more expensive and would require further design to make a reality. We will continue to further investigate the abilities and limits of the Solar Flower tracker through prototyping and through contact with the Solar Flower creator.Our “Plan B” is the Solar Cell Tracker because it is simple, proven, and not highly design or build intensive. It also had the next best results from the Pugh Matrix iterations. There is a concern that wiring the solar cells directly to the motor may short out the cells and cause damage to the cells over a long period of time. Further investigation must be done in order to know how to avoid this problem. A simple circuit with diodes that only allow current to run in one direction may be necessary. A subject matter expert will be needed for the completion of this design. Because the Solar Flower Tracker has the potential to be very cheap, there should be money in the budget to purchase the components for the Solar Cell Tracker.Selected Solar Tracker Sub-System Design:Solar Flower TrackerSee “Sub-System Design – Solar Tracker” for more detailed designs of this sub-system. [Drip Feed and Plant Matter Container]Benchmarked Items Concept GenerationFeasibility AnalysisQuestions that need to be answered:Does the water need to be held in a stainless steel/copper container prior to having contact with the plant or only after the plant and water has been combined? No.How much water will be needed? 2.16 gal for steam + 2 gal (for condendser?) + 25% design margin = 5.2 gallonsWhat is the minimum acceptable flow rate at any given time? Design so that trough can produce steam through set period of time. (~5 hours peak sunlight)What is the maximum acceptable flow rate that the condenser can condense? How much will water flow deviate as the water level decreases? (Flow for specific tube size vs. head, various curves for different tube sizes).Will the needle valve be able to compensate for water flow deviation? (Flow for specific tube size vs. head, various curves for different tube sizes).How much water will be contained in the plant matter container, how much water will be contained in the drip feed? Toilet valve possibly different.What is the most efficient method of directing steam past the plant material? Low pressWhat is the best way to implement fittings from pot to pipe?Will the bronze needle fitting pose a potential chemical reaction which could decrease the quality of the oil? (Bronze is a mixture of mainly copper with some tin.) NoIs the selective black spray paint going to have a large enough difference in solar efficiency that it would be worthwhile to purchase?Is it better to have a black pot exposed to sunlight or an insulated pot which will lose less heat but collect less heat? Insulate everything except for the drip feed/condenserIs a black pot with a selective coating a potential safety hazard?How much can efficiency be increased by adding fins to dump heat to surrounding environment for condenser?Information other sub-system owners:Steam flow out of plant matter containerTemperature? (To know when burner needs to be used) Unless there is some visual verification of steam flow.1”NPC thread for John.Concept SelectionSeperatory Funnel to regulate water flow/to be used as a drip feed, I thought this might be a good idea, but it is not ideal. Water would not collect as much heat from the sun, multiple seperatory funnels would be needed, and there may be potential for a chemical reaction when in contact with the PTFE.Sub-System DesignSketches, rough solid model imagePreliminary BOMLikely based off benchmarked items ................
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