P16487: Biochar Kiln Heat Recovery System
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Systems Design

Table of Contents

Since the Project Planning phase, there has been some considerable changes to our system design. Upon further communication with customers and international contacts, the following changes will be made:

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Team Vision for System-Level Design Phase

For a complete list of action items our team planned to accomplish during Phase II, please click here.

For a list of actual action items and their progress during this phase, please click here.

Functional Decomposition

PDF Version

Benchmarking

Serbian Air-Dryer HRS:

Nepal Conduction Water Heater

Nepal Oil Distillation System

Morphological Chart and Concept Selection

Based on the critical functions acquired from the functional decomposition, the Morphological Chart shown below was created. For a chart with words instead of pictures please see the Excel Version.

Each team member then generated at least three concepts from the morphological chart. We then reconvened and as a team narrowed down our concepts to the eight shown below.

Concept Selection

Our team then identified 11 system-level selection criteria that would be useful in comparing the eight concepts.

A Pugh chart was then created to compare these concepts with each other using this criteria. In the end, eight Pugh charts were created with the datum being rotated to the next concept each time. The first Pugh chart with concept 1 as the datum is shown below. For all eight charts, please see the complete version here.

Looking solely at the Pugh charts, concept 3 was a clear winner. However, through team discussion, we quickly omitted that option as it could hinder airflow and create unsafe conditions as the kiln is continuously reloaded. Concept 4 was another that we agreed to omit, as it would require an external electrical source like a solar panel to implement.

We were still having difficulty narrowing down our concepts, so we decided to take a new approach by breaking down the concepts into sub-systems and creating different combinations of these sub-systems. This is explained in greater detail in the Concept Development section below.

Concept Development

The HRS can be broken down into two main subsystems. There is an initial heat exchange from the kiln that is then transferred to a second heat exchange that is applied to the unprocessed goods. Concepts were generated for each subsystem separately as shown below.

Found above are concepts for both heat exchange interactions. Each design from the concept generation phase is categorized and analyzed by subsystem.

Each concept is then compared to other concepts in their respective subsystem categories, as well as analyzed in terms of feasibility and how well they fared to the selection criteria. As shown above, several concepts were either refined or scrapped.

Systems Architecture: Designs and Flowcharts

From the system architecture development, four initial and two secondary heat exchange concepts are left for consideration. The following links show combinations of subsystems and their respective functional architecture. Each subsystem was paired based on compatibility of each design (e.i. the working fluid between each exchange has to to be the same.)

Feasibility: Analysis

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Risk Assessment

Plans for next phase

Outlined in the link below is the vision and plan for the next phase. It includes deliverables and goals we would like to accomplish by the next review. The ultimate goal is to assign more detail to the proposed design that can then be used to ensure feasibility of our concept(s) through quantification and specificity.

Team Shared Vision for Phase III

Design Review Materials


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