P17422: Continuous System for Black Solider Fly Composting
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Preliminary Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase

What did the team plan to do:

During the Preliminary Detailed Design Phase our team planned to setup tests that allowed us to get familiar with the larvae. We planned on learning about how to collect food for the larvae, their feeding rates, and their bi-products. From the standpoint of our system, we planned on testing whether the larvae stay in the top layers of food as new layers as added, filter options for the leachate, analyzing the digestate left by the larvae, and different options for collecting the pupae.

What did the team actually accomplish:

During this phase the team performed testing with the larvae that allowed the team to familiarize themselves with the larvae. The team built an insulated test box that was bigger than prior insulated containers. This allows the team to test bigger containers than previously available. A test procedure was drafted for a larger test to simulate a continuous system in order to answer the necessary questions about the design of our system.

Familiarization Test

Link to Data/Graphs.

Question:

Context:

Objectives:

Materials Needed:

Procedure:

Process:
Data Collection:

Table:

Table illustrating how each row was attained.

Table illustrating how each row was attained.

Container 1:

Container 1 Day 5

Container 1 Day 5

Container 1 Day 9

Container 1 Day 9

Container 1 Day 19

Container 1 Day 19

Container 2:

Container 2 Day 9

Container 2 Day 9

Container 2 Day 19

Container 2 Day 19

Results:

Container 1 data

Container 1 data

Container 2 data

Container 2 data

 The calculated weight of 300 larvae and their feeding rates

The calculated weight of 300 larvae and their feeding rates

 Percent reduction of food added.

Percent reduction of food added.

Observations:

Outcomes of Familiarization Test

Future Outcomes

Prototyping Container

Design Requirements:
  1. Sealed/doesn't leak to prevent escape of larvae and wastes
  2. Disposable or easy to clean
  3. Enables separation of layers for bottom layer extraction
  4. Cheap and easy to build
  5. Clear walls can see layers
  6. Aerobic

Challenge: To develop a container to use for digestate studies

Plan: Develop ideas and selected the optimal container

Prototype 1:

Container idea #1

Container idea #1

Prototype 2:

Container idea #2

Container idea #2

Prototype 3:

Container idea #3

Container idea #3

Prototype 3 was selected to be the optimal container based off of ease of use and reusability.

Prototyping Layer Divider

Idea: Develop an integrated divider system that would make our container system more reusable.
Layer Divider

Layer Divider

Live working development document

Prototyping Hot Box

Challenge: To develop a large box to house all container studies that will be used for digestate and larvae studies.

Plan: Develop and build a container that will provide an ideal environment for larvae.

Engineering Requirements:

Draft design:

Hot Box Structure

Hot Box Structure

Hot Box Inside Structure

Hot Box Inside Structure

Final built Product

Outside structure of the Hot Box

Outside structure of the Hot Box

Inside structure of the Hot Box

Inside structure of the Hot Box

Bill of Material (BoM)

Link to Bill of Material (BoM) BSFL Composter and Hot Box live document.

See below for screenshot of our BoM:

Bill of Material (BoM) BSFL Composter and Hot Box

Bill of Material (BoM) BSFL Composter and Hot Box

Test Plans

Test Plan for Larvae Evacuation Study

Feasibility Question: Do the larvae evacuate the bottom two-three inches of a container when the food waste is higher than 10 plus inches suggesting that the larvae migrate to the top 7” of food?

Background: All current concepts for waste removal assume larvae automatically migrate towards recently-added food and evacuate the digestate zones containing inedible leftovers. This test attempts to verify that the evacuation assumption is correct. It will also verify that the larvae will relocate to the top 7 inches of food even when the bottom layer contains edible food.

Goals:

  1. Primary: Count larvae in bottom layer after the bottom layer is removed from the system. Calculate the percent loss of larvae from the entire system.
  2. Secondary: Use the removed digestate to test multiple filter systems for the filtration of leachate.
  3. Third: Continue to document information of the feeding and growth rates of the larvae.

The live working document for the test plan.

The test plan includes

Engineering requirements that will be satisfied

Test Plans for Engineering Requirements

Test Plan for Engineering Requirements

Test Plan for Engineering Requirements

Link to live Test Plans excel sheet.

Design and Flowcharts for the Upcoming Test Plan

Flow Chart for the 1 week feeding containers

Flow Chart for the 1 week feeding containers

Flow chart for the 2 day feeding containers

Flow chart for the 2 day feeding containers

Risk Assessment

Link to our Risk Management Table.
Risk Management Table.

Risk Management Table.

Design Review Materials

Isometric view of the Shed

Isometric view of the Shed

Top view of the Shed

Top view of the Shed

Plans for next phase

Link to Detailed Design Phase Plan live document.

See below for screenshot of our plan:

Detailed Design Phase Plan

Detailed Design Phase Plan

See below for screenshot of our Gantt chart:

Detailed Design Phase Gantt Chart

Detailed Design Phase Gantt Chart

See below for individual plans:


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