P17487: Kontiki Kiln Heat Recovery System
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Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

During this phase, our team starting building the physical system. Necessary items were purchased and the Bill of Materials was updated as part needs and naming conventions changed. A demo was conducted to cover most of the test plans from the Build & Test Prep phase. Results are documented here, as well as discussion of importance and next steps moving forward.

By the end of this phase, we built and tested our system, and discovered what worked in our design, and what needed to be changed. Specifically, we found out that we needed connectors of a different material, since the plastic ones we were using ended up melting during our test burn. Additionally, we got temperature data from the test burn to use to validate the model.

Test Results Summary

Analysis: Temperature Data

For our subsystems build demo, our team tested the capabilities of the system with the reservoir and platform that were built. Our team completed a fourth burn trial to collect temperature data with thermocouples for the reservoir water temperature. The details of the testing conditions are outlined in the timeline below:

Timeline of events

Timeline of events


The schematic and actual setup images below show the placement of the thermocouples and the newly constructed platform and reservoir used to complete this test:

public/Detailed Design Documents/Schematics/system_schematic4.png public/Detailed Design Documents/Schematics/kiln_4th_burn_schematic.png

The final results from the test are summarized below:

Parameter Values
Starting water temperature 15.8 °C 60.44 °F
Increase +8.1 °C +14.58 °F
Ending water temperature 23.9 °C 75.02 °F
Amount of water heated 12.3 gallons
Time elapsed 1 hour
Date completed 2/9/17
Location Rochester, NY
Ambient temperature 13.89 °C 57 °F

The trial did not reach the target temperature of 35°C, which was due to the choice of burn material used during the trial and windy conditions. Some of the feedstock was wet, while others did not burn well in general. Some leakage occurred, which was mitigated by duct tape, and formally addressed in post-analysis. Additionally, there was not enough material for a full two hour burn, so the results were not truly representative of use conditions. Based on the linear trend of the average water temperature, which is labelled "cold water" in the figure below, if the burn lasted another hour, the target temperature could have been met.

Test results of water temperature at the inlet and outlet

Test results of water temperature at the inlet and outlet


Our team has completed 4 burn trials thus far testing the capability of the heat recovery system. Three of the trials are summarized on the chart below; trial 1 was neglected since water temperature data was not taken:


Test results for 3 trials

Test results for 3 trials

This proves that there is capability with heating the water by the system. Burn technique will be more closely documented in the training manual as well, since Trial 3 noticed an improved temperature increase due to proper feedstock.

Test Plans Status

A screenshot of an overview of our test plans has been included below, and a link to a PDF for the test plan results can be seen here.

The overview for our test plans

The overview for our test plans

Risk and Problem Tracking

Problem Tracking Version 2

Problem Tracking Version 2

The live problem management document can be found here.

Updated Engineering Requirements

As of the end of this phase, we have also updated our engineering requirements to better match the reality of our project. This was due to a lack of information on our part when we were originally specifying engineering requirements. A screenshot of the current iteration of the engineering requirements can be see below, and a link to the live document can be found here.

Screenshot of updated engineering requirements

Screenshot of updated engineering requirements

Functional Demo Materials

Include links to:

Plans for next phase

As a team, where do you want to be in three weeks at your next demo?

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