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Industrial Ecology – Spring 2012. Mr. Coffee – Redesign and Conclusions. Recap – Disassembly & Analysis Conclusions Redesign – Use Phase and Additional Improvements Conclusions – Total Impact Reduction. Table of Contents. Disassembly- Explosion Diagram. - PowerPoint PPT Presentation
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1
MR. COFFEE – REDESIGN AND CONCLUSIONS
Industrial Ecology – Spring 2012
2Recap Redesign Conclusions
Table of Contents
Recap – Disassembly & Analysis ConclusionsRedesign – Use Phase and Additional ImprovementsConclusions – Total Impact Reduction
3Recap Redesign Conclusions
Disassembly- Explosion Diagram
http://www.buyspares.co.uk/tefal/coffee-makers/896115-vitesse-coffee-maker/catalogue.pl?shop=tefal&path=290047&model_ref=41271&illustration_ref=27443
4Recap Redesign Conclusions
Eco Audit- Energy SummaryPhase Energy (MJ) Energy (%) CO2 (kg) CO2 (%)Material 139 4.7 6.43 3.7Manufacture 30.4 1.0 2.31 1.3Transport 3.87 0.1 0.275 0.2Use 2.77e+03 94.1 167 94.8Disposal 1.3 0.0 0.0912 0.1Total (for first life) 2.94e+03 100 176 100End of life potential -33.3 0.968
Carbon and Energy Totals
5Recap Redesign Conclusions
Eco Audit- Water Consumption Summary
USE(99.5%)
Materials, Manufacturing, End of Life(.5%)
6Recap Redesign Conclusions
Problem Statement – Where we left off
Identify
• 14 Million Coffee Makers are sold each year in the United States(consumer watch)
• Consumer coffee makers require energy to compensate for heat loss.
Hypothesize
• Reduce Energy Consumption during use through redesign• Aim to move to insular materials to reduce waste heat• Reduce energy consumption through behavioral change
Impleme
nt
• Energy conservation by changing key components: Pot, Conductive plate and Heating element
• Propose Use Based conservation– How many cups do you drink compared to your waste?
Recap Redesign Conclusions
Function, Objectives, Constraints, Free Variables
• Provide at home fast, easy, cost efficient coffee
Function
• Produce hot water at appropriate temperature for coffee brewing
Objective
• Water Resistance, heat resistance, stiffness, capacity
Constraints
• Heating time, material choice, material thickness
Free Variables
Recap Redesign Conclusions
Redesign – Design RequirementsComponent Function Objective Constraints Free Variables
Packaging Protection/Marketing Minimize Eco- Impact Load < Damaging Load
Material Choice, Thickness
Polypropylene Shell Structure & Support Minimize Eco- Impact and maintain cost
Stiff and Strong Enough, Cost
Material Choice, Thickness
Electronics Controls machine operation
Minimize Eco- Impact Simple Coffee Controls
N/A
Filter Basket Hold Coffee Grinds Minimize Eco- Impact Stiff and Strong Enough, Cost
Material Choice, Thickness
Coffee Pot Contain and Insulate Coffee
Reduce Thermal Losses
Contain 8 Cups, Hold Liquid
Material Choice, Thickness
Heating Element & Tubing
Heat the water Reduce Thermal Losses
Electric – Thermal Conversion
Material Choice, Thickness
Recap Redesign Conclusions
Redesign – Coffee Pot Materials Selection
Recap Redesign Conclusions
Redesign – Analysis of Polypropylene
Recap Redesign Conclusions
Redesign – Analysis of Polypropylene
Recap Redesign Conclusions
Use Phase – Key Design Changes
• Insulated Coffee Carafe• Heating Element Location• Stainless Steel Reusable Filter• 8-cup Water Capacity
Recap Redesign Conclusions
Redesign: Insulating Carafe
• Dual shell vacuum insulation.
• Minimal points of contact.
• Minimal heat loss by conduction.
• Keeps coffee warm at 160F (71C) for up to 6 hours.
• No need for reheating of coffee
Recap Redesign Conclusions
Redesign: Result of Insulating Carafe
• Heat transfer by conduction. • Heat transfer is minimized by the
coefficient of thermal conductivity of insular material.
• Heat transfer is minimized by the insulation thickness.
Energy Calculations. - Input at 900watts -10min/day on time
Energy = 900J/s*600s=540kJ/day - Life time = 6yrs Energy = 540kJ/day*365day*6years=1182.6MJ/lifetime
Life time energy saving2770MJ-1182.6MJ=1587MJ57% cut in energy consumption
Recap Redesign Conclusions
Usage Adjustments – Reusable Filters
Saves up to 334.3 MJ of energy and 7.5kg of CO2
Energy (MJ)
CO2 (kg)
Stainless Steel Reusable Filter
Total Before End of Life 7.7 0.5
Total After End of Life 2.0 0.2
Paper Filters Total 336.3 7.7
Recap Redesign Conclusions
Usage Adjustments – Reduction in Water Capacity
Original Use Water Consumption: 93,220kg
• By reducing capacity to 8 cups, an estimated
reduction in daily use is 2 cups
Total Use = 74,661kg
New Water Consumption:
Water Savings: 18,559kg
Recap Redesign Conclusions
Redesign – Analysis & Redesign of Packaging Materials
Original PLA0
2
4
6
8
10
12
14
Energy (MJ) in Packaging Materials
Material Manufacturing Total (MJ)
OriginalPlastic Bag 1.7MJ 0.13
0.66MJMJ
Styrofoam 10MJ
Original Total 11.7MJ 0.79MJ 12.49New PLA 1.546MJ 0.18MJ 1.726
Energy Savings 10.76
Recap Redesign Conclusions
Redesign – Eliminating water transport in Use phase
Assumptions:• The entire reservoir,8 cups is transported through the
machine in approximately 10 minutes• The Coffee is warmed to 90.5-96C (Environmental
impacts of different methods of coffee preparation by Eva Brommer,Britta Stratmann and Dietlinde Quack)
• Energy losses can be directly correlated to energy savings.
• Room temperature is 23 degrees Celsius.• The tubing is a perfect cylinder of length .3556
meters• Coefficient of Thermal Conductivity of the Tubing
is .13 W/mK (http://www.engineeringtoolbox.com/thermal-conductivity-d_429.html)
Recap Redesign Conclusions
Redesign – Calculating Energy Gains
Recap Redesign Conclusions
Redesign – Calculating Energy GainsTemperature© Q (W/m) Energy Lost Per Year Per Life Cycle
90.5 -40.248731 -8587.469264 -3.1344263 -18.80655769
91 -40.384441 -8616.424283 -3.1449949 -18.86996918
91.5 -40.519953 -8645.337254 -3.1555481 -18.93328859
92 -40.65527 -8674.208508 -3.1660861 -18.99651663
92.5 -40.790394 -8703.038368 -3.176609 -19.05965403
93 -40.925324 -8731.827154 -3.1871169 -19.12270147
93.5 -41.060064 -8760.575181 -3.1976099 -19.18565965
94 -41.194614 -8789.282762 -3.2080882 -19.24852925
94.5 -41.328975 -8817.950204 -3.2185518 -19.31131095
95 -41.463151 -8846.57781 -3.2290009 -19.3740054
95.5 -41.59714 -8875.16588 -3.2394355 -19.43661328
96 -41.730946 -8903.714709 -3.2498559 -19.49913521
Energy Consump-
tion Source
Disposal Phase Eliminating Water
Transport
Transportation Phase
Manufacturing Phase
0
5
10
15
20
25
30
35
Saves Approximately 18 MJ Per Unit
Recap Redesign Conclusions
Redesign:
Recap Redesign Conclusions
Redesign: Water & Heating Diagram
Recap Redesign Conclusions
Redesign: Filter & Basket
Recap Redesign Conclusions
Redesign: Cumulative Results
Improvement CO2 Reduction (kg)
Energy Reduction
(MJ)
Water Consumption
(kg)Insulated Pot 85 1587 N/A
Packaging Materials
.35 10.76 12
Reduction of Water Capacity
N/A N/A 18559
Relocation of Heating Element
N/A 18 N/A
Recap Redesign Conclusions
Conclusions- Overall Impact
Water Reduction (kg) CO2 Reduction (kg) Energy Reduction (MJ)0%
20%
40%
60%
80%
100%
120%
21%53% 66%
Summary of Reductions Through Redesign
Recap Redesign Conclusions
Conclusion
Comparability:• Costs – New Design is in the same price bracket as original• End-of-Life – Both glass and stainless steel can be recycled
Significant Findings:• Insulated carafe is responsible for the most dramatic
energy savings• Stainless steel would be an easy substitute for the glass
carafe
Recap Redesign Conclusions
Final Conclusions and Changes
1.Insulated Carafe
2.Reusable Stainless Steel Filter
3. 8-Cup Water Capacity
4.Location of the Heating Element
Recap Redesign Conclusions
Works Cited
http://www.buyspares.co.uk/tefal/coffee-makers/896115-vitesse-coffee-maker/catalogue.pl?
shop=tefal&path=290047&model_ref=41271&illustration_ref=27443
http://www.statista.com/statistics/220433/life-expectancy-of-coffee-machines/
http://www.energystar.gov/ia/products/downloads/ENERGY_STAR_Scoping_Report_Coffee_Makers.pdf