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Varese, Ville Ponti October 29, 2013

LIFE HEO Mid term conference. Varese, Ville Ponti October 29, 2013. LIFE PLUS – HEO Summary Mid Term Conference. AGENDA. HIGHLY EFFICIENT OVENS PROJECT.

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Varese, Ville Ponti October 29, 2013

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  1. LIFE HEO Mid termconference Varese, Ville Ponti October 29, 2013 LIFE PLUS – HEO Summary Mid Term Conference

  2. AGENDA

  3. HIGHLY EFFICIENT OVENS PROJECT HEO project aims to contribute to the main European environment policies, by addressing the issues of energy-efficiency, over-dependence from fossil fuels, and GHG emissions, chemicals, and waste. http://www.highefficientoven.eu/

  4. HEO PROJECT SCOPE • To demonstrate production feasibility of a domestic electric ovens with a stainless steel sol-gel coated cavity that: • Reduces in-use energy consumption of 30% • Achieves up to 50% in energy savings in the production process, if compared to state-of the art ovens. • Eliminates enamel from production process

  5. HEO PROJECT • LIFE + 11 ENV/IT/103 • TOTAL Budget: 1709 kEuro • Total EC funds : 854 Keuro • Partner: Manchester University • Start : June 2012 • End : Nov 2014 • Duration: 30 months

  6. PROJECT BACKGROUND • Core of the project is the substitution of a steel enamel cavity with a stainless steel cavity (with increased reflectivity) • To avoid stainless steel deterioration with time, a specially developed sol-gel coating is applied on the material • Due to change in cavity wall reflectivity typical oven heating system will also be upgraded. New heater set give also an additional energy consumption advantage (applicable also to enamel oven). Details of this study is covered by confidentiality • Data here presented are obtained with a similar heater set up for an equal foot comparison Steel Enamel Cavity Stainless Steel Sol Gel Coated Cavity 3 Heater set up: GrillConvection RingBake New Heater Set Up: 2 Grill 2 Convection Ring

  7. PROJECT ACTIONS AND TIMELINE A - Preparatory phase Whirlpool B - Prototype construction and key functionality test Whirlpool (Scamm) C- LCA/LCC impact Manchester D- Dissemination Activity Whirlpool E- Management Whirlpool

  8. ACTION A – SUMMARY FOR US PLATFORM • Preparatory phase has been done on a US platform • Data were gathered on teflon block matrix to evaluate energy saving (a procedure internally used to evaluated energy consumption) • It is representative of cooking process on large sheet • Measured an average increase of efficiency of 27% 150 °C 180 °C

  9. ACTION A - STAINLESS STEEL COATING • Coating selection and deposition on selected stainless steel has been investigated • Saving from elimination of enameling process has been evaluated and also considered in the LCA analysis Stainless steel coated cavity after accelerated life test (ALT) Stainless steel coated cavity after ALT with uncoated baffle • Details in : • HEO Coating Material (Doyle) • HEO Material application (Doyle)

  10. ACTION A - EUROPEAN OVEN • New regulation (to be voted before end Nov). • Mandatory 1st Jan 2015 • Provision for voluntary use from Jan 14 • A significant change compare to today directive 2002/40/EC) • Introduction of energy Class above A (today the maximum)

  11. ACTION A - EUROPEAN OVEN • Action A has been extended to analyze technology potential on an European product application by • modifying the emissivity of enamel cavities (with Aluminum foils) • creating an early stainless steel prototype • Details in: • Coating reflectivity (Niro) • HEO Energy Consumption (Capablo/Garcia)

  12. ACTION A - EUROPEAN OVEN RESULTS • Benchmark of HEO versus other WH model and competitors *Efficiency  = Energy to brick/ Energy absorbed Energy to brick 0,159 KWh % Difference= (Cons. X – Cons HEO )/ ½ (Cons. X + Cons HEO) • HEO • Increase in efficiency ranging from 10% to 50% depending on model (also with the more demanding test with the wet brick) • Meet A+ oven classification

  13. ACTION B - PRODUCT CONFIGURATION AND TOOLS • Product Design Configurations is Frozen • Dual broil (quartz lamp or tubular) • Dual fan convection • 70 liter cavity volume • Ready to launch tooling for prototypes

  14. HEO COATING MATERIAL OVERVIEW • The material used to coat the HEO stainless steel cavity—and called CC2—is a truly nanocoating, both in terms of: • Material composition (i.e., nano-particles) • Coating dimensions (i.e., nano-layers) • The coating material is based on a proprietary sol-gel inorganic chemistry (mainly SiO2) • The coating is constituted of two transparent nanometric layers applied over a stainless steel substrate, maintaining high IR reflectivity • The coating is applied through a proprietary roll-on application • Short curing times and low curing temperatures are required • The coating presents outstanding properties in terms of: • High-temperature oxidation resistance • Mechanical and Chemical attack resistance • Formability • Durability and food-contact compatibility

  15. HEO COATING MATERIAL OVERVIEW • The CC2 sol-gel material used to coat stainless steel substrates an be applied according to two proprietary manufacturing application processes: • Pre-forming application process • Post-forming application process • For the HEO project, CC2 is applied according to a pre-forming roll-on application process • Short curing times and low curing temperatures are possible • Significant energy saving compared to enameling application process is achieved

  16. Pre-Coated material deep drawing : design guidelinesFormability assessment on bended and stamped samples To verify the behavior of the coating during bending and molding of the parts we analyzed the phenomenon in the electron microscope (SEM), determining a relationship between the portion of the coating that is damaged during these operations and the color change (Delta E, or yellowing) resulting from lack of protection after the high temperature cycles. Bending test description Deep draw test description DE 1 < DE < 5 5 < DE < 10 10 < DE < 15 DE > > 15 Color variation (DE) analysis after 4 cycles at 450° Microscope coating analysis Very visible change No significative visible change Very light visible change Perceivable visible change

  17. Pre-Coated material deep drawing : design guidelines Cavity formed parts SEM analys   D Sample  A, B, C Sample  500x vision, the little white areas (coating detachment) are not detectables by human eye Sample presents some yellow spot, this is still acceptable but is the most critical area.

  18. LIFE HEO Mid term conference Varese, Ville Ponti October 29, 2013 COMPARATIVE LIFE CYCLE ENVIRONMENTAL AND ECONOMIC IMPACTS OF CONVENTIONAL AND HIGHLY EFFICIENT OVENS (HEO) David Amienyo and Adisa Azapagic

  19. Goal, scope and system boundaries • Main goal to estimate the life cycle environmental impacts and costs of conventional and highly efficient ovens from ‘cradle to grave’ with particular focus on the oven cavity • Functional unit: manufacture and use of 1 domestic oven over a lifetime of 19 years • Lifetime: 19 years • Data sources • Primary activity data • Whirlpool • LCA data • Ecoinvent (2010) • ELCD and European Steel Association (2011) • LCC data • European Energy Portal (2013) • Hogg (2012)

  20. Methodology • Life Cycle Assessment (LCA) according to ISO 14044 • Life Cycle Costing (LCC) defined in line with ISO 14044

  21. Carbon footprint and costs

  22. Other environmental impacts • AP acidification potential, EP eutrophication potential, ODP ozone depletion potential, POCP photochemical ozone creation potential, HTP human toxicity potential, ADP abiotic depletion potential

  23. Carbon-Cost intensityCradle to gate

  24. Summary of findings • The HEO (Hypotheses 1 and 2) has a lower carbon footprint than the conventional oven by 8% and 16%, respectively • Use of ovens is the main contributor to the carbon footprint (98%) mainly due to electricity • Linear relationship between increasing energy efficiency and carbon footprint reduction, ranging from 8-30% for the same increase in efficiency • The HEO (Hypotheses 1 and 2) has lower life cycle costs than the conventional oven by 6% and 16%, respectively • Use of ovens is the main contributor to the LCC costs (95-97%) • ‘Cradle to grave’ carbon-cost intensity for the HEO is only 2% lower than the conventional oven • However, the difference between the two models is 43% from ‘cradle to gate, despite 57% higher manufacturing costs for the HEO relative to the conventional oven

  25. Key aspects planned for next phase • Update of LCA and LCC models taking into account new energy consumption values • Sensitivity analysis showing impact of pyrolytic cleaning and chemicals used for manual cleaning

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