Source: Greenwood Clean Energy, Inc submitted to NRP
EVALUATING SOURCE AND CONTROL METHODS FOR SMALL SCALE HYDRONIC HEATERS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
1007130
Grant No.
2015-33610-24212
Cumulative Award Amt.
$436,324.00
Proposal No.
2015-04344
Multistate No.
(N/A)
Project Start Date
Sep 1, 2015
Project End Date
Aug 31, 2017
Grant Year
2015
Program Code
[8.12]- Small and Mid-Size Farms
Recipient Organization
Greenwood Clean Energy, Inc
13429 SE 30th Street, Suite A
Bellevue,WA 98005
Performing Department
(N/A)
Non Technical Summary
The U.S. Environmental Protection Agency (EPA) has issued a new directive for improving air quality standards for hydronic heater wood smoke emissions. Over a five-year period, the New Source Performance Standards (NSPS) will prohibit the sale of a majority of existing log wood based hydronic heaters that are used for central heating. As large consumers of wood heat, small and midsize farms are adversely affected by these stricter regulations, significantly more expensive appliances, and the diminished number of products available. Bridging from a successful Phase 1 program where the SBIR Technology reduced particulate matter measured in g/hr by 75 percent, the Phase 2 research program will remove the artificial boundaries of the controlled laboratory environment where the technology was exposed to a fraction of the variables seen in a rural, real-world environment. The Phase 2 research will monitor the real-time performance of the SBIR technology in an environment that will expose it to the full spectrum of unknowns - i.e. operating conditions, fuel quality, demand situation(s), and installation - enabling the research team to more fully evaluate the viability, the impact on cost or maintenance of the appliance, and propose improvements to the technology based on its true operating environment. The project aligns with the current and future EPA mandate to reduce wood smoke in rural markets, while preserving the freedom for rural and farm operators to use the readily available log wood fuel source to heat their homes and businesses.
Animal Health Component
10%
Research Effort Categories
Basic
70%
Applied
10%
Developmental
20%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
1330410200050%
1410410200050%
Goals / Objectives
The exploration of the SBIR Technology has progressed to a point where the questions about the impact of real world operating scenarios outweigh the potential improvements that might be explored in a lab setting. Therefore the overall objective of the SBIR Phase II research is to:Determine the feasibility and effectiveness of operating the SBIR Technology in a normal home heating environment that is subject to unpredictable demands while burning a non-uniform fuel and to assess the impact (i.e. maintenance and/or cost) on the operator.Four technical criteria will be evaluated in accomplishing the overall objective of the research.Technical Objective 1Assess the changes in efficiency (and thereby emission) performance between pre- and post- algorithms. (Metric: Gross efficiency gains)Technical Objective 2Identify real world burn profiles that permit tuning the boiler performance to real world scenarios (Metric: Identification - yes or no)Technical Objective 3Assess the real world impact on safety, service and maintenance issues. (Metric: Analyses of support logs)Technical Objective 4Identify opportunities to educate operators to minimize or mitigate performance or operational issues (Metric: Identification - yes or no)
Project Methods
The Phase 2 project's focus is to determine the feasibility and effectiveness of operating the SBIR Technology in a normal home heating environment that is subject to unpredictable demands while burning a non-uniform fuel and to assess the impact (i.e. maintenance and/or cost) on the operator. Therefore, the SBIR Technology must be evaluated in a broader range of 'real-world' operating scenarios.As summary of the workplan, the SBIR Technology developed in Phase 1 will be coded into software and loaded onto the existing Frontier microprocessor control board. This will enable autonomous, repeatable operation of the boiler. This will be followed by benchtesting the algorithmns and software. To enable acquisition of the rich burn cycle data continuously collected by each field test unit, in parallel, Frontier test units will be equipped with internet connectivity for real time remote performance monitoring and collection of burn cycle data. A data base will be established as a centralized data repository for all field test burn data, that will enable import, export, and data scrubbing and analysis.Before beginning field testing, operator profiles representing the spectrum of the most common demand, fuel, installation, and operator scenarios will be specified. With these guidelines, 10-15 field test participants will be selected and retrofitted with the necessary equipment upgrades. This will conincide with training of participants on the requisite data collection processes and procedures. Technical and program support will be available for program participants.The field test will be divided into two test periods of alternating control approaches. The first test period will test field performance of the existing algorithm (pre-SBIR technology). The second test period will test performance of the SBIR technology algorithm. These periods will be altered so that data may be collected that provides distinction between pre and post SBIT-Technology application. User logs will be maintained and data will be collected in real-time from participating boilers.Daily monitoring by GCE of each field test program installation through the central data base will ensure that the automated collection of all performance data, boiler states, and interrupts is working as specified.With each reload, field test operators will record per piece fuel charge weight, format, species, and moisture content. This data will be collected weekly and combined with the automatically collected burn cycle data to calculate per fuel charge efficiencies, analyze combustion phase performance of each burn cycle, and identify the discrete phase impact on overall performance.Field test operators will also document the cleaning of the Frontier heat exchanger at the end of each field test period. Documentation will include photographing the undisturbed heat exchanger and collecting samples of residue. This documentation will provide additional insight into completeness of combustion on a gross level.Explanations for significant performance variances and opportunities for further combustion improvements derived from analysis of the field test data set will be verified and confirmed through combustion testing in the lab simulating the field findings.

Progress 09/01/15 to 08/31/16

Outputs
Target Audience:During this reporting period, the company continued to educate consumers, installation technicians and other key influencers on the merits of proper wood burning and advanced small-scale biomass combustion appliances/platforms. Specifically, the following audiences were reached by the company during this period. A regional technical training program was implemented that would educate installation technicians on the installation and maintenance of the appliance. Periodic webinars were conducted with prospective consumer customers to inform, educate and gain feedback on the commercial viability of the appliance. Several events, including the annual Bioenergy Day, were used to bring a broad group of stakeholders, including legislators, regulators, installers, and consumers to educate and inform about the merits of the technology and the appliance category. Representative customers from the rural, small town and farm communities were contacted and screened for participation in the research program. Changes/Problems:There were two situations that have impacted the project -- a contractual delay and unforseen programming complexity. These required higher participation from the principal investigators earlier in the project. The overall project budget and timeline remain unaffected, however the allocation/distribution of resources has been adjusted slightly to address these circumstances. What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest?As noted in another section, the company has been able to showcase the SBIR Technology through live demonstrations (either in the lab or in a demonstration trailer) to rural consumers, installation technicians and local and international politicians. Some of these efforts have included: A regional technical training program was implemented that would educate installation technicians on the installation and maintenance of the appliance. Periodic webinars were conducted with prospective consumer customers to inform, educate and gain feedback on the commercial viability of the appliance with homeowners and farmer operators. Several events, including the annual Bioenergy Day, were used to bring a broad group of stakeholders, including legislators, regulators, installers, and rural consumers to educate and inform about the merits of the technology and the appliance category. What do you plan to do during the next reporting period to accomplish the goals?The company will continue with the workplan presented in the application. These steps include field test monitoring and data collection, comparative algorithm testing, data and user log analyses, and laboratory verification testing as required.

Impacts
What was accomplished under these goals? This project continues the work that began in the Phase 1 program where the SBIR Technology reduced particulate matter by 75 percent through manual operation. The Phase 2 research program was to automate these lab controls and incorporate them in appliances outside of a laboratory setting, exposing them to a broad spectrum of unknown conditions and variables -- i.e. operating conditions, fuel quality, demand situation(s), and installation. This was to enable the research team to more fully evaluate the technical viability, the impact on cost and maintenance of the appliance, and propose improvements to the technology based on its true operating environment. The following are the major accomplishments to date: Objective 1 - Gross Efficiency Gains: The SBIR Technology algorithm was programmed, bench-tested and operated autonomously in the Greenwood Development and Innovation Center laboratory. The technology met all Phase 1 performance thresholds under the laboratory controlled conditions. This algorithm has been deployed to a variety of field test sites where the appliances are being remotely monitored as the heating season begins. Objective 2 - Real World Burn Profiles: While in the laboratory, fuel quality (e.g. fuel moisture) and fuel size (e.g. crib, small split, large log rounds) were examined in an attempt identify characteristic burn profiles. Conditions were identified which enabled the identification and coding of variables/states which enabled further tuning of the SBIR Technology. Objective 3 - Real World Support. Nothing to report. Objective 4 - Educational Support. Initial findings indicate there is an opportunity to use gross boiler conditions, fuel quality/type and environmental conditions to educate the consumer operator on how to best manage the boiler to optimize performance. These will be further documented as field trials continue.

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