Progress 09/01/20 to 04/30/21
Outputs
Target Audience:Our primary target market is an Agricultural industry with an initial focus on small and mid-size farms. Therefore, our target audience is the key personnel of these farms who have purchase decision authority. It is either farm owners or hired managers. On a large scale, we will target Farm and Processing plant owners and managers from various agricultural sectors across the country, Agricultural Cooperatives, and Farm Management Companies. They are all interested in lowering operating costs, improving energy efficiency and sustainability, and keeping their product clean and safe. It is critical to properly introduce our technology to them, show the benefits of accepting renewable thermal technology, and prove it to gain their loyalty and reach the market. References and introductions from the industry insiders and subject matter experts, trial-based engagements, and participation in tradeshows and other industry events will help us to reach over to our target audience and engage them to accept our technology. Another market segment we are planning to target in the near future is the rural area communities, including Amish and Tribal communities. There are a variety of applications for thermal energy systems in rural areas and on the farms: heating dwellings, livestock buildings, and greenhouses, dry crops, cleaning, use hot water in dairy operations, etc. Providing a cost-effective and efficient source of renewable clean energy to this market, we anticipate making a positive impact on the sustainability and profitability of the farms and, therefore, on the economy of the rural areas overall. Changes/Problems:During the SBIR Phase I project, our team encountered the following problems: Technical problems: 1.One of the innovations we implemented in our concentrated solar-thermal system was mirror sandwich technology dedicated to significantly reduce cost, simplify maintenance, and eliminate the need for precise focusing. To manufacture the mirror sandwich units, we engineered and built a state-of-the-art press form that holds the mirror sheet and lower acrylic layer in place while the premixed foam components are poured in between. Then, the press-form closes until the foam fills the area between two layers and form the given shape parabolic mirror sandwich. First-time built, the press-form shown that the surface became uneven near the welding stitches. Even though we applied the layer of filler, the surface did not become perfectly leveled. To eliminate this problem, we changed the design of the press-form and used a different assembling technique. The upgraded press form was used to fabricate the last two mirror sandwiches that came out with the satisfactory quality of the mirror surface. 2.Having a previous relationship with SES Foam-polyurethane foam manufacturer, we applied to them to create a pour-foam customized to our application. Their chemists created a special formula that had to meet our needs. But while testing, it turned out that the final product is very fragile and not rigid enough. SES Foam is willing to improve the formula, but considering the cost of this job, they need to see the upcoming orders from us that we cannot secure right now. In the meantime, we decided to utilize the pour-foam made for structural applications. This worked well, but it is still not the perfect product to be used in a closed environment of the press form. We continue our research in this matter by reaching out to the companies that have experience using the pour-foam with the press forms. 3.At the point when we built our final assembly stand, we saw the opportunity to improve the engineering design and make it even more advanced. So, we immediately made the appropriate changes. Sliding extensions have been added to the assembly stand structure to allow assembled frame to slide out so that the collector can be mounted on the frame while still on the stand. 4. Regardless that the size of the acrylic mirror and clear acrylic sheets declared by the manufacturers is 48"x96", the actual size of these materials was 49"x97". This deviation affected the production of the mirror sandwich units. Additional cutting was required to fit the acrylic into the press form. To solve this issue in the future, we will communicate with the acrylic manufacturers and request to follow the 4'x8' standard or order cut-to-size materials. Other problems: 1.Due to the COVID-19 restrictions, many organizations and government institutions utilized a remote working environment. For the majority of the companies, it was a first-time experience that did not go well. As a result, we have been facing difficulties reaching out to people, a long responding time, and a high no-response rate. Besides, delivery of materials we have ordered from suppliers was significantly delayed. But despite that these circumstances affected our Work Plan and schedule, we completed the project on time. 2.Over the course of the Phase I project, we have seen a significant increase in materials and supplies prices. In particular, the price of steel increased 45.2% from October to December 2020. 3.While it is preferable that all materials and components used for the SBIR projects be made in the US, we faced a situation when not all required components were available on the US market. In particular, it concerned two important parts of our system: Slew Drive and plastic bearings. Both products can be found for sale in the US, but they are all made overseas. All the above-mentioned problems will be taken into consideration and will be addressed during the Phase II project. What opportunities for training and professional development has the project provided?Although this was not a direct opportunity provided by the Phase I project, the following professional development was achieved within the preparation for the future commercialization of our technology that we began to develop during Phase I. To advance in marketing, sales, funding, and commercialization, our Project Manager Olga Marinkina completed Tech Venture Accelerator for Women conducted by Colorado Small Business Development Center (SBDC). It helped us to further identify potential customers, investors, partners, and subject matter experts. Series of interviews with representatives of all of these categories were conducted, and future direct and indirect sales channels and possible market entry challenges were identified. How have the results been disseminated to communities of interest?During Phase I, SunCatch conducted initial interviews with potential customers, investors, partners, and subject matter experts. We introduced our technology, discussed how farms and ranchos could benefit from its adoption and received feedback that helped us better understand the needs, trends, and fears of our potential customers and the agricultural industry overall. The pictures and descriptions of the testing solar module built during the Phase I project, the results of our experiments with phase change materials that could be used to improve the efficiency of the thermal energy storage, and economic justification, including competition comparison to show the economic feasibility was shared and aroused significant interest in the further development of our technology. In particular, two groups of small farm owners regretted that our technology is not fully ready yet to be implemented on their farms. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
During Phase I, we accomplished the following outcomes under the initially stated goals and objectives: 1.Research 1.1 To make our technology more efficient and reliable in providing thermal energy to the consumers, we studied the possibility of utilizing phase change materials (PCM) in the form of salt hydrates as the heat storage medium for thermal energy storage (TES). Our task was to identify the required properties, analyze the suitability of the salt hydrates for TES to increase its efficiency 2-8 times compared to water-based TES, and determine the most appropriate salt hydrates for further research in Phase II. Considering potential applications of our technology, we determined the following criteria for PCM selection: low cost, environmentally friendly, meltingpoint rating 25-80°C, long cycle life, high thermal conductivity, less corrosive, low coefficient of expansion, stable performance, and congruent melting. Therefore, six low-cost, environmentally friendly salt hydrates with a melting point between 30°C and 75°C were researched by our team. The research data obtained showed the possibility of increasing the heat capacity of the TES from 2.5 to 9 times that exceeds the desired parameters. We determined that some salt hydrates cannot be used for our application due to their high expansion rating during the change of state, high corrosiveness, or unstable performance. As a result, two salt hydrates out of six were chosen for further research in a volume of a full-size TES. 1.2We proposed to validate our innovative approach to fabricate reflector out of pre-formed mirror sandwich units made of acrylic mirror, acrylic sheet, and pour foam. The press-form with a given radius was designed and custom-made to fabricate mirror sandwich units. Eight rigid mirror units were successfully made while experimenting with different types of foam and different designs of the press-form. We stepped further and compared the Acrylic mirror and Stainless-Steel polished mirror sheets for the reflector. The collected data showed that the Acrylic mirror is more suitable for our application. We have proved that this mirror sandwich technology can significantly reduce the system's cost, simplify production, installation, and maintenance, and eliminate the need for precise focusing. The installation or replacement of one mirror with an area of 32 sq. ft. takes only 30-60 seconds. 1.3This objective was to find the best combination of the frame parts that will fulfill the tasks, be easy to manufacture, transport, and install, and have the lowest cost in mass production. The frame design was re-engineered to achieve Design for Manufacturability. To simplify and speed up the frame's assembly and set the precise parameters of the focal length used in the system, a Part Assembly and Final Assembly Stands were designed and built. These stands help eliminate any mistakes and allow one-person fast assembly of the frame, including all parts of the collector and reflector's housing. In addition, the optimal center of mass of the horizontal axle of the assembled frame was determined to minimize the load on the slew drive. The rigidity and durability of the frame have been tested and proved to be withstanding severe weather conditions, including heavy snow accumulation, hail, and strong wind gusts. We have the full list of components, including frame parts and the engineering drawings for the frame and other parts of the CST, ready to build a full-scale prototype. 1.4The task was to optimize the design and choice of materials and find the best geometry of the collector body. In addition to fulfilling these tasks, SunCatch developed a simple way to fasten and replace glass in the collector without additional sealing, created the method to join collector pipes of several CST modules, implemented the idea of assembling the collector on assembly stand, and used a sliding fit to attach the collector to the frame that allows for thermal expansion of the collector and easy installation. This concept has been proven to be inexpensive, simple, and fast to connect. 2.Test module 2.1This objective was to select all system components, find the best combination and layout to fully optimize the work of the CST, and have the lowest cost. As an outcome, we made a table of components and other technical documentation that will be used to manufacture, assemble, and install the full-scale prototype. The chosen components will reduce the cost of technology, ease manufacturing and operation, increase efficiency and competitiveness. The engineering design of our technology was conducted in three-dimensional graphics. A 3D in-scale model of the whole system, including press-form and two assembly stands, with all the dimensions, is available in .DXF or .SKP file format and will be used for manufacturing a full-scale prototype. 2.2To make our system scalable, we designed it in 16' long sections to optimize the material use and make it easy to assemble, transport, and connect. We built a functioning testing 16' long module of the CST to prove our concept. Several in-house innovations were implemented and evaluated during the testing. We have proved that our proposed innovations like the pre-formed mirror sandwich units with their fastening system, collectors' joint system, and method of final assembly and installation can significantly lower the system's cost, simplify production, installation, and maintenance, and therefore reduce total cost of ownership for potential customers. 2.3A 16' long module was successfully tested in various modes and conditions. It's been proved to be withstanding severe weather conditions, like heavy snow, hail, and wind gusts up to 85 mph. Analysis of the preliminary data collected showed the following results of performance: 1 sq. ft /mirror surface/ can generate up to 0.112kWh or 382 BTUh, One 16' module (128 sq. ft)-up to 14 kWh/48916 BTUh, and CST system /ten 16'modules (1280 sq. ft)-up to 143 kWh/489165 BTUh. The payback period for our system was calculated to be 2.7 - 5.4 years that is within the expected timeframe. Though it was planned to additionally test this solar module at the Dream Acres Farm, due to COVID-19, the farm was not able to support our effort. Additionally, we developed and tested a trial version of the controller module that calculates sun position, taking current time and geolocation of the CST as input parameters, collects sensor data, monitors for safe operating conditions, and makes independent decisions to adjust system states if critical conditions occur. It will be the main component of the electronic control and safety system of the full-size CST. According to CDC, the virus that causes COVID-19 is sensitive to high temperatures with over 99.99% inactivation at 70°C. Our CST heats water to a boiling point that exceeds this temperature and, therefore, can help fight coronavirus. In summary, the Phase I project resulted in one 16'-long working testing module of the CST with appropriate documentation for further production of the full-scale prototype. The module was tested under different conditions. Based on the data collected, we can state that our technological approach to developing a high-efficiency zero-emission solar-thermal system that can reduce farm operating expenses is technically and economically feasible. Therefore, it is a solid base to create a market-ready product upon final testing of the full-scale prototype when PCM and water-base TES will be added to secure continuous operation. By adopting our zero-emission autonomous technology, various Ag sectors can improve sustainability, take advantage of long-term energy savings, significantly reduce reliance on fossil fuels and the grid while lowering operating costs, maximizing energy efficiency, and cutting the total amount of GHG emissions that is consistent with the goals set by the Federal Government and USDA.
Publications
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