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

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Presentation on theme: "Varese, Ville Ponti October 29, 2013 LIFE HEO Mid term conference LIFE PLUS – HEO Summary Mid Term Conference."— Presentation transcript:

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

2 1 HEECS CONFIDENTIAL AGENDA TimeWhoAffiliationTitle 10:30 -- 11:00D. GerolaWhirlpoolHEO Project 11:00 -- 11:30BREAK & NETWORKING 11:30 -- 11:50A. AzapagicManchester UniversityHEO Sustainability 11:50 -- 12:05J.DoyleWhirlpoolHEO Coating Material 12:05 -- 12:20J.DoyleWhirlpool/ LampreHEO Material Application 12:20 -- 12:50M. DanieleWhirlpool/ ScammHEO Manufacturing 12:50 -- 13:05A. NiroPolitecnico MilanoHEO Coating Reflectivity 13:05 -- 13:20J. Capablo / N. GarciaWhirlpoolHEO Energy Consumption 13:20 – 13:30WRAP UP

3 2 HEECS CONFIDENTIAL 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.

4 3 HEECS CONFIDENTIAL 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 4 HEECS CONFIDENTIAL 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 5 HEECS CONFIDENTIAL PROJECT BACKGROUND Steel Enamel Cavity Stainless Steel Sol Gel Coated Cavity 3 Heater set up: Grill Convection Ring Bake New Heater Set Up: 2 Grill 2 Convection Ring 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

7 6 HEECS CONFIDENTIAL PROJECT ACTIONS AND TIMELINE A - Preparatory phaseWhirlpool B - Prototype construction and key functionality testWhirlpool (Scamm) C- LCA/LCC impact Manchester D- Dissemination ActivityWhirlpool E- Management Whirlpool

8 7 HEECS CONFIDENTIAL 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 ACTION A – SUMMARY FOR US PLATFORM

9 8 HEECS CONFIDENTIAL 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 ALT with uncoated baffle Stainless steel coated cavity after accelerated life test (ALT) Details in : HEO Coating Material (Doyle) HEO Material application (Doyle)

10 9 HEECS CONFIDENTIAL 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 10 HEECS CONFIDENTIAL 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 11 HEECS CONFIDENTIAL ACTION A - EUROPEAN OVEN RESULTS Benchmark of HEO versus other WH model and competitors 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 *Efficiency = Energy to brick/ Energy absorbed Energy to brick 0,159 KWh % Difference= (Cons. X – Cons HEO )/ ½ (Cons. X + Cons HEO)

13 12 HEECS CONFIDENTIAL 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 13 HEO COATING MATERIAL The material used to coat the HEO stainless steel cavityand called CC2is a truly nanocoating, both in terms of: 1)Material composition (i.e., nano-particles) 2)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 OVERVIEW

15 14 HEO COATING MATERIAL The CC2 sol-gel material used to coat stainless steel substrates an be applied according to two proprietary manufacturing application processes: 1.Pre-forming application process 2.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 OVERVIEW

16 15 DE1 < DE < 55 < DE < 1010 < DE < 15DE > > 15 No significative visible change Very light visible change Perceivable visible change Very visible change Pre-Coated material deep drawing : design guidelines Formability 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 descriptionDeep draw test description Microscope coating analysis Color variation (DE) analysis after 4 cycles at 450°

17 16 Pre-Coated material deep drawing : design guidelines Cavity formed parts SEM analys A, B, C Sample 500x vision, the little white areas (coating detachment) are not detectables by human eye D Sample Sample presents some yellow spot, this is still acceptable but is the most critical area.


19 18 Goal, scope and system boundaries o 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 o Functional unit: manufacture and use of 1 domestic oven over a lifetime of 19 years o Lifetime: 19 years Data sources o Primary activity data o Whirlpool o LCA data o Ecoinvent (2010) o ELCD and European Steel Association (2011) o LCC data o European Energy Portal (2013) o Hogg (2012)

20 19 Methodology o Life Cycle Assessment (LCA) according to ISO 14044 o Life Cycle Costing (LCC) defined in line with ISO 14044

21 20 Carbon footprint and costs

22 21 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 22 Carbon-Cost intensity Cradle to gate

24 23 Summary of findings o The HEO (Hypotheses 1 and 2) has a lower carbon footprint than the conventional oven by 8% and 16%, respectively o Use of ovens is the main contributor to the carbon footprint (98%) mainly due to electricity o Linear relationship between increasing energy efficiency and carbon footprint reduction, ranging from 8-30% for the same increase in efficiency o The HEO (Hypotheses 1 and 2) has lower life cycle costs than the conventional oven by 6% and 16%, respectively o Use of ovens is the main contributor to the LCC costs (95-97%) o Cradle to grave carbon-cost intensity for the HEO is only 2% lower than the conventional oven o 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 24 Key aspects planned for next phase o Update of LCA and LCC models taking into account new energy consumption values o Sensitivity analysis showing impact of pyrolytic cleaning and chemicals used for manual cleaning

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