Final ReportSummary - ECOWATERHEATER (Development of an energy efficient domestic electric storage water heater with a >40% reduced standing heat loss, priced competitively.)
ECOWATERHEATER is a Seventh Framework Programme (FP7) 'Research for small and medium-sized enterprises (SMEs)' project. The official start date of the project was 1 November 2009. The ECOWATERHEATER project had a duration of 24 months. The beneficiaries in the project are as follows:
- OSO AS (SME)
- Siegert GmbH (SME)
- Hydrus LTD (SME)
- Theohalko Solar Energy LTD (SME)
- Thermia Värme AS (other)
- Ahlsell Norge as (other)
- Teknologisk Institutt as (RTD)
- CNE Technology Ltd. (RTD)
- Fraunhofer Gesellschaft IFAM (RTD)
- The Uk Health & Environment Research Institute (RTD)
The projects main objective has been to develop an energy efficient domestic electrical storage water heater (DESWH) with a significantly reduced standing heat loss, to meet the energy label requirements best possible rating, in the suggested mandatory European Union (EU) EcoDesign scheme, and in addition develop a product which is competitive in relation to market price.
During the project the scientific understanding, which functioned as the criteria for the development, was established. Development work to find the optimal bonding of the inner tanks, development and design of the inner tank, development of insulation options and development of operational control were done. The results can be found in the sections below. Dissemination activities and demonstrations of the final prototype have been conducted as part of the project.
Project context and objectives:
The SME participants in this project set out to develop an energy efficient DESWH by improving insulation and production process and by adding an intelligent control system. The aim was that:
- the improved insulation combined with a temperature control system will reduce standing heat loss with more than 40 % for each tank size;
- the weldless tank production will reduce production costs as regards reducing material thickness and grade needed;
- the thinner-walled stainless steel tank will ease transportation (saving energy) and reduce material costs;
- the weldless tank production will eliminate corrosion problems related to weld seams / heat affected zones (HAZ) and increase lifetime, which reduces life cycle costs (selling point)
The scientific objectives of the project were as follows:
- Identify specific requirements and constraints set for the DESWH; identify market needs and customer preferences.
- For both deep drawing and for adhesives, make a profound literature study and a feasibility study (for the adhesive on long term properties in humid- and high temperature environments). Identify material requirements and possible technological constraints.
- Evaluate temperature sensing elements.
- Make a profound literature study on aerogel and other highly efficient insulation materials, feasibility study, case studies from comparable applications and studies on energy savings based on water storage temperatures. Identify material requirements and possible technological constraints.
The technological objectives of the project were as follows:
- Find the optimal insulation solution (material(s), form, thickness) to achieve a heat loss reduction of more than 40 % for each tank size (30 - 100l) to an increased insulation cost of maximum 500 %, e.g. maximum EUR 50 compared to current EUR 10. This includes use of an aerogel type insulation and improving insulation design around fittings etc.
- Develop a user-friendly control system with 25 years life time that can utiliSe a two-tariff system by heating water in off-peak periods for the power grid, that monitors temperature and at regular intervals heats the water to above to above critical level for bacteria growth (60 degrees Celcius to 70 degrees Celsius, depending on duration), that prevents dry heating, and adds production costs of maximum EUR 9.
- Find the ultimate material quality for drawing and drawing process by finite element method (FEM)-analysis, reducing material thickness to 0.8 mm average (current thickness is 1.4 mm). Define the overall design (with respect to deep drawing limitations, connection points and bonding surface area). Find an industrial applicable adhesive with a bonding strength significantly high (tank design dependent) to withstand a design pressure of 10 bar and test pressure of 15 bar that provides water sealing throughout the life span of the tank. The production costs for the inner tank shall be reduced with EUR 23 (30 %) for the 100 litres storage tank compared to current design model from OSO made with welding. This will compensate for 47 % of the increase in production cost of EUR 49 which improved insulation and control system will lead to.
Project results:
Scientific understanding
In the beginning of the project, studies were made to identify specific requirements and constraints for the development and production of the ECOWATERHEATER. These studies included considerations of relevant legislations, standards, approvals, operational conditions and consumer preferences. In addition, pre-studies were made, related to the development and production of the inner tank (extreme deep drawing), the smart control system and insulation solutions. These findings were used to get a more profound scientific understanding of the design criteria and to identify the most feasible approach to solve the technical objectives of the project.
The main results from WP1 can be found in the following reports:
D1.1: Report with detailed overview of minimum requirement specifications, and legislative and technological constraints for the DESWH and its materials (confidential)
D1.2: Report on feasible approach to solve the scientific and technological (S&T) objectives of the project and results of pre-studies (confidential)
Technological development
Studies, development work and tests concerning adhesive bonding of the inner tank parts were completed, and the best suitable adhesives were identified. However, pressure tests at OSO showed that none of the proposed bonding solutions were strong enough to be used for their hot water inner tank. IFAM has suggested some possibilities for further alterative adhesive recipes to be tested, but due to lack of time and resources, this work would have to be done later outside this project. The alternative technical solution for the inner tank was to continue welding together domes and cylinder, and to focus on the huge improvement gained by extreme deep drawn domes.
The development and design of the inner tank was completed. Considerable efforts were spent on extreme deep drawing, which led to a design of the inner tank which simplified its construction and reduced the production costs. The inner tank prototype is complete.
Reports:
D2.1: Design documents and assembly specifications for the inner tank, including material specifications and production documents for inner tank, and adhesive recipe and data sheet (confidential)
D2.2: Test reports (restricted)
D2.3: Physical prototype of inner tank (PP)
The development of an electronic smart control has been completed, and a fully functional prototype has been produced. Calculations concerning its impact on the heat loss have been made, which show an expected improvement of 7 - 12 %.
Reports:
D3.1: Design documents, assembly specifications, bill of materials (BOM) resulting in physical prototype (confidential)
D3.2: Physical prototype of control system (PP)
The studies and tests concerning advanced insulation solutions were completed. The study identified the most suitable, economic solution for the insulation material and design: the use of PUR square shaped foam which doubles the insulation volume and also keeps the heater overall size within acceptable dimensions. Calculations predict a heat loss improvement of about 40 %. Oso has produced a (functional) prototype with the new shape, which has been tested. The results have been analysed and confirmed a heat loss improvement of approximately 40 % is possible.
Reports:
D4.1: Design documents and assembly specifications for the DESWH. Including material specifications and production documents for improved advanced insulation material (confidential)
D4.2: Test reports (restricted)
D4.3: Physical prototypes and standard components (PP).
TI has designed all components for a 100 litre water heater in detail (three-dimensional (3D), using Solid Works) and produced prototypes of all components. The components were assembled and integrated to a visual prototype, which represents the final design and construction of the product. The other water heater sizes (35, 50, 80 litres) , which are about 95 % constructively identical to the biggest version, have been produced visually by the use of Photoshop.
Reports:
D5.1: Physical prototype DESWH for further verification and demonstrations (PP)
D5.2: Test reports documenting prototype performance (restricted)
D5.3: Preparations for CE certificate (public)
Patent searches were carried out. There was not found any patents which could stop the ECOWATERHEATER technology; on the other hand it was not considered necessary or possible to apply for any patent. But a design application for the ECOWATERHEATER product has been submitted.
Potential impact:
The expected exploitation results of the project were:
- a DESWH with improved insulation properties which lead to a significant reduced heat loss (about 40 %) - achieved during testing;
- a smart control system giving an additional reduction of heat loss (about 7 - 12 %) - achieved;
- reduced production costs for the inner tank by using improved production methods (extreme deep drawing), which also lead to improved technical quality and better construction logistics - achieved.
Impact:
The new ECOWATERHEATER technology will lead to a new product range for OSO which will contribute to the reduction of the energy consumption within the European Union (EU). OSO will strengthen their position as a leading DESWH manufacturer. The SMEs Siegert GmbH, Hydrus LTD and Theohalko Solar Energy LTD, have gained considerable new technological insight and an opportunity for commercial advantages. Siegert GmbH is the preferred supplier for the control system.
Dissemination activities:
The ECOWATERHEATER project has a home web page which has been updated continuously throughout the project to share non-sensitive project results and related activities (see http://www.ecoheaterproject.com online).
From 20 to 22 October 2010, the ECOWATERHEATER project was presented at the Scandinavian HVAC (heating, ventilation and air conditioning) exhibition in Oslo with a poster explaining the advantages of this new domestic electric storage water heater. The poster was located on the stand of Oso. The exhibition was visited by over 9000 people.
A presentation of OSO and the ECOWATERHEATER project was held at a Norwegian conference for the manufacturing industry on 23 and 24 November 2010, at Sundvolden Hotel, Norway. The conference was organised by User-driven Research based Innovation (BIA) which is a part of the Research Council of Norway. OSO was represented by TI/ Frode Paulsen.
During the second period of the project, interviews have been made with the marketing department from Ahlsell and Thermia, both project partners, and OSO Hotwater UK Ltd, regarding the marketing plan and strategy for the ECOWATERHEATER.
Ahlsell is planning to demonstrate the ECOWATERHEATER prototype to a number of their clients in Norway and Sweden. The company is planning to give the ECOWATERHEATER products priority in the future regarding warehousing, availability, and quick delivery. They will also develop a special customized connection kit (water) for the product. Advertisement campaigns are planned as well.
The prototype has already been used for a number of demonstration activities: Oso demonstrated the ECOWATERHEATER prototype during a 'Road Show' in Norway, October 2011, where OSOs sales and product development representatives had meetings with many plumber companies and a number of specially invited persons, at 17 different cities in Norway.
The meetings were used to demonstrate the new product and to get feed backs from these user groups. The feed backs from plumbers are very positive:
- the ECOWATERHEATER concept appears to offer a considerably improved insulation (maybe the best on the market- selling point);
- the smart control and the new design are regarded to be very valuable selling points for the ECOWATERHEATER products.
Oso is planning similar activities in the United Kingdom (UK).
The project has a public web page:
http://www.ecoheaterproject.com
For further information, please contact the coordinator of the project:
Mr David Zijdemans
OSO AS
Phone: +47-322-56500
E-mail: david.zijdemans@osohotwater.com
- OSO AS (SME)
- Siegert GmbH (SME)
- Hydrus LTD (SME)
- Theohalko Solar Energy LTD (SME)
- Thermia Värme AS (other)
- Ahlsell Norge as (other)
- Teknologisk Institutt as (RTD)
- CNE Technology Ltd. (RTD)
- Fraunhofer Gesellschaft IFAM (RTD)
- The Uk Health & Environment Research Institute (RTD)
The projects main objective has been to develop an energy efficient domestic electrical storage water heater (DESWH) with a significantly reduced standing heat loss, to meet the energy label requirements best possible rating, in the suggested mandatory European Union (EU) EcoDesign scheme, and in addition develop a product which is competitive in relation to market price.
During the project the scientific understanding, which functioned as the criteria for the development, was established. Development work to find the optimal bonding of the inner tanks, development and design of the inner tank, development of insulation options and development of operational control were done. The results can be found in the sections below. Dissemination activities and demonstrations of the final prototype have been conducted as part of the project.
Project context and objectives:
The SME participants in this project set out to develop an energy efficient DESWH by improving insulation and production process and by adding an intelligent control system. The aim was that:
- the improved insulation combined with a temperature control system will reduce standing heat loss with more than 40 % for each tank size;
- the weldless tank production will reduce production costs as regards reducing material thickness and grade needed;
- the thinner-walled stainless steel tank will ease transportation (saving energy) and reduce material costs;
- the weldless tank production will eliminate corrosion problems related to weld seams / heat affected zones (HAZ) and increase lifetime, which reduces life cycle costs (selling point)
The scientific objectives of the project were as follows:
- Identify specific requirements and constraints set for the DESWH; identify market needs and customer preferences.
- For both deep drawing and for adhesives, make a profound literature study and a feasibility study (for the adhesive on long term properties in humid- and high temperature environments). Identify material requirements and possible technological constraints.
- Evaluate temperature sensing elements.
- Make a profound literature study on aerogel and other highly efficient insulation materials, feasibility study, case studies from comparable applications and studies on energy savings based on water storage temperatures. Identify material requirements and possible technological constraints.
The technological objectives of the project were as follows:
- Find the optimal insulation solution (material(s), form, thickness) to achieve a heat loss reduction of more than 40 % for each tank size (30 - 100l) to an increased insulation cost of maximum 500 %, e.g. maximum EUR 50 compared to current EUR 10. This includes use of an aerogel type insulation and improving insulation design around fittings etc.
- Develop a user-friendly control system with 25 years life time that can utiliSe a two-tariff system by heating water in off-peak periods for the power grid, that monitors temperature and at regular intervals heats the water to above to above critical level for bacteria growth (60 degrees Celcius to 70 degrees Celsius, depending on duration), that prevents dry heating, and adds production costs of maximum EUR 9.
- Find the ultimate material quality for drawing and drawing process by finite element method (FEM)-analysis, reducing material thickness to 0.8 mm average (current thickness is 1.4 mm). Define the overall design (with respect to deep drawing limitations, connection points and bonding surface area). Find an industrial applicable adhesive with a bonding strength significantly high (tank design dependent) to withstand a design pressure of 10 bar and test pressure of 15 bar that provides water sealing throughout the life span of the tank. The production costs for the inner tank shall be reduced with EUR 23 (30 %) for the 100 litres storage tank compared to current design model from OSO made with welding. This will compensate for 47 % of the increase in production cost of EUR 49 which improved insulation and control system will lead to.
Project results:
Scientific understanding
In the beginning of the project, studies were made to identify specific requirements and constraints for the development and production of the ECOWATERHEATER. These studies included considerations of relevant legislations, standards, approvals, operational conditions and consumer preferences. In addition, pre-studies were made, related to the development and production of the inner tank (extreme deep drawing), the smart control system and insulation solutions. These findings were used to get a more profound scientific understanding of the design criteria and to identify the most feasible approach to solve the technical objectives of the project.
The main results from WP1 can be found in the following reports:
D1.1: Report with detailed overview of minimum requirement specifications, and legislative and technological constraints for the DESWH and its materials (confidential)
D1.2: Report on feasible approach to solve the scientific and technological (S&T) objectives of the project and results of pre-studies (confidential)
Technological development
Studies, development work and tests concerning adhesive bonding of the inner tank parts were completed, and the best suitable adhesives were identified. However, pressure tests at OSO showed that none of the proposed bonding solutions were strong enough to be used for their hot water inner tank. IFAM has suggested some possibilities for further alterative adhesive recipes to be tested, but due to lack of time and resources, this work would have to be done later outside this project. The alternative technical solution for the inner tank was to continue welding together domes and cylinder, and to focus on the huge improvement gained by extreme deep drawn domes.
The development and design of the inner tank was completed. Considerable efforts were spent on extreme deep drawing, which led to a design of the inner tank which simplified its construction and reduced the production costs. The inner tank prototype is complete.
Reports:
D2.1: Design documents and assembly specifications for the inner tank, including material specifications and production documents for inner tank, and adhesive recipe and data sheet (confidential)
D2.2: Test reports (restricted)
D2.3: Physical prototype of inner tank (PP)
The development of an electronic smart control has been completed, and a fully functional prototype has been produced. Calculations concerning its impact on the heat loss have been made, which show an expected improvement of 7 - 12 %.
Reports:
D3.1: Design documents, assembly specifications, bill of materials (BOM) resulting in physical prototype (confidential)
D3.2: Physical prototype of control system (PP)
The studies and tests concerning advanced insulation solutions were completed. The study identified the most suitable, economic solution for the insulation material and design: the use of PUR square shaped foam which doubles the insulation volume and also keeps the heater overall size within acceptable dimensions. Calculations predict a heat loss improvement of about 40 %. Oso has produced a (functional) prototype with the new shape, which has been tested. The results have been analysed and confirmed a heat loss improvement of approximately 40 % is possible.
Reports:
D4.1: Design documents and assembly specifications for the DESWH. Including material specifications and production documents for improved advanced insulation material (confidential)
D4.2: Test reports (restricted)
D4.3: Physical prototypes and standard components (PP).
TI has designed all components for a 100 litre water heater in detail (three-dimensional (3D), using Solid Works) and produced prototypes of all components. The components were assembled and integrated to a visual prototype, which represents the final design and construction of the product. The other water heater sizes (35, 50, 80 litres) , which are about 95 % constructively identical to the biggest version, have been produced visually by the use of Photoshop.
Reports:
D5.1: Physical prototype DESWH for further verification and demonstrations (PP)
D5.2: Test reports documenting prototype performance (restricted)
D5.3: Preparations for CE certificate (public)
Patent searches were carried out. There was not found any patents which could stop the ECOWATERHEATER technology; on the other hand it was not considered necessary or possible to apply for any patent. But a design application for the ECOWATERHEATER product has been submitted.
Potential impact:
The expected exploitation results of the project were:
- a DESWH with improved insulation properties which lead to a significant reduced heat loss (about 40 %) - achieved during testing;
- a smart control system giving an additional reduction of heat loss (about 7 - 12 %) - achieved;
- reduced production costs for the inner tank by using improved production methods (extreme deep drawing), which also lead to improved technical quality and better construction logistics - achieved.
Impact:
The new ECOWATERHEATER technology will lead to a new product range for OSO which will contribute to the reduction of the energy consumption within the European Union (EU). OSO will strengthen their position as a leading DESWH manufacturer. The SMEs Siegert GmbH, Hydrus LTD and Theohalko Solar Energy LTD, have gained considerable new technological insight and an opportunity for commercial advantages. Siegert GmbH is the preferred supplier for the control system.
Dissemination activities:
The ECOWATERHEATER project has a home web page which has been updated continuously throughout the project to share non-sensitive project results and related activities (see http://www.ecoheaterproject.com online).
From 20 to 22 October 2010, the ECOWATERHEATER project was presented at the Scandinavian HVAC (heating, ventilation and air conditioning) exhibition in Oslo with a poster explaining the advantages of this new domestic electric storage water heater. The poster was located on the stand of Oso. The exhibition was visited by over 9000 people.
A presentation of OSO and the ECOWATERHEATER project was held at a Norwegian conference for the manufacturing industry on 23 and 24 November 2010, at Sundvolden Hotel, Norway. The conference was organised by User-driven Research based Innovation (BIA) which is a part of the Research Council of Norway. OSO was represented by TI/ Frode Paulsen.
During the second period of the project, interviews have been made with the marketing department from Ahlsell and Thermia, both project partners, and OSO Hotwater UK Ltd, regarding the marketing plan and strategy for the ECOWATERHEATER.
Ahlsell is planning to demonstrate the ECOWATERHEATER prototype to a number of their clients in Norway and Sweden. The company is planning to give the ECOWATERHEATER products priority in the future regarding warehousing, availability, and quick delivery. They will also develop a special customized connection kit (water) for the product. Advertisement campaigns are planned as well.
The prototype has already been used for a number of demonstration activities: Oso demonstrated the ECOWATERHEATER prototype during a 'Road Show' in Norway, October 2011, where OSOs sales and product development representatives had meetings with many plumber companies and a number of specially invited persons, at 17 different cities in Norway.
The meetings were used to demonstrate the new product and to get feed backs from these user groups. The feed backs from plumbers are very positive:
- the ECOWATERHEATER concept appears to offer a considerably improved insulation (maybe the best on the market- selling point);
- the smart control and the new design are regarded to be very valuable selling points for the ECOWATERHEATER products.
Oso is planning similar activities in the United Kingdom (UK).
The project has a public web page:
http://www.ecoheaterproject.com
For further information, please contact the coordinator of the project:
Mr David Zijdemans
OSO AS
Phone: +47-322-56500
E-mail: david.zijdemans@osohotwater.com