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Systems Design for Fuel-Efficient Stoves

ETHOS 2014 Kirkland, WA

25 January 2014Michael Helms

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Let’s Have a Conversation

• The world of fuel-efficient stoves has evolved.• Big changes in the last few years include:– Greater public awareness for all types of stoves.– New stove organizations have been created.– Lots of money has been raised and spent.– Stove technology has greatly improved.– The power and influence of stoves is recognized.– Even the UN is aware! (UN-GACC, UNHCR, WFP, ?)

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Are we making progress?• Stoves are better, but IMHO not good enough…• Are we asking the right questions?• Are stoves *really* improving?• What is the goal? What are the goals?• What are the priorities? Whose are they?• Why does it matter? What are the outcomes?• Are “less than perfect” solutions better than the

status quo? Is the stove world converging?• Most stove work appears focused on stoves… not

the complete system (holistic): stove & context.

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Systems Engineering and Systems Design

• Systems Engineering – “…an interdisciplinary field of engineering that focuses on how to design and manage complex engineering projects over their life cycles. “ (Wikipedia)

• Systems Design – “…process of defining the architecture, components, modules, interfaces, and data for a system to satisfy specified requirements. Systems design could be seen as the application of systems theory to product development. “ (Wikipedia)

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What is my viewpoint and why do I care?

• Many years of stove & cooking experience.• Mechanical engineer (BS, MS, Ph.D.)• Expert in design, manufacture & problem solving.• Worked in Darfur on a FE stove project (2007).• Wrote paper for ETHOS 2012 on lessons learned –

available online or send me email for Rev. 1.• Working on the urgent need for 500,000+ stoves

for IDPs in Darfur… and more elsewhere.• Desire to do “good”, and do “well” - in parallel.

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Systems Design and Stoves

• Stoves are a component of the local energy systems – personal, household, village, etc.

• Stoves are important elements of the energy systems … and are profoundly interconnected with the user and her/his environment.

• Stoves appear to be simple (hah!). Many believe that implementation of improved stove solutions is a simple task – just add $$.

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Why is Systems Design Important?

• I assert that the stove design is very difficult.• Every situation is different.• Stove requirements differ everywhere.• A stove must function within its environment,

with its users, and must be an improvement over existing stoves so users will adopt them.

• The opportunity exists for many unforeseen consequences. Recognizing them is essential.

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Stove Systems Design Variables

• The stove itself (hundreds of variables…)• Fuel (biomass, hydrocarbons, vapor, etc.)• Users (geography, culture, language,

education, age, gender, skills, knowledge)• Type of cooking (frying, boiling, grilling, etc.)• Stove embodiment (stationary, portable, ?)• Economics: Short term & Long term.• Environmental & Political concerns.

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Some Stove Solution Goals• Fuel-efficiency, which lowers cost• Simple to use, no training needed, safety• Environment - air quality, carbon credits, biochar• Time savings – cook faster, save on fuel collection• Sustainability – stove life cycle, low impact stove

creation/use, system is kind to environment• Create jobs, create wealth, improve quality of life• Robust usefulness – able to work well in all local

conditions (weather, fuels, cooking tools, foods, flexibility, seasons, locations, cooking use, etc.)

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Are current metrics appropriate?

• How are stoves rated? How should they be rated?• Tons of carbon saved? Reverse deforestation?• Money saved by users? Impact on economy?• Wood (or other fuel) that is not burned?• Stove performance and value to users?• Are current stove tests important, useful,

valuable, and/or appropriate? WBT? CCT?• Can we develop better metrics? Could that help?

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Common Stove Project Issues

R&D Cost Funding PovertyGovernments NGOs Stove failuresCompetition Fuel suppliers TheftSolving the wrong problem Time M&ELack of sustainability Import duties TaxesCorruption (baksheesh and similar) Process lossesAdoption by users Microfinance issuesPerformance of stoves in local conditions TestingRequiring the users to change their cooking habitsCost-effective materials Stove material sourcingLocal technology capacity Manufacturers KnockoffsHawthorne effect When outsiders leave, stove use ends

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How many variables exist within a Stove System? Probably hundreds. Which are vital?Stove Users Fuel Food DraftCulture Cooking Costs Time VentilationTraining Cultural fit Emissions Cook potsSafety Materials Carbon Service/repairCombustion Market Traditions TestingEnergy use Lighting Heating NGOsGovernments Regulations StandardsFuel Efficiency Overhead costs Support structureAir Quality Portability CO, CO2 ParticulatesHeat output Fuel reuse Charcoal TemperaturesToxics End-of-use Scaling CatalystsUser ROI Carbon Credits Stove longevity & impactWind Thermodynamics Heat Adjustability

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Systems Design Is Not EasyUnderstanding stove requirements is important.

Characterizing the entire stove context is vital. Can you model the essential aspects of the current stove system and use that to design improvements? If not – beware.

Everything is connected to everything, and then some. A wide variety of tools exist to manage systems design.

A weighted matrix of priorities will help, along with new product design methods. Design thinking may also help to innovate big improvements that increase value. Superb design & manufacturing helps, but is just part of the story.

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Which sector am I focusing on?

• Geography : sub-Saharan East Africa including Sudan (Darfur), Chad, South Sudan, Uganda, Kenya, Ethiopia, Eritrea, C.A.R., D.R.C.

• Target Market Customers: IDPs, Refugees, and others earning less than $5 US per day.

• UNHCR estimates 10.4 million IDPs in those regions. Actual number is probably higher.

• The number of refugees is also high (millions).

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Darfur IDP camps are filled with women and children

Context is important when designing an improved stove system. The terrain, people, affordances (fuel, materials, food, cookware), culture and more must all be understood. © 2007 Michael Helms

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A fuel-efficient stove in Darfur

This photo was shared with many organizations to promote the Darfur Stoves Project. Photo taken by Michael Helms ©2007

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A Darfur Stove in use

© 2007 Michael Helms

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Using Systems Design for this sector

• Requires a very simple, low cost stove design.• Contract manufacture (probably Asian suppliers).• Ship in 20’ or 40’ container volumes (like IKEA).• Stoves should be durable, portable, light-weight,

easy to assemble and repair, easy to use.• Eliminate as many external costs as possible.• The goal is a cost-effective “lifeboat” stove that

can be deployed in alignment with NFI practices.

Other Systems Design Considerations

• Silicon Valley – start-up culture – design thinking, entrepreneur , value propositions.

• Lots of rapid product development, technology development, novel methods.

• Use lean practices for design, manufacturing, distribution, organization, supply chain, etc.

• I am currently a lecturer in the ISE department (Industrial Systems & Design) at SJSU.

• Helms Research uses many “loosely coupled networks” to accomplish specific tasks.

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What can I share with you today?

• I encourage all to think big and small – and use systems design techniques throughout your project.

• I am glad to offer advice & suggestions informally for others with their stove projects – in the ETHOS spirit.

• I’m available for consulting and/or assisting academic and/or commercial stove projects.

• I’m always open to talking with anyone who can assist me in moving forward with my IDP/refugee stove design & manufacturing for East Africa use.

• Michael Helms helmsresearch@gmail.com

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A closing thought or two…

“We can think new if we think together.”- Mark Bryden (25 Jan 2014 @ ETHOS)

Perhaps… if we take a step back, and make use of the many existing interdisciplinary systems design and engineering tools – we can together make big, disruptive, positive changes in the stoves/energy area. A paradigm shift is likely needed to meet goals.