The increasing number of the world population leads to scarcity in energy resources. The production of additional energy is not a universal solution if we do not use the present one wisely. The forms of energy that come from water have a wide range and application in our daily lives. Especially considering the fact that water is used for electricity production – in hydroelectric power plants. Water supply is a type of service that also consumes a lot of energy. Water is a resource that must be valued, and nowadays every single benefit of it and the residual energy it releases must be used optimally. The investments in energy-saving innovative solutions must be a priority. The solution is limitation on the wasting of resources and on their chaotic “draining”. The ecological side of the topic is also of high significance since it concerns the society more and more each day, and thus leads to a number of regulatory changes. The limitations on the wasting of resources and putting an end to their chaotic usage are the factors that brought us to the idea for the creation of the “System for Energy Savings” product. By transforming the secondary energy from the hot water into an extremely useful residual product, we can save money and natural resources

DESCRIPTION:

When using hot water for daily needs, we lose many benefits and do not ponder how much residual energy water actually has. Looking at the details of renewable energy sources, we will understand that this is a source that completes the overall look of the so-called “green energy”. The “System for Energy Savings” optimally uses residual energy from hot water in a particular direction – a combination of prudent use of natural resource and money saving. The lower the base temperature in the water tank, the more electricity is required to heat it. Going through the system, the refuse water warms the cold one coming through the plumbing without mixing and direct contact between them, and returns the already heated water to the water tank. As a result of all this, the used heater works less, saves more and uses less energy. We decided that at this stage it is more appropriate “System for Energy Savings” to be installed at an earlier stage. Can be adapted in newly built houses, passive buildings, residential complexes, hotels, restaurant kitchens, business buildings, shopping centers and more.

THE SOLUTION:

The development is based on the residual energy from hot water, using it before it flows into the sewer. On the plumbing, the cold water comes with a temperature between 5 and 15 ° C (seasonally adjusted), “System for Energy Savings” heats this cold water by using the residual energy of the warming we use for everyday life. When returning this already warmed water back to the boiler/the instantaneous water heaters, the corresponding heater in the water tank starts to operate more economically and consumes less energy. The „System for Energy Savings“ achieves levels of 50-70% efficiency of the process.

THE PROGRESS:

“System for Energy Savings” has gone through a number of changes and prototypes until we reached the current design of the product. The idea originated in 2012 as a solution to everyday problems – high domestic hot water consumption. These are prototypes tested within 3 years and 5 months in real life conditions – from 2012 to 2014. In these, the efficiency reached between 30% and 40%…

In 2014, we participated in an event related to the presentation of inventions and innovative developments – “Inventions-Transfer-Innovations” ITI’2014. The event was held at the National Palace of Culture, at the initiative of the Union of Inventors in Bulgaria. In this case, we presented one of the first experimental prototypes of “System for Energy Savings”…

Regardless of the positive results, we decided to change its structure because of the high cost price, the big number of details and the high percentage of copper alloy. The current product development was still in the process of being upgraded and improved. The product has undergone significant transformation and great development – from 2014 until today. The development underwent a number of changes to achieve the current product design. Over the years, the project “System for energy savings” has undergone evolution in its main concept. He went through several main prototypes to reaching a pre-production prototype. All this contributed to a significant improvement in product development – its production cost and its functional characteristics. In the first prototypes was achieved efficiency of around 30%. As product development progresses, the structure of the main product and the materials used to produce it have improved significantly. Additional products were added to the system and this further optimize the process. This resulted in significant results and maintained efficiency of around 50%. In some situations, the efficiency varied between 50% and 70%. During the 6 years of development, all prototypes were subjected to intensive testing and under different conditions.

PRODUCT USAGE:

It is mounted under the siphon of the sink, and the operation and cleaning of the sink is convenient and easy. The system will be installed by the respective construction company or subcontractors involved in the furnishing of the respective room. In the presence of already built plumbing infrastructure by the construction company. Besides the main product to the product set of “System for Energy Savings” will be added two more products and several small plumbing accessories. The second product is a “diversion-mixer” which is again our development. The third product of the system will be a small electric water heater. For the third function of device it is possible to adapt or modify ready market product. But in this case, too, there are options for authoring your own product. The water tank needs to be located as close as possible to the other two products of the “System for Energy Savings”. All this is done in order to limit the losses of the extracted heat energy, which is transferred to the respective boiler/instantaneous water heater/water heating system. Immediately prior to production, all products in the system’s product kit will be subject to final development and technological preparation of production. “System of Energy Savings” can be combined with flow systems and Renewable Energy Sources.

In the process of product development, a conceptual idea for packaging emerged. The main purpose of the packaging is for storage when transporting “System for Energy Savings” to new buildings. We decided that with a more detailed approach to packaging design, we would show our attitude towards the product. By developing a “transport packaging” type, the end customer will not participate or spend any additional funds for the installation of the system.

THE DEVELOPMENT:

Different manufacturing and prototype technologies and materials were used for test models and prototypes, as well as for the pre-production prototype: 3D printing – PLA material; CNC milling machines and lathes – milling of polypropylene and brass parts, turning and processing of copper pipe. The pre-production prototype is made mainly of polypropylene, used for the two main parts mounted on both sides of the pipe, which is also made of polypropylene, with a wall thickness of 10 mm. For the serial production of the two main parts, the pipe, as well as some additional parts, it is planned to use plastic injection molding technology. For parts such as the inner pipe, a copper alloy was used, with a wall thickness varying in the range of 0.3-0.4 mm, until a final version is reached. In the serial production of the copper pipe, a certain type of production technology will be used – induction forging. For the purpose of the pre-production prototype, some additional parts have been made of brass, which will be replaced with polypropylene in serial production. The materials used for the manufacture of the pre-production prototype are fully recyclable. The purpose of the pre-production prototype, in its current form, is to approximate to some extent the characteristics of the final product – in this case, they approach 70-75% of the real product characteristics. The efficiency achieved after testing the prototype in question reached the range of 50 to 70%. Immediately before implementation in production, all details of the system’s product kit will undergo final refinement and technological preparation for production – be it redesign and reengineering.

ADVANTAGE ANALYSIS:

The long development process led to optimization, and hence to a significantly reduced production cost – compared to the initial idea, test prototypes and products. All this has the real possibility to lead to a potentially higher profitability per unit of product sold. The development has led to a reduction in the number of parts from which “System for Energy Savings” is built. Development efforts paid off after the production of the first pre-production prototype. Final adaptation to the technological requirements of the production is forthcoming, in order to implement it, which will require the production of another pre-production prototype. The production tooling (plastic injection molds), the materials used and the implementation in the type of production are specified. Significantly improved cost is obtained by flexible adaptation of the product to the specific production technology and type of materials – its main structure is made of polypropylene, and metal (copper alloy) is present in only one component. The materials that will be used to produce the product are recyclable. The tests accumulated over the years, in the process of intensive and detailed development – showed increasing efficiency in the tested pre-production prototype within 3 years. All this is based on a solid foundation, which is built on the old structure and prototypes of the system, which have been tested for 3 years and 6 months. The results obtained over the years, as a result of various tests, were constantly analyzed – with each new test, the data collected were more and more encouraging. When washing with hot water in the sink and using the residual heat energy, with installed “System for Energy Savings”, energy savings were reported within the minimum range of 25 – 30 kWh to maximum levels of 50 kWh. This is energy savings for a family of 4, within a month. Of course, over the years we have performed comparative analysis with already known solutions and products on the market, which showed us where we are and in which direction we are moving. All this was achieved on the basis of systematic analysis and objective evaluation of the achieved results. Without claiming that this is the “perfect product”, for the simple reason that such does not exist on the market! With standard heat exchangers, we noticed that they are relatively fast, but at very high water temperature levels – in the order of 80 degrees. But the exact question is: “Who washes something with such a temperature?”. A competitive product on the market was tested by us, but its real action and effectiveness was not justified, given the required temperature levels – 80 degrees. Its efficiency was reduced due to the presence of too much metal in the structure. While with “System for Energy Savings” the levels at which the process starts and the use of the residual heat energy from the hot water flowing through the siphon and passing through the system is 40 degrees. The known heat exchangers on the market are strong as a structure, but with excessive use and high consumption of metal (especially copper) for their production. This leads to incomplete functionality and low levels of efficiency, as well as problems with the connection to the plumbing, the entry of unpleasant odors, etc. Another specific direction are recuperators with heat pumps. They have too many disadvantages because they consume not small amounts of electricity and have requirements for the appropriate power supply. They need regular cleaning, have complex structures and are capricious in the process of operation. Last but not least – they are too bulky and take up large areas during installation, which logically leads to a non-compact product that is not applicable to the specific area under the sink. Their high prices are also unaffordable, as well as their return on time, which does not allow the investment to pay off no earlier than 7 to 10 years. This is too long a period for this type of product, which automatically makes them an unreasonably expensive investment. The latest prices in the survey showed a range of at least €700, and in some cases over € 3000. In the case of the “System for Energy Savings”, the market price is predicted at this stage in the range of 450 – 550 €, which will be finally specified during the implementation of the product. When no waste hot water passes through the “System for Energy Savings”, but only cold water passes through, this does not lead to any return and payback of the product. Each product has conditions in which it is not exploited, so then no levels of efficiency and return can be sought! Other types of products that we have analyzed and compared with the product “System for Energy Savings” are passive heat exchangers. They are too rarely used at the moment. They have serious dimensions, which makes them also inapplicable in the area under the sink. The predominant material used for their production is metal. They have too slow action and low efficiency. They allow installation in places that are difficult to access in most buildings and this also does not make them cost effective to use. They are relatively expensive as a final market price, which is essential in this case.

THE CONTINUATION:

In early 2015, a new idea arose around the development “System for Energy Savings”. We did not deviate from the concept of using secondary heat energy from waste hot water, but simply continued it and focused on developing a system that is placed on the bathroom wall: Bathroom System – https://solo-form.com/en/project/bathroom-system/. In view of the trends and developments of the world, as well as developing market niches such as clean technologies and smart homes, the “Bathroom System” has a hybrid concept in place, in which there will be the possibility of adapting a hardware solution, developing software control, combined with simple mechanics. The designing is in an advanced phase, which will gradually move to models, test parts and prototypes. The development is a continuation of the “System for Energy Savings”, but in a much more advanced version and with application in another environment, based on part of the structure of the “System for Energy Savings”, but in combination with several other devices and principles.

CONCLUSION:

Electricity is used for the reproduction of hot water, we do not ignore this fact and we have tried with our product to make optimal use of residual heat energy – from waste hot water. Instead of leaking into the sewer in vain, the residual heat is transformed into real benefits and saves electricity, which is regenerated and used efficiently. It is a quantitative accumulation over time that brings only benefits to consumers and the economy as a whole. The principle is very simple: drinking water – electricity – hot water – use of waste hot water – saving electricity. With this product, although in small quantities, we support the process in a specific direction. We also contribute to the protection of the environment by judiciously using the residual heat energy from the water before it leaks into the sewer. This has a direct and immediate bearing on concepts such as “green energy”’ and “smart homes”. We offer a comprehensive approach and technology for regeneration, with an affordable and applicable product. Demand for this type of “energy saving” products such as “System for Energy Savings” and “Bathroom System” will grow more and more. Especially products with real efficiency, return and profitability, solving specific problems with resources such as water and valuable residual energy from it. It should be viewed from different points of view of energy efficiency – “inside-out” in the building and the room in which water is used for domestic purposes. The solution to the problem is by looking at the individual details of the general problem, and one of them is the search for all possible ways to save and use water optimally. This greatly affects the residual heat energy, which is discharged chaotically without using its various forms of application. The waste of electricity is palpable in buildings, but this cannot be compensated only by thermal insulation, because it does not return the amount of electricity that “leaks into the sewer”. This is also part of an emphasis called “energy efficiency”. All that has been achieved in this product, as well as solving a specific problem with it, is a small step towards more efficient use of such a valuable resource as water. But isn’t that exactly the way – through small steps, big steps are taken towards change!