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Project S.T.E.A.M.: A Journey from Vision to Impact to villager

Team

Next Gen Cook Stove

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Agenda

▪ Who are we? What we do?▪ Motivational drivers for clean cook-stoves project▪ CES Clean Cook stoves Vision ▪ Cookstove Journey so far...▪ Way forward

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Who are We ? What we do ?

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Cummins : We are cause for Motion !!

Global presence

Countriesand territories

190+

Develop, design and manufacture products on

6continents

Employeesworldwide

55,000

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Motivational drivers for clean cook-stoves project

While some still argue that business has no social responsibility, we believe that our survival in the very long run is as dependent upon responsible citizenship in our communities and in the society, as it is on responsible technological, financial and production performance. --- J. Irwin Miller

“”

7

Corporate Responsibility 2015 Engagement

Kiloliters of water conserved

130KPeople educated350K

Trees planted77,820

Global projects88

Every Employee Every Community

Recorded volunteer hours globally

3 9 1 9 7 1

Impact

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Cummins Emission Solution (CES) Clean Cookstoves Vision

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Need for Clean CookstoveHealth impacts ( 3 billion people affected)

• Health hazards from indoor pollution from firewood stove

Livelihood impact• Time and effort spent per day in

collecting firewoodEnvironmental impact

• Deforestation

3 stone fire

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CES VisionReduce problem of

Household Air Pollution (HAP) through the adoption of

clean cookstoves in the markets where Cummins

does business

leveraging the time, talent and skills of employees

and forging partnerships with business,

government and community organizations

by

1. Engage our employees on fit-for-region product designs, manufacturing, distribution and support of clean cookstoves

2. Building capacity in regions and partnering with key stakeholders to support standards, testing, education, application and monitoring of clean cookstoves.

Core Strategies

• Better health !• Save Time !• Less wood to

gather !• Study more !

Courtesy from Vasu Iyer

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Cook stove initiatives so far in India !!!

• Timeframe: 2011- 2019• Budget: Project based funding • Approach: Develop sustainable ecosystem at rural

level & building capacity of private sector players where needed to achieve scale as well as collaborate with key non-profit partners for Standards, Testing, Education, Application and Monitoring.( STEAM)

13Insert Data Classification

Nandal cookstove project

2011

CRTI designed EcoFlame declared as winner in Global cookstove competition

Dec 2013

Cookstove strategy workshop

April, 2014

Model village Dhawlewadi deployment

May, 2015

Nexleaf project for cost effective sensor development

March, 2016

Model village Manjarsumbha village deployment

August, 2016

25 stoves 25 stoves

Deployements at model villages Dewas and Pithampur

November, 2016

50 stoves

Procurement of PM Sensor from Approvecho Procurement of CO Sensor

Cookstove Six sigma

Samuchit Ecoflame Prakti Prakti PraktiMimi Moto

Cookstove Journey in Cummins India

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Lessons Learned (1 of 3)▪ Nandal Deployment:

– Importance of reliability– Education of users– Free stoves are poorly adopted

▪ EcoFlame Development: – “Never release unknown

technology within unknown product in unknown market”

– Choose your partners wisely– Is this what villager wanted?– Clarity on Intellectual Property

before engagement– Employee skills (

Computational fluid dynamics )

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Lessons Learned (2 of 3)▪ Recent

Deployments:– Monitoring,

measurement, right tools and placement

– How to be effective – Six Sigma improvements: streamlining internal processes and creating a tool kit for replicating deployment best practices

– Speed and quality

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Lessons Learned (3 of 3)▪ Cummins Corporate Responsibility

– “Making the Elephant dance”– Difference between corporate and NGO style– Empowered but not unlimited

• Maximizing resources• Setting high expectations

– Results oriented expectations• Time, deliverables and numbers

– Dependent on stakeholders & consensus driven solutions

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Model Villages in India

▪ Rural villages nearby Cummins sites▪ Community needs include basic survivability▪ Goal is to meet basic needs and increase social mobility and growth

options▪ Common projects across Model Villages

– Check dams and irrigation systems enabling multiple crop cycles– Clean water, sanitation, education and some power generation from

alternative fuels

▪ Villagers don’t find value in Clean Cookstoves until basic needs are met

▪ Mobile phones and Coca-Cola have arrived but clean cooking and other basic needs have not improved

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Way Forward 2017-2019▪ Supporting Alliance “100 Million” Vision▪ Synergy of CSR Projects

– Clean Cookstoves plugged into all 12 Model Villages

▪ Partnering to Execute– Collaborating with multiple stakeholders (Alliance, suppliers,

University ,NGOs and government)– Develop and deploy EcoFlame

▪ Technical Partnerships– Project-based collaborations (like Nexleaf) in design, testing

and supply chain– Focusing on our strengths (employee skills and expertise)

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Thank you !!!

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Acknowledgement

Ecoflame Team From left to right- Enoch Nanduru , Ambarish khot ,Nitin pise ,Suhaschandra Gaddamwar, Mayur pote , Mahesh Jamdade , Jagjyot Saluja

Computational Fluid dynamics Team ( CFD ) From left to right- Sai Shankar,, Pragdeeshwaran S , Ambarish Khot ,Arun Kumar , Udit shah & Paul Amal Raj

Cookstove project leadership Team @ Cummins

Cruz BaisaDr. Sachin JoshiVasu Iyer S. Ravichandran

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Appendix

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Problems in deployment

Communication Gap

Asynchronous consecutive or

deployment Delay

Six Sigma

C&E for different

selections

Standard Templates

Process flow and

RACI

Problems in deployment due to lack of process

Six Sigma (6σ)

Optimized Deployment

Process

Six Sigma Project for Effective, Fast and Concurrent Deployment

1/28/2017 2:50:58 AM23

Templates Prepared for effective Deployment

• Village selection Input form• Village selection C&E• Preliminary material• Initial Household Selection Survey on Socioeconomic Background and

Cooking Habits• Worthy villager C&E• Supplier selection C&E• Training presentation example• RACI Template• Deployment team selection• Feedback from Villager’s template• Team Meeting Schedule template• Minutes of meeting template

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Cookstove :Best design practices

1. Primary air should not be blocked in any case- Primary flow from bottom where Natural draught is maximum

2. Secondary air is essential for emission performance- Provided with venturi control3. Bottom part of furnace should not be contact in ground- 60 mm above ground4. Preheating of air & fuel is necessary- bottom air & secondary air waste heat use5. Flue gases & plume should not flash back-> backpressure in furnace is maintained ->

Proper gap between outside wall of skirt design6. Ash removal is necessary to control emission & cleanliness-> Slots at bottom & with

serviceable Grate7. Increase contact heat transfer efficiency- > skirt design & increase heat transfer

coefficient (HTC) of turbulent buoyant plume jet out of furnace exit8. Flame should not touch walls of furnace (may result in flame cooling & emission rise)- >

bottom air entry will keep the flame straight9. Control of Gasification process is necessary for high thermal efficiency & reduced

emission, less ash buildup - > Secondary air staging & air quantity is controlled10. Lesser heat losses from system & fast startup -> Low cost light weight insulation of

pumice rock

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Villager Education and Emission measurement

– Leaders (GK & Ravi) visited Village – Leaders interacted with Sarpach & visited

the site.– Design Team interacted with Sarpach and

Users– Educated them about the benefits of Clean

Cook stove– Captured the VOC on Stove usage – Site Data captured for simulation (

emission data required)

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1/28/201726

Measuring Temperature data Smoke in room due to use of stove

Volunteers Trained

Educating users

Analysis Led Design for Cook stove development

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Cook STOVE

Flow field within

cookstove

Thermal CFD

Chemical kinetics

Structural using FEA

*Fuel burn rate, PM, CO/CO2* - In development

Typical deliverables from Finite Element Analysis (FEA)• Static load • buckling loading• Weld life• Furnace oxidation rate

Flow Field Analysis using CFD• Air to Fuel ratio• Prediction of secondary air needed

for soot oxidation• Flow Distribution Indices (FDI )

Typical deliverables from Computational Fluid Dynamics (CFD)• Hot spots • Skin temp• Temperature

distribution Index (TDI )

Key capabilities with clean cook stove team at

Cummins that will help propel development of

Ecoflame 2.0

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Combustion Physics behind Cook stove

1/28/201728

Emissions caused by incomplete combustion are mainly a result of either:▪ Inadequate mixing of combustion air and fuel in the combustion chamber, giving room for local fuel-rich combustion zones;▪ an overall lack of available oxygen;▪ combustion temperatures that are too low;▪ residence times that are too short; ▪ radical concentrations that are too low, ▪ Heat losses to surrounding▪ Flame cooling due to excess air entry

Combustion recipe for development of our cook stove

[ 2] - The_Handbook_of_Biomass_Combustion_and_Co-firing_(2008) by Sjaak van Loo and Jaap Koppejan]

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Comparison of promising stoves

▪ Table shows Ecoflame is far better than other stoves.▪ Apart from Approvecho stove, all data is taken from MNRE website

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*Source : http://mnre.gov.in/file-manager/UserFiles/approved-models-of-portable-improved-biomass-cookstove-manufactures.pdf

MNRE Lab testing at India Ecoflame Greenway Envirofit Adarsh Prakti Apprevecho Biolite units

Type of Stove Natural

draftNatural

Draft Natural Draft Natural DraftNatural

Draft TLUDForced draft

High Power Thermal Efficiency % 28.42 25 25.46 28.1 30 45.16 36.92High Power CO g/MJd 4.06 5 4.84 4.65 4.39 0.01 0.91High Power PM mg/MJd 58.37 239 331.4 212.13 241 7.96 120.2Indoor Emissions PM mg/min 0.05 0.73 Power wattage KW 1.69 1.4 0.77 1.41 1.68Weight Kg 8.31 6.6 Number of burners Single Single Single Single Double Single SingleCost of stove $

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Why Ecoflame is unique? ▪ Continuous ash disposal mechanism▪ Availability of preheated air irrespective of Fuel loading▪ Venturi principle based preheated secondary air control for

soot burning & char oxidation▪ Inclined fuel sticks for fast fire initiation ▪ Skirt design & turbulent buoyant jet for enhancing contact

heat transfer efficiency▪ Faster Warm up time ( double layer insulation)▪ Uniform heat spread over bottom of vessel▪ Lower part of the stove is a charcoal burner

Ecoflame 2.0 Development

1/28/201731

Ecoflame 2.0Ecoflame 1

Cummins’ Dhawlewadi experience

Voice of Customer (villager feedback)

Functional & design Improvements

Cook stove deployment guide

• Dual Burner stove equipped with Ecoflame 1.0 tech.

• Material reduction• Mfg capability

improvement• Supply chain

improvements

▪ Field measurement be done by – Ambient room quality within houses ( CO , PM )– Quantity of Fuel needed to cook the food– Time to cook the food

Cookstove Emission measurement project

Field Testing

equipment's

CO sensors

PM monitor

Stop watch

Infra red thermal

gun

Weigh balance

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Field data gathering process

Measurement of Fuel , 5 lit water in

vessel

Installation of 3 CO sensors and 2 PM sensors in exhaust path & distance from

stove recorded

Cooking experiment is conducted till

water temperature

reaches to 98 C

CO data is monitored throughout

cooking period

PM 2.5 micron data is

obtained from the instrument acquired from Approvecho

Throughout the experiment following things kept constant1. Size & type of Vessel2. Wood used with baseline & improved stove within same house3. Doors, Windows of house were open ( usual cooking condition)

House 1: 3D Model and sensor locations

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Top View of house 2

Existing stove Clean Cook stoveTime to boil 5 lit water 23 mins 23 minsFuel consumption to boil 0.82 kg 0.7 kgMax CO while cooking 398 ppm 257 ppmMax PM2.5 generated 90,878 µg/m3 15,173 µg/m3

1/28/201735

Field Data measurement at House 1

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Emission impact measurement in House 1

Note that Y axis scale is not the same for both graphs

Reduction

Reduction

CFD MODEL – House 2

Cummins Confidential37

Voice of Customer and usual complaints

What Is prime customer need while cooking ?– Flame should be visible in furnace for better control of cooking– Fuel entry should be at front ( easily accessible)– Least controls needed while cooking– Less cost for low income family– Cooking should be faster ( so they can utilize time for other activity)

Usual customer complaints– Manual efforts for Ash removal from stove– Black smoke at bottom of vessel reduces heat transfer efficiency & increase

consumption in long term– Furnace break into two-half & furnace corrosion– Indoor health issue ( eyes wetting & thorat cancer)– Structural buckling when heavy vessel kept over stove– Clogging of Grate– continuous feeding preferable instead batch feed cook stove

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Magnitude of Problem in India

Source: 2012 Report from GACC

Population 1.16 Billion

Number of people affected by HAP 913 Million

Rural Population 770 Million • 69%

Rural Population using Solid Fuels 677 Million • 88% of 770 Million• Primary Fuel Used : Wood

Population using improved biomass CC 92 Million • 8.3%

Maharashtra Rural Population 61 / 112 Million • 55%

Average Household Size (India) 5

Income per day (USD) $4 / day • Avg. for whole population• Income varies from region to region

Women’s Empowerment Score 0.61• Closer the score to 1, the better • 2012 highest score 0.85 (Iceland)• 2012 lowest score 0.45 (Yemen)

Courtesy from Vasu Iyer

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Local Challenges : Diversity in terms of Cooking needs

Hence for them no single solution will work !!

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Cook stove variants in India

Transform & Broaden Basic & Intermediate cooking segment

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Theme for Stove design (USE SAFE)

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▪ Cook Stove design development drivers

– Usability ( do not change cooking habit of people)– Safer ( Improved emission related health hazards)– Efficient ( less fuel burnt )

– Sustainable (Long Lasting ecological balance)– Aesthetic & Ergonomic design ( beauty of kitchen)– Faster ( Lesser turnaround time)– Easier ( fatigueless & less dependency on infrastructure)