Project Frío Project Documentation - EED Courses
Transcription
Project Frío Project Documentation - EED Courses
Project Frío Project Documentation Project Frío: A Mission to Cool Insulin Without Electricity Trip Date: May 9th – May 23rd 2015 Choluteca, Honduras Submitted April 21, 2015 By, Cameron Duffner Charlie Goettler The Ohio State University 2015 Instructional Staff: Roger Dzwonczyk and Mariantonieta Gutierrez-Soto Executive Summary This project involved solving the issue of overheated insulin in tropical climates using three methods, but was centralized upon the climate of Choluteca, Honduras and the passive methods of geo-cooling and evaporative cooling. Following studies on the viability of each solution, the final implementation recommends use of an insulin pot in the dry season and an insulin hole in the rainy season for insulin preservation. The project also explored the viability of absorption cooling as an alternative, more active method. The geo-cooling study involved digging holes at various depths to test the optimum depth at which the insulin could be stored in order to take advantage of the hypothesized cooler temperature of the Earth’s crust in relation to the air in the tropics. Upon determining the ideal depth, the project progressed to installing holes at that depth for further testing for the effects of width and amount of shade. The holes were lined with capped PVC pipes for cleanliness and sustainability of the cooling pit. The results of the study showed a tube of either 2” or 3” width installed approximately 40” down into the ground in a shaded area could maintain a temperature of 85 degrees Fahrenheit during the dry season test period, falling just within the recommended insulin storage temperature range of 59-86 degrees Fahrenheit. This solution is strong in its ease of installation and probable sustainability but does not provide as much potential cooling power during the dry season. What it does provide is a much more constant, natural cooling method that does not require any maintenance. It is likely that the insulin hole will have a greater cooling effect in the rainy season; however, this information will not be known until the data logger that currently resides at the bottom of a test hole is retrieved in 11 months. The second solution is an evaporative cooling device known as a zeer pot. This solution is an ancient technology that contains an inner and outer pot, between which is sand. Water that is poured into the sand provides a cooling effect within the inner pot when it evaporates into the air. Testing during the dry season showed that this technology could maintain a temperature of approximately 80 degrees with water replacement every 3-4 days. The pot saw its greatest success during periods of lower humidity but was much more ineffective during the humid nights. Due to the high humidity of southern Honduras, this project has a low potential utility in this region during the rainy season and is more high maintenance than the cooling pit. However, it is strong in ease of implementation and probable sustainability and is especially viable during the dry season. The absorption refrigeration system was composed of two ½ liter tanks (one full of a 50/50 mixture of LiBr and H2O, one empty) that were connected by metal piping and displaced by 3 feet from each other. The general process included heating the full tank in boiling water while the empty tank was partially submerged in room temperature water. Once heating was complete, the full tank was placed in the room temperature water, and the previously empty tank was placed in a plastic cooler. It was at this point partially full of condensed water. The attraction of that water back to the side that still was full of lithium bromide was intended to create a cooling effect on the tank in the cooler. This solution is in theory the most powerful cooling method in terms of potential but is worst among the solutions in terms of cost, ease of implementation and use, and probable sustainability. At the time of this report, the absorption refrigeration system does not function as intended. 2 Table of Contents Executive Summary……………………………………………………………………………………2 List of Figures, Pictures and Sketches………………………………………...……………….……5 Section 1: Team Member and Other Participant Information…….……………...………………..7 1.1 Team Member and Other Participant Information…………………………...……….….7 1.2 Project Location………………………………………………………...…………………...8 Section 2: Background Narrative………………………………………………………………….….8 2.1 Insulin Background………………………………………………………….………………8 2.2 Choluteca Climate Background……………………………………………………………8 Section 3: Scope of Work…………………………………………………………………………..…8 3.1 Goal of the Project………………………………………………………….……………….8 3.2 Problem Statement………………………………………………….………………………8 3.3 Customer Identification…………………………………………………….……………….9 3.4 Assessment of Need……………………………………………………….……………….9 3.5 Specific Itemized Objectives…………………………………………...…………………..9 3.6 Deliverables………………………………………………………………………………...10 3.7 Sustainability Plan…………………………...………………………….…………………11 3.8 Ownership Plan…………………………………………………………………….………11 Section 4: Research and Design Process……………………………………………………..…..12 4.1 Participant Roles and Responsibilities…………………………………………………..12 4.2 Background Research……………………………………………………………………..12 4.3 Design Process and Prototyping Details……………………...…………………………13 4.4 Pre-Trip Testing and Results…………………………………………………......………13 4.5 Pre-Trip Project Schedule…………………………………………………………………14 4.6 Tools/Materials/Equipment to be Brought from Columbus…………………………….15 4.7 Tools/Materials/Equipment to be Obtained in Honduras……...……………………….15 4.8 Limitations of Project Pre-Trip……....…………………………………………..………..15 4.9 Photos and Figures……………..……………………..…………………………………..16 Section 5: In-Country Implementation………………………………………………………………...34 5.1 Implementation……………………………………………………………………………..34 5.2 In-Country Schedule……………………………………………………………………….34 3 5.3 Issues Encountered………………………………………………………………………..34 5.4 Testing, Results, Assessment, Evaluation………………………………………………35 5.5 List of Supplies/Materials Given to the Customer………………………………………40 Section 6: Post-Trip Results……………………………………………………………………………40 6.1 Issues Encountered………………………………………………………………………..40 6.2 Objectives Achieved……………………………………………………………………….41 6.3 Sustainability and Ownership……………………………………………………………..41 6.4 Cost Analysis……………………………………………………………………………….41 6.5 Conclusions…………………………………………………………………………………45 6.6 Recommendations…………………………………………………………………………45 Section 7: References…………………………………………………………………………………..46 7.1 Works Cited…………………………………………………………………………………46 Section 8: Acknowledgements…………………………………………………………………………47 8.1 Acknowledgements………………………………………………………………………..47 Section 9: Appendix…………………………………………………………………………………….47 9.1 Team Agreement…………………………………………………………………………..47 9.2 Project Proposal……………………………………………………………………………49 9.3 Instruction Manuals………………………………………………………………………..52 4 List of Tables, Figures, and Photos Table 1 Team Member and Other Participant Information…………………………………...7 Table 2 Absorption Refrigerator R&D Costs………………………………………………….42 Table 3 Hole R&D Costs………………………………………………………………………..42 Table 4 Zeer Pot R&D Costs…………………………………………………………………..43 Table 5 General R&D Costs……………………………………………………………………43 Table 6 Cost of Insulin Pot……………………………………………………………………..44 Table 7 Cost of 2” Insulin Hole…………………………………………………………………44 Table 8 Cost of 3” Insulin Hole…………………………………………………………………45 Figure 1 Gantt Chart (Pre-Trip)……………………………...………………………………….14 Figure 2.1 Humidity in Choluteca [7]………………………………………………….................29 Figure 2.2 Temperature in Choluteca [7]………………………………………………………...30 Figure 2.3 Minimum Temperature Possible Due to Evaporation [1]………………………….31 Figure 3.1 Simple Absorption Cooling Schematic [6]…………………………………….........31 Figure 3.2 Simple Adsorption Cooling Schematic [6]………………………………................32 Figure 4 Absorption Test Results…...………………………………………………………….33 Figure 5 In-Country Schedule…………………………………………………………………..34 Figure 6 First Holes Data………………………………………………………………………..36 Figure 7 2in vs 3in Tube Test…………………………………………………………………...37 Figure 8 3in Tube at Veronica’s………………………………………………………………...38 Figure 9 Zeer Pot Testings……………………………………………………………………...40 Photo 1. Testing in Progress (Heating)………………………………………………………...16 Photo 2. Testing in Progress (“Cooling”)…………………………………………………........17 Photo 3. Crosley Icyballs [2]…………………..………………………………………………...18 Photo 4. Zeer Pot [5]……………………………………………………………………………..18 Photo 5 Hole-In-Ground: Ice Cave…………………………………………………………….19 Photo 6 Icyball Concept: Stand Variation 1…………………………………………………..19 5 Photo 7 Icyball Concept: Cooler Fit……………………………………………………………20 Photo 8 Icyball Concept: Top View…………………………………………………………....20 Photo 9 Icyball Concept: Stand Variation 2…………………………………………………..20 Photo 10 Icyball Concept: Stand Variation 3…………………………………………………..21 Photo 11 Icyball Concept: Mounted Stand Variation………………………………………….22 Photo 12 Icyball Concept: Valve Possibility 1………………………………………………….23 Photo 13 Icyball Concept: Valve Possibility 2………………………………………………….23 Photo 14 Icyball Concept: Stand Variation 4………………………………………………......24 Photo 15 Icyball Concept: Stand With Valve 1………………………………………………...24 Photo 16 Icyball Concept: Stand With Valve 2………………………………………………...25 Photo 17 Icyball Concept: Cymbal Stand………………………………………………………25 Photo 18 Icyball Concept: Filled Cooler……………………………………………………......26 Photo 19 Icyball Concept: Variation With Valve……………………………………………….26 Photo 20 Beaker-Bottom Design……………………………………………………………......27 Photo 21 Final Prototype Design ……………………………………………………………….28 Photo 22 Map of Hole Locations………………………………………………………………...35 Photo 23 Locations of First Two Holes…………………………………………………………36 Photo 24 Location of Tube Diameter Test……………………………………………………...37 Photo 25 Location of Veronica’s House………………………………………………………...38 Photo 26 Location of Zeer Pots………………………………………………………………….39 6 Section 1: Team Member and Other Participant Information 1.1 Team Member and Other Participant Information Figure 1 below contains the names, roles, specializations, and contact information of both team members and all those that contributed to the project including the instructional staff, the professional consultant, and project sponsor. Members Roles Specializations Phone Email Cameron Duffner Chief Communication Officer, Primary Documenter Industrial & Systems Engineering, Spanish (260) 515-3757 duffner.9@osu.edu Charlie Goettler Chief Financial Officer, Presentation Coordinator Civil Engineering (614) 949-2362 goettler.5@osu.edu Dale Andreatta Consultant Mechanical Engineering (614) 634-2901 dandreatta@SEAlimited.c om Roger Dzwonczyk Professor Electrical Engineering (614) 570-2073 dzwonczyk.1@osu.edu Mariantonieta Gutierrez Soto Teaching Assistant Civil Engineering, Spanish (614) 315-4988 gutierrez-soto.1@osu.edu Angie Overholt Project Caretaker Nursing - angieover@gmail.com Table 1 7 1.2 Project Location Project development, research and testing took place at The Ohio State University as part of the Engineering 4692.01S course, Engineering Service Learning in Choluteca, Honduras with the Engineering Department. The implementation of the project took place in Choluteca, Honduras and the surrounding region, with headquarters located at World Gospel Mission in Choluteca. Section 2: Background Narrative 2.1 Insulin Background Insulin is a hormone produced in the pancreas that regulates blood sugar levels. Diabetes, a disease that is characterized by blood sugar imbalances, is treated with synthetic insulin injections. In order to be effective for up to a month, the insulin should be kept between 59 and 86 °F, according to the FDA [3]. According to the American Diabetes Association, insulin lasts for one month at room temperature (≈ 72 °F), but should be stored in a refrigerated environment if the intended use range is longer than one month [4]. 2.2 Choluteca Climate Background According to Weather Spark records from 2007 to 2012, the average high daily temperature in Choluteca, Honduras over the course of a year is over 90 °F [7]. Therefore, at points during any given day, Honduran diabetics are likely to be storing their insulin at higher temperatures than are recommended for optimum effectiveness of the treatment. 2.2 Choluteca Climate Background According to the project sponsor, diabetics in the region are often unable to obtain insulin for treatment due to their lack of a method to reliably store insulin within the optimum temperature range; the healthcare providers will not supply insulin to those who cannot prevent it from overheating. Section 3: Scope of Work 3.1 Goal of the Project Design and implement a passive insulin preservation (cooling) technology at a low cost and complexity. 3.2 Problem Statement Injected insulin is an effective treatment for diabetes. However, insulin is heat sensitive and must be stored between 59 and 86 °F for its long-term preservation [3]. People in rural Honduras without electricity often do not have a means to keep insulin cool and the compound can become prematurely inactive and ineffective in controlling blood glucose levels. 8 3.3 Customer Identification In a broad sense, World Gospel Mission is the general customer in that it identified the problem and requested the assistance. However, the diabetic residents of Choluteca, Honduras and the surrounding areas who are without access to refrigeration or other cooling means are more directly served by the project. 3.4 Assessment of Need Insulin, an essential component in the treatment of diabetes, is only effective at temperatures between 59 and 86 °F [3], a range that is below the average lowest annual temperature of Choluteca [7]. This, combined with the lack of refrigeration and electricity available to a significant proportion of the populace of Choluteca and the surrounding region generates a critical need for a method to cool the insulin at a low cost and without electricity. 3.5 Specific Itemized Objectives ● ● ● ● ● ● ● ● ● ● ● ● Design a cooling mechanism that can contain insulin between 60 and 80 °F. The mechanism must be inexpensive. The mechanism must not use electricity. The mechanism must be able to contain 3 Humalog injection pens. The mechanism must be composed of parts available in Honduras. The mechanism must be easy to use and contain instructions for build and use. The mechanism must be durable and usable for extended use. The mechanism must be safe to use. Design LiBr absorption cooling device Design ground cooling well Design evaporative cooling device Test attainable cooling ranges and timeframes 9 3.6 Deliverables Absorption refrigeration: ● ● ● 1 absorption refrigeration test prototype ○ If successful: 5 prototypes instructional pamphlets 2 kg extra LiBr Cooling pit: ● PVC pipe wells as needed Evaporative cooling: ● 1 zeer pot test prototype ○ If successful: 5 prototypes ● instructional pamphlets The primary deliverable of this project was intended to be 5 lithium bromide absorption cooling units, complete with tube-connected dual canisters, enclosed lithium bromide and water mixture, and coolers. An informational instructional pamphlet would accompany each unit and would detail the construction, use, maintenance, and safety involved with the device. In the interest of finding the best solution, cooling pits and zeer pots will be implemented and tested for effectiveness in Honduras. If one or both of the secondary options are found to be a viable or even a better alternative to the primary solution, additional units will be produced and will be accompanied by informational pamphlets containing the same information categories as the primary solution’s pamphlets. In the case that the cooling pits are the most effective solution, wells will be dug for as many customers as possible during the trip’s timeline. 10 3.7 Sustainability Plan • Absorption refrigeration: Sustainability of this solution requires a parts list for replacement of failed components, and maintained connection of the customers to Angie if replacement lithium bromide is needed (due to the difficult nature of its acquisition). In addition, a manual for safe and effective handling and distribution of lithium bromide into the system will also be provided. • Cooling pit: Sustainability of this solution will be ensured by installing a double capped PVC well into the cooling pit. It will therefore be impervious to water entering the system from the soil or from the air. Sustainability of the cooling source will be provided naturally by the property of the Earth’s crust to maintain a relatively constant temperature despite the outside temperature of the air. • Evaporative cooling: Sustainability of this solution will be implemented by providing an instructional manual for proper water maintenance of the solution if it is found to be viable. The solution itself is sustainable in that it only requires water (of any cleanliness level) to be replaced. The sand could potentially need replaced eventually but would not require a large degree of difficulty in its replacement. The pots themselves would be functional indefinitely and could be replaced if broken as needed. 3.8 Ownership Plan • Absorption refrigeration: Ownership of this project depends on its ability to provide significant cooling. The cooler than contains the cold component of the device has enough space to hold several drinks or food items alongside the insulin. If provided with this previously absent ability to cool drinks and food, the customer will be more likely to use it than they would be if the daily heating of the device were only applied to cooling insulin. • Cooling pit: Ownership of this project will be established through education on the issue of overheated insulin and an explanation of the solution before implementation. This provision of clarity as to why the pit is necessary and how it will positively affect the customer will ensure its use. In addition, the location of the pit in the customer’s own yard will provide another form of literal ownership. • Evaporative cooling: Ownership of this project will be created with the decorative elegance of its design and participation of the customer in its construction. An explanation of how it functions and what maintenance it requires will also produce a form of ownership by 11 giving the customer an understanding of what he or she is watering each day (and why) to increase the likelihood of that happening. Section 4: Research and Design Process 4.1 Participant Roles and Responsibilities Specific leadership roles are defined in Table 1 of in Section 1.1. As for participation, both Cameron and Charlie contributed equally to the research, design and testing aspects of Project Frío. 4.2 Background Research The first step in the research process was to identify passive methods of cooling because it was known that electricity would not be available. During this step, it was determined that the options included building a zeer pot (evaporative cooling) and digging a deep hole in the ground. Once the options were determined, they were each researched in more depth. Zeer pot technology has been around for thousands of years, so finding information was relatively simple. After some digging, the exact reason why the zeer pot works and how it works was discovered. The zeer pot cools as wind blows through the porous clay pots, pulls moisture out of the saturated sand through evaporation, and – in the process – pulls heat out of the inner pot where the insulin would be held. For this process to work, relative humidity has to be relatively low; otherwise evaporation will not occur. Logically, the next step was to research the climate in Honduras. Data for the humidity in Honduras can be found in Figure 2.1 and data for the temperature in Honduras can be found in Figure 2.2. It was then found that 6 months out of the year, the relative humidity in Honduras is above 90%, getting as high as 99%. Comparing the humidity and the temperature to a graph that shows the minimum temperature possible due to evaporation given relative humidity and temperature (Figure 2.3) made it clear that the zeer pot could not serve as a full-year primary solution. After many failed attempts to find any information on the ground soil temperature in Choluteca, it was determined that no such data existed and therefore the hole solution could not be considered a sure option until data was obtained. Unlike the zeer pot, the hole could still work year round, but the effectiveness will not be known until testing is done in Honduras. Left with no absolute solutions, the Project Frío team turned to an outside source for information and assistance. Following an in-class lecture on sanitation and health, Dr. Dale Andreatta, an alumnus of The Ohio State University with a degree in mechanical engineering, sat down with the group to discuss the Goswami cycle. He also brought up the idea of absorption/adsorption cooling as a possible option. Research was conducted to figure out what exactly absorption cooling was and how it differed from adsorption cooling. Essentially, the main difference between absorption cooling 12 and adsorption cooling is that absorptive cooling uses a fluid as the absorbent, creating a working solution while adsorptive cooling uses a solid as the adsorbent [6]. Once the team felt it had a general understanding of the two, the group met with Dr. Andreatta who agreed to help. Together, the three came up with a design for an intermittent absorption refrigerator that combined aspects of both Figure 3.1 and Figure 3.2a. Lithium bromide would be used as the absorbent, and water would serve as the refrigerant, whereas other models of intermittent absorption refrigerators used ammonia and water. Dr. Andreatta explained that an ammonia and water system is constantly under high pressure and the ammonia itself is toxic so LiBr and water would be best for Project Frío’s purposes – especially in terms of safety. 4.3 Design Process and Prototyping Details As it is explained in the above section, Project Frió started out with the goal of cooling insulin without using electricity. Initially, the focus was on cost, sustainability, and ease of use. The zeer pot fit these qualifications perfectly because it was something that could be made entirely from resources found in Choluteca for very little money, and in theory, it was extremely easy to use and maintain. After the discovery of Figure 2.3 and the limitations of the zeer pot in Honduras, the focus shifted to the hole-in-the-ground approach. After hitting another wall with the lack of information about soil ground temperatures in Honduras, Project Frió abandoned their prior goals in the hopes of finding any method at all that could be relied upon to work yearround. The design for the intermittent absorption refrigerator started out resembling the design for the Crosley Icy Ball (Photo 3), but a lot more simplified. The original design also included a fixed stand. The design evolved as new ideas for a stand were thought up. Stand variations ranged from a simple T-bar design to a sophisticated, wall mounted stand. Finally, the team decided that a cymbal stand (from a drum kit) would work best because of its ability to be adjusted to meet any circumstance. As the team talked with Dr. Andreatta more, it was explained to them that instead of spherical vessels, something with a flat bottom would work best, thus, the design changed again. When the team was unable to find a beaker shaped vessel that could be connected to another vessel to form a closed system, they had to look for the next best thing. That next best thing was a Coleman propane tank used for camping stoves and the likes. After the propane was extracted and the valve removed, the propane tanks served as the perfect vessels in theory. Now that the vessel was determined, how to connect the two tanks was the next concern. The threading on the propane tanks is ¾” so there were some limitations, but that highlighted a great starting place. After trying out various ¾” threaded tubes, the final decision was made to use two hot water heater tubes connected with a foot of copper piping. This decision was made because the hot water heater tubes were flexible, which allowed for more mobility and adaptability of the system. 4.4 Pre-Trip Testing and Results The first prototype of the absorption refrigerator used two empty Coleman propane tanks as the two vessels with a copper pipe connected by water heater tubes serving to connect the two 13 vessels to create a closed system. The first round of testing was conducted outside due to the uncertainty of what may happen. Instead of a cook stove, a charcoal grill was used to boil the water which would drive the absorption cooling process. Once the water was brought to a light boil, the tank with the lithium bromide and water solution was put into the water while the empty tank was placed in a bowl filled with cool tap water. After 30 minutes, the water stopped boiling so the solution tank was removed from the grill and put into the cool tap water, and the other tank (now containing condensed water) was placed into the cooler and left with thermometers taking readings at intervals on the inside and outside of the cooler. As can be seen in Figure 4, the temperature of the condenser tank did drop momentarily before evening out to the original outside temperature. The temperature outside the cooler also dropped, apparently affected by the internal temperature change of the cooler (the entire system was contained in a temperature controlled indoor location that would not have provided any external temperature changes). 4.5 Pre-Trip Project Schedule • Project Schedule: 2/9/15 - acquired insulin for prototyping reference 3/9/15 - met with advisor to discuss absorptive cooling 3/26/15 - acquired parts for absorptive cooler 4/1/15 - met with advisor to discuss construction of absorptive cooler 4/13/15 - acquired lithium bromide 4/16/15 - constructed and tested absorptive cooler (test 1) 4/19/15 - tested absorptive cooler (test 2) • Gantt chart: Figure 1 14 4.6 Tools/Materials/Equipment to be Brought from Columbus ● ● ● ● 2 kg Lithium Bromide 5 informational pamphlets 5 USB thermometers 1 infrared thermometer 4.7 Tools/Materials/Equipment to be Obtained in Honduras Absorption Cooler: ● ● ● ● 2 propane tanks per cooling unit (10 total) Tubing to connect tanks 1-2 coolers per unit (5-10 total) Water Cooling Pit: ● PVC Pipe approximately 1-meter long ● Caps for both ends of pipe ● String to retrieve insulin Evaporative Cooling: ● Two clay pots, one bigger than the other ● Sand to go between pots ● Cloth to go overtop 4.8 Limitations of Project Pre-Trip Absorption Refrigeration: ● ● ● ● Functionality Ease of use Repeatability Sustainability Cooling Pit: ● ● Existing soil temperature data Amount of cooling power Evaporative Cooling: ● Functionality in a humid climate 15 4.9 Photos and Figures Photo 1 16 Photo 2 17 Photo 3 [crosleyicyballs.com] [5] Photo 4 18 Photo 5 Photo 6 19 Photo 7 Photo 9 Photo 8 20 Photo 10 21 Photo 11 22 Photo 12 Photo 13 23 Photo 14 Photo 15 24 Photo 16 Photo 17 25 Photo 18 Photo 19 26 Photo 20 27 Photo 21 28 [7] Figure 2.1 29 [7] Figure 2.2 30 [1] Figure 2.3 31 [6] Figure 3.1 [6] Figure 3.2 32 Figure 4 33 Section 5: In-Country Implementation 5.1 Implementation While pre-trip testing focused upon the absorption refrigeration concept, the final iteration of Project Frío centered upon two solutions: an insulin hole that produces its cooling effect using the relatively constant temperature of the ground for use in the rainy season and an insulin pot that produces its cooling effect using evaporation and biweekly water replacement for use in the dry season. Because the viability of each of these solutions relied upon local soil temperatures and climate respectively, relevant testing could be performed only once the onsite portion of the project began. In country, the implementation of these solutions was focused upon obtaining enough data to determine whether or not they were truly effective before handing them off to those who would use them. Once both of the two methods were deemed successful, implementation involved instruction for construction and use to 5 community health leaders. 5.2 In-Country Schedule (Figure 5) May 2015 5.3 Issues Encountered Perhaps the largest issue encountered in Honduras as it pertained to the insulin cooling project was miscommunication. Before the trip, it was understood that the project would involve cooling existing insulin, specifically Humalog injection pens. However, during the trip, it was discovered that nearly no one within the region of service actually had insulin, while some 34 actually did have refrigerators (though their dependability relied on questionable electricity supply). It was the learned that healthcare sources in the region do not supply insulin to people who cannot effectively maintain it at acceptable temperatures. This new knowledge shifted the project from one of digging holes and making zeer pots for individual people to one of digging holes and making zeer pots for effectiveness testing purposes in order to provide people with a way to construct outlets for insulin cooling as a preemptive method to convince healthcare providers to supply it. The insulin project had its own issues with supply when it came to attempting construction of the third solution, the absorption refrigerator. Parts used for testing in the United States, specifically copper tubing and Sharkbite connectors, were not as readily available in Choluteca, Honduras. However, this was not the only reason that pursuit of the absorption cooling portion of Project Frío was abandoned. Despite extensive attempts to produce a working prototype in the days leading up to the trip, the method never reached a high enough level of functionality to justify its pursuit in Honduras. In addition, its cost of implementation was significantly higher than the other two solutions combined (see 6.4 Cost Analysis). Leaving this method behind to pursue the others reduced the cost and increased the amount of schedule slack for Project Frío’s in-country implementation – ultimately allowing the other two solutions more attention and greater chance at success. 5.4 Testing, Results, Assessment, Evaluation (Photo 22: Map of Hole Locations) Testing of the insulin hole involved 5 different holes of approximately 1 meter each in depth. Data-logging thermometers were placed at the bottom and halfway down the tubes, one of which was in the sun, the other in the shade. This, combined with testing different tube widths, led to the determination that the most effective insulin hole was one of 1-meter depth in a shaded area. The difference between tubes of 2” and 3” widths was negligible. While the holes technically functioned in the dry season, they were often only 1 degree Fahrenheit below 35 the top of the acceptable temperature range for insulin. Because the insulin pots are a better alternative in the dry season but lack rainy season efficacy, it is recommended to use the insulin holes as a rainy season solution. The effectiveness of insulin holes during this timeframe is currently undergoing testing; the customer hole, with a thermometer logging the temperature every 30 minutes for the next 11 months, will confirm or refute whether this cooling method is viable for the entire rainy season. Figure 6: First Holes Data Photo 23: Locations of first two holes 36 Figure 7: 2in vs 3in Tube Test Photo 24: Location of Tube Diameter Test 37 Figure 8: 3in Tube at Veronica’s Photo 25: Location of Veronica’s House The hole that was implemented at Veronica’s house is a 3” width hole in the shade with concrete at the bottom to hold it in place. The test above shows the concrete did not negatively impact the cooling efficacy of the hole. 38 Photo 26: Location of Zeer Pots Testing of the insulin pot in Honduras involved evaluating 3 zeer pots over 5 days: one wet with a gourd as its inner container, one wet with a clay pot as its inner container, and one dry with a gourd as its inner container as a control. All three used clay pots as the outer container. The wet clay pot received the best results, functioning within the acceptable insulin storage range into day 4 of testing. The wet gourd pot was less effective, and the gourd rose out of the sand due to its low relative weight and displacement caused by the water. The control pot produced negligible cooling. It should be noted that the zeer pots functioned best at a relatively lower humidity and barely functioned at all during times of high humidity, reaching only 4 degrees Fahrenheit of temperature reduction. Higher humidity (up to above 70%) occurred during the night, so the insulin pot still remained in an effective range during this time. However, in the rainy season, when the days are also humid (reaching above 90% at times, according to average humidity reports [7]), the insulin cooling cannot be recommended for use. 39 Figure 9: Zeer Pot Testings 5.5 List of Supplies/Materials Given to the Customer • 1 Insulin Pot model, including insulin pen for demonstration purposes • 5 Insulin Pot manuals for construction/use • 2 (2” and 3”) Insulin Hole PVC models, including insulin pen for demonstration purposes • 1 Insulin Hole full implementation • 5 Insulin Hole manuals for construction/use • extra string • ~10 ft each of extra 2” and 3” PVC pipe Section 6: Post-Trip Results 6.1 Issues Encountered In hindsight, several issues arose during the trip that became day-to-day obstacles requiring adaptive attention more than prior planning. One of these issues was transportation. With 2 large groups, one of which contained 3 smaller groups – all requiring transportation for their own purposes from a supply of 3 vehicles – it became necessary to make compromises when traveling. Often, this meant traveling to somewhere that was not relevant to the project so that another group could accomplish a 40 portion of their own project. This reduced available work time and required patience between groups. Another issue that set the tone for the trip and required adaptation was that people in the area did not have an understanding of diabetes and thus did not even know they needed insulin. Further diluting the project was the fact that some people had refrigerators. This meant that not only did they not have the problem given by the project problem statement – they also had a solution to that non-existent problem. Getting past this frustration with the project was a major hurdle in terms of focusing upon what needed to be accomplished, if anything at all. Proceeding past this issue enabled the project to reach its final goal of instructing community leaders in how effective devices could be built for those who need them. Are these solutions even actually any better than a refrigerator that has lost power but still is maintaining a temperature that is low enough. 6.2 Objectives Achieved All scope of work objectives listed in Section 3.5 Specific Itemized Objectives (page 9) were achieved except that the absorption refrigerator was not completed. 6.3 Sustainability and Ownership Both the hole and pot are sustainable solutions in that they both require little to no energy or resource consumption. The hole uses only the ground as its cooling source, while the pot uses water that requires replacement at a rate of less than 1 gallon every 3-4 days. The water does not need to be clean. Leaving the health promoters with instructional manuals, models, and information on how and when to use each device also perpetuates sustainability of both the hole and the pot. Ownership will be particularly strong for this project if it leads to people acquiring insulin and thus becoming healthier. Knowing they were only able to obtain medicine from healthcare providers due to the cooling confidence created by their new devices, people will likely see their insulin pots and holes as vital instruments for their health. The cultural appeal and ease of use of the devices will also promote ownership. The holes require no maintenance and use a process that resembles that of a well, which is used prevalently as a daily water source in the region. The pots are similarly uncomplicated and also provide a cultural appeal in that they are decorative in nature while still providing practical utility. 6.4 Cost Analysis Total R&D Cost: $751.46 The most expensive research and development arose from the pre-trip expenditures related to design of the absorption refrigerator. Because the hole and pot required in-country testing based upon soil temperatures and climate differences, most pre-trip design went into producing the absorption refrigerator – which both could be tested in the United States and could not be completed in just the two weeks in Honduras. 41 Therefore, the high total R&D cost of the project is not reflective of how affordable the two chosen solutions actually are. While the absorption refrigeration research used $456.93, the hole and pot required only $17.72 and $10.58 respectively. The cost of implementing one of each was even lower than that. From this, it can be seen that the most effective solutions in terms of function were also the most cost effective solutions – which is the ideal scenario. Table 2: Absorption Refrigerator R&D Date Item Quantity Cost of Quantity $6.99 Purpose 1 Unit Cost $6.99 3/26/15 Propane tank (2 pack) 3/26/15 1 $2.79 $2.79 removing Sharkbites Ace Hardware 2 $16.99 $33.98 connector tube for tanks Ace Hardware 1 $3.49 $3.49 connector tube 3/26/15 Sharkbite remover clip (3/4") Sharkbite water heater connector (3/4" x 18") Copper piping (3/4" x 12") Sales tax 4/13/15 Cooler 1 Ace Hardware Ace Hardware Target 4/13/15 Sales tax 4/29/15 Thread seal tape 4/29/15 Sales tax 5/4/15 Sharkbite Connector (3/4" female) Sharkbite Elbow (3/4" female) Sharkbite remover clip (3/4") Copper piping (3/4" x 12") Sales tax 2 $9.49 $18.98 2 $12.99 $25.98 1 $2.79 $2.79 Connecting copper piping to threaded tanks New absorption fridge design Removing Sharkbites 2 $3.49 $6.98 Connector tube 5/7/15 Sharkbite couple (3/4" female) 1 5/7/15 Sales tax 4/8/15 Lithium Bromide, 99%, PU 1KG 3/26/15 3/26/15 5/4/15 5/4/15 5/4/15 5/4/15 Place Purchased Ace Hardware Cooling vessel $3.55 $12.94 $12.94 Insulated refrigerator $0.97 1 $0.99 $0.99 Target Sealing thread on tanks $0.08 Ace Hardware Ace Hardware $4.11 $9.99 $9.99 Couple to replace valve apparatus and connect copper pipes $0.75 3 $107.19 $321.57 TOTAL: Absorbant for absorption refrigerator Ace Hardware Ace Hardware Ace Hardware Ace Hardware Ace Hardware Ace Hardware Ace Hardware Fisher Scientific $456.93 Table 3: Hole R&D Date Item Quantity 5/10/15 2" PVC Cap ("Tapón") 4 Unit Cost $0.16 Cost of Quantity $0.64 42 Purpose Caps for PVC tubes Place Purchased Promaco 5/10/15 Rope stuff ("Pita Rollo") Sales tax (15%) 1 1 $6.00 $6.00 Tube for hole in ground Promaco 5/15/15 3" PVC pipe (20' long) 3" PVC cap 1 $0.24 $0.24 Cap for tube Promaco 5/15/15 Sales tax (15%) 5/18/15 Enjoy Kiwi 2 $0.37 $0.74 5/14/15 1/4" x 3" Steel Nipple Sales tax (15%) 1 $0.76 $0.76 1/4" x 3" Steel Nipple 3" PVC Cap ("Tapón") Sales tax 1 $0.76 $0.76 1 $0.24 $0.24 2" PVC pipe (20' long) 2" PVC cap ("Tapón") 1/4" x 2" Steel Nipple Sales tax (15%) 1 $3.59 $3.59 Tube for hole in ground Promaco 2 $0.15 $0.30 Caps for tube Promaco 1 $0.56 $0.56 Handle for 2" cap on cooling tube Promaco 5/10/15 5/15/15 5/14/15 5/18/15 5/18/15 5/18/15 5/18/15 5/18/15 5/18/15 5/18/15 $1.68 $1.68 String to retrieve insulin from bottom of hole $0.34 Promaco $0.94 Promaco Vessle for 2" PVC pipe design Handle for 3" cap on cooling tube $0.11 Maxi Despensa Promaco Promaco Handle for 3" cap on cooling tube Cap for tube Promaco Promaco $0.15 Promaco $0.67 TOTAL: Promaco Promaco $17.72 Table 4: Pot R&D Date Item Quantity 5/12/15 Small clay pot 5/12/15 Hollow, dried gourd Large clay pot 5/12/15 Cost of Quantity $4.14 Purpose 2 Unit Cost $2.07 2 $1.15 $2.30 Inner pot for zeer pot 3 $1.38 $4.14 Large pot for zeer pot TOTAL: Inner pot for zeer pot Place Purchased Variedades "ARTEAGA" Variedades "ARTEAGA" Pulperías in Las Cuchillas $10.58 Table 5: General R&D Date Item Quantity Cost 4/7/15 2 5 5/7/15 EL-USB-2-Plus Data Logger 3.6V 1.2AH Lithium 1/2AA battery Sales tax 5/14/15 Wall thermometer 3 5/14/15 Sales tax (15%) 5/7/15 TOTAL: Purpose Place Purchased $112 Total Cost (of transaction) $224 Data collection $6.99 $34.95 Replacement batteries for data logger thermometers DATAQ Instruments Interstate All Battery Center Interstate All Battery Center DeTodo $2.44 $1.61 $4.83 Included in price $266.22 43 "Executive decision" by project leader DeTodo Cost of Installed Technology (Note: Full prototypes of the hole and pot were only implemented in Honduras, so the cost of installed technology refers also to the replication cost in Honduras) The cost of implementing one of each type of device is calculated below. Though PVC tubes are often sold as an entire 20-ft unit, the cost was prorated to that of a 45-inch unit. The cost of PVC cement and wire were left out of the calculations for the insulin hole, as these were acquired free from the sponsor and are used in small amounts that are dependent on user preference. In addition, these two particular components can be used to construct a multitude of insulin holes. The insulin pot does not include costs for sand, water, or the towel. These components are readily available in the area. The sand does not need to be of a particular type, the water does not need to be clean, and the towel can be any rag or similar cloth that is no longer fit for use in other areas of life. Table 6: Cost of Insulin Pot Item Quantity Large Clay Pot Small Clay Pot Sand Water Rag/Towel Total 1 1 1 1 1 Cost Per Unit (Lempira) 30 Lempira 45 Lempira N/A N/A N/A 75 Lempira Table 7: Cost of 2” Insulin Hole Item Quantity 2"x45" PVC tube 2" PVC Cap ("Tapón") 1/4"x2" Steel Nipple ("Niple”) Rope/String (full bundle) Enjoy (plastic bottle) Wire Cement Cost Per Unit (US Dollars) $1.38 $2.07 $3.45 1 2 1 Cost Per Unit (Lempira) 14.64 3.19 12.17 Cost Per Unit (US Dollars) $0.67 $0.15 $0.56 1 36.52 $1.68 1 2 Dependant on size of hole 8 unknown unknown $0.37 unknown unknown 89.3665 $4.12 Total(+ 15% sales tax) 44 Table 8: Cost of 3” Insulin Hole Item Quantity 3"x45" PVC tube 3" PVC Cap ("Tapón") 1/4"x3" Steel Nipple ("Niple") Rope/String (full bundle) Plastic Bottle (Pepsi or otherwise) Wire Cement 1 2 1 Cost Per Unit (Lempira) 24.46 5.22 16.52 Cost Per Unit (US Dollars) $1.13 $0.24 $0.76 1 1 36.52 ~ 20 $1.68 ~ $1 2 Dependant on size of hole unknown unknown unknown unknown 124.131 $5.81 Total(+ 15% sales tax) 6.5 Conclusions The main output of this project is distinctly seasonal two-fold solution based on the data acquired during this trip. First, holes can maintain a steady temperature for insulin storage in southern Honduras, and will be especially effective in the cooler rainy season (pending the further data acquisition that has been set up for this time period). Second, though they will not be dependable in the rainy season, zeer pots are an effective way to store insulin during the dry season, when the holes are closer to the fringe of efficacy. The utility of these solutions is that they provide a preemptive measure for diabetics to show healthcare providers who are currently not supplying them insulin (on the basis of a lack of confidence in their ability to keep it at an effective temperature) that they now have methods to reliability store it for up to a month. This new development provides the basis of a path for diabetics to begin receiving insulin on a monthly basis. 6.6 Recommendations For the results of this project to be allocated to their greatest potential, it is recommended that Larry and Angie use the information in this report toward their grant work in regard to obtaining insulin for distribution to diabetics in the area. This approach likely has a higher probability of success than convincing healthcare providers to accept the findings of a single report when determining their insulin distribution practices and decisions. However, Angie’s connections in the medical community of Choluteca should be used to their greatest potential in utilizing these findings to get people the medical care they need. It is also the recommendation of this report that the health promoters who have been instructed in the construction of the insulin holes and pots also communicate to people in the region the importance of getting treated, and that they are even sick in the first place. They must also know that implementing these devices will increase their chances of treatment. Convincing diabetics in the region to construct these solutions preemptively will strengthen the case for obtaining insulin via grant. For the specific use of the zeer pot, it is recommended to monitor it for effectiveness whenever possible, which can be done by putting a thermometer in the inner pot and checking it 45 intermittently. Because the dry season can also reach high humidity at times, it is beneficial to ensure the pot is still functioning well enough during those periods. Also, as is explained in the instructions, it is important to re-saturate the sand every 3-4 days for best results. For implementation of the hole, it is beneficial to pour a small amount of concrete into the bottom of the hole before placing the PVC tube. This securely keeps the tube in place. Another recommendation is to monitor the effectiveness of the PVC cement sealant and to use caulk or another sealant if the PVC cement proves insufficient. Caulk was used on the final test hole, and its effectiveness will be revealed upon collection of the data logger in 11 months. Section 7: Resources 7.1 Works Cited [1] "Build an evaporative refrigerator - no moving parts, no electricity." RebuildingCivilization.com. N.p., n.d. Web. 21 Apr. 2015. <http://rebuildingcivilization.com/content/build-evaporative-refrigerator-no-movingparts-no-electricity>. [2] CrosleyIcyball.com. N.p., n.d. Web. 23 Apr. 2015. [3] "Information Regarding Insulin Storage and Switching Between Products in an Emergency." FDA.gov. N.p., 10 July 2013. Web. 23 Apr. 2015. <http://www.fda.gov/Drugs/EmergencyPreparedness/ucm085213.htm>. [4] "Insulin Storage and Syringe Safety." Diabetes.org. American Diabetes Association, 7 June 2013. Web. 23 Apr. 2015. <http://www.diabetes.org/living-with-diabetes/treatment-andcare/medication/insulin/insulin-storage-and-syringe-safety.html>. [5] "Methods of Alternative Refrigeration." Provident-Living-Today.com. N.p., n.d. Web. 21 Apr. 2015. <http://www.provident-living-today.com/Alternative-Refrigeration.html>. [6] N'Tsoukpoe, Kokouvi Edem, Daniel Yamegueu, and Justin Bassole. "Solar Sorption Refrigeration in Africa." Elsevier (2014): 319-21. Print. [7] WeatherSpark.com. Cedar Lake Ventures, n.d. Web. 21 Apr. 2015. <https://weatherspark.com/averages/32508/Choluteca-Honduras>. 46 Section 8: Acknowledgements 8.1 Acknowledgements This project was supported by our instructors Roger Dzwonczyk and Mariantonieta Gutierrez-Soto and our technical advisor, Dale Andreatta. Their assistance helped immensely throughout the research, design, and implementation process. In-country we were additionally aided by Larry and Angie Overholt. Section 9: Appendix 9.1 Team Agreement Project Frío Team Agreement Identifying the project: • Term of contract: 1/27/2015-5/28/2015 • Team Members and contact info Cameron Duffner (260) 515-3757 Duffner.9@osu.edu Major: Industrial & Systems Engineering Minor: Spanish Charlie Goettler (614) 949-2362 Goettler.5@osu.edu Major: Civil Engineering Minor: Spanish Teamwork Criteria: 1. Team Leadership Roles: • Cameron Duffner: CCO (Chief Communications Officer), Primary documenter/scribe/recording secretary. • Charlie Goettler: CFO/Accountant, Presentation Coordinator. • Shared: Photographer, videographer. 2. Preferred Methods of Communication: • Email and phone communications. • Information will be stored on a Google Drive. 47 • Project timeline will be created and edited with Clarizen. 3. Meeting Guidelines: • At the end of each class session, partners will define tasks required for before next class session. • Meetings will be arranged at times that both partners are available. 4. Participation: • Project partners will put forth effort to complete all tasks and participate as much as possible. 5. Responsibilities: • The project is a partnership, so both members are equally responsible for completing the project. • Team members will hold each other accountable during all aspects of the project. • The Chief Communications Officer will be in charge of communicating with WGM in Honduras and anyone else involved in developing the project • The Chief Financial Officer is responsible for maintaining financial records of project expenses. • The Presentation Coordinator is responsible for assembling any digital presentations or other presentation aids required for the project. • The Primary Documenter is responsible for submitting documents on time and assembling any written reports required for the project 6. Approaches to conflict resolution: • Conflicts will be resolved internally on a flexible, case-to-case basis. • For conflicts that cannot be resolved internally, group members will seek help from one of the instructors to serve as a mediator. 48 7. Approaches to problem solving: • Both team members will have equal opportunity to solve a problem. All ideas will be considered. • After all possible solutions have been proposed, team members will discuss further options for solving the problem. 8. Approaches to decision making: • Decisions will be made as a team as often as possible. • In the case that team members cannot agree on a decision, efforts will be made to try both ideas given that the circumstances permit trying more than one. 9. Signatures (dated) of all team members, thereby agreeing to abide by this contract Cameron Duffner (1/27/15)________________________________________________________ Charlie Goettler (1/27/15)_________________________________________________________ 9.2 Project Proposal Project Frío Project Proposal Date: 1/29/2015 Identify the customer: Honduran Diabetics Team: Members Roles Major (Minor) Phone Email Cameron Duffner CCO, Primary Documenter Industrial & Systems Engineering (Spanish) (260) 515-3757 Duffner.9@osu.edu Charlie Goettler CFO, Presentation Coordinator Civil Engineering (Spanish) (614) 949-2362 Goettler.5@osu.edu 49 Caretakers: Angie Overholt Caretakers/guardians of diabetics who require assistance Background: Insulin is a hormone produced in the pancreas that regulates blood sugar levels. Diabetes, a disease that is characterized by blood sugar imbalances, is treated with synthetic insulin injections. In order to be effective, the insulin should be kept between 59 and 75 °F. According to the American Diabetes Association, insulin lasts for one month at room temperature (≈ 72 °F), but should be stored in a refrigerated environment if the intended use range is longer than one month. According to Weather Spark records from 2007 to 2012, the average temperature in Choluteca, Honduras over the course of a year normally varies from 73 to 98 °F, and is usually higher than room temperature. Therefore, at any given time, Honduran diabetics are statistically most likely to be storing their insulin at higher temperatures than are recommended for optimum effectiveness of the treatment. Problem statement: Injected insulin is an effective treatment for diabetes. However, insulin is heat sensitive and must be stored between 59 and 75 °F for its long-term preservation. People in rural Honduras often do not have a means to keep insulin cool and the compound can become prematurely inactive and ineffective in controlling blood glucose levels. Goal of the project: Design and implement a passive insulin preservation (cooling) technology at a low cost and complexity. Scope of work/specific objectives: ● ● ● ● ● ● Design a cooling mechanism that can contain insulin between 59 and 75 °F. The mechanism must be inexpensive. The mechanism must be able to contain 3 Humalog injecting pens. The mechanism must be composed of parts available in Honduras. The mechanism must be easy to use and contain instructions for build and use. The mechanism must be durable and usable for extended use. Testing: Testing will be implemented to determine how cold of an environment can be created, how long the lowest temperature can be retained, and how often water and other materials will need to be replaced. Trials will also be performed to discover how many vials of insulin can effectively be cooled to an appropriate temperature at one time. Testing would additionally include determinations of which materials or collection of materials would best serve the design in terms of insulation. Specifically, testing will involve repeat temperature readings of the insulin within the cooling unit, water saturation testing at the point in which the device begins to lose effectiveness, thermal insulation testing on different materials of varying specific heat values, as well as analysis of cost versus functionality. Deliverables: The design process for this solution will include a design and implementation of cooling units, instruction manuals for build and use (translated to Spanish), a cross-sectional diagram of the cooling unit, a parts list (including prices and where they can be found in Choluteca, also translated to Spanish), and a thermometer so the customers may monitor the temperature of their device and insulin. A mold for producing components of the device may be supplied as well. Paints and brushes may also be provided for children to paint the device. 50 Plan for partnering, end user involvement, training, and education: In order to create a fair trade community partnership, any knowledge about diabetes and proper insulin storage that is gained throughout the design process will be passed on to the Honduran diabetic community. User manuals, diagrams, and other informational literature will be made and translated to Spanish prior to departure to Honduras. Upon arrival, both group members will integrate their knowledge of the Spanish language to further vocally communicate information. This will aid in working alongside, teaching, and learning from the citizens of Choluteca. The making of the device will serve as involved training and education for its construction and use. Plan for sustainability and ownership: The ideal plan is for the cooling unit to be made entirely out of materials that would be readily available to Honduran diabetics at a low cost, allowing for sustainability of the project, especially for when replacements are eventually required. Establishment of ownership of the cooling project will be integrated through partnered construction of the device components between the designers and customers. A single person within the customer community could be assigned as a designated parts replacement and maintenance authority. Another way that ownership could be established is by proving its value to the customer and teaching proper maintenance. The paints for the children will serve to create ownership and involvement. 51 9.3 Instruction Manuals 52 53 54 55 56 57 58 59