Modular Storage Boiler Manufacture
Project challenges
The heat cell design comprises several large component parts which need to be low cost and scale-able. Manufacture of these components at the anticipated production volumes requires the utilisation of standard manufacturing techniques where possible and innovative ways to manage the materials handling. Novel processes were also considered through the process to ensure that the parts were being manufactured in the most cost-efficient manner and that new technology was not being ignored.
The challenge presented to the MTC was to develop an efficient and lean method-of-manufacture and assembly with a strong focus on automation.
Business challenge
Sector
Power & Energy
Technology or capability
Industrial Transformation
The Challenge
Caldera has developed storage boiler technology which provides on-demand heat for industrial applications. The system is designed to provide energy storage from local renewable energy sources such as solar. The heart of the system is the ‘heat cell’, comprising blocks of Caldera’s patented thermal storage materials, which are enclosed in a vacuum-insulated chamber. The modular design of the system enables a storage capacity up to 100MWh with no combustion, hazardous materials, and few moving parts.
The heat cell design comprises several large component parts which need to be low cost and scale-able. Manufacture of these components at the anticipated production volumes requires the utilisation of standard manufacturing techniques where possible and innovative ways to manage the materials handling. Novel processes were also considered through the process to ensure that the parts were being manufactured in the most cost-efficient manner and that new technology was not being ignored.
The challenge presented to the MTC was to develop an efficient and lean method-of-manufacture and assembly with a strong focus on automation.
During the project the heat cell design was modified in response to customer requirements and captured the MTC manufacturing recommendations. The latest iteration of the heat cell design favoured a lower volume production of larger single 4MWh heat cells, offering cost-effective and scalable manufacturing which was key to Caldera's strategy for a rapid global roll-out.
The deliverables for this project were achieved, with an optimised method-of-manufacture and assembly sequence. This included determining suitable resources e.g. capital plant & equipment, tooling, fixtures,, lifting strategies etc., as well as the equipment capacity required to meet the production volume requirements.
MTC's Solution
- Design Review & Design for Manufacture and Assembly (DfMA): The MTC identified various opportunities to optimise the design of the heat cell to enable efficient manufacture and assembly of the product at increasing volumes.
- Assembly Sequencing: A production-appropriate assembly sequence was developed for manufacture & assembly of the major heat cell components, along with on-site installation. This was illustrated through a detailed process flow map. The approach proposes manufacture of heat cell components within a dedicated manufacturing facility, or with sub-contract specialists, and a final on-site assembly to complete the heat cells. This allows for rapid deployment of large & heavy storage boiler systems.
- Welding Process Selection: Multiple candidate welding processes were explored for each of the heat cell components. The team used standard methods to down-select optimal welding processes for each operation, and proposed corresponding design optimisations to reduce manufacturing and assembly times.
- Supplier Identification: The team identified & contacted a range of suitable equipment manufacturers in the UK and Europe and obtained representative quotes for provision and integration of equipment. This enabled the generation of estimated capital costs for a future production facility, as well as supporting make vs. buy decisions for certain components of the heat cell system.
- Capacity Analysis: The MTC conducted an extensive capacity analysis by developing a detailed Bill-of-Process capturing a range of key metrics e.g. process time, capacity requirements, and equipment footprint. The exercise was focused on achieving a defined TAKT time for heat cell components, as well as defining the footprint and CapEx requirements for a future manufacturing and assembly facility.
It was a pleasure to work alongside a professional and organised team at the MTC, especially with the additional pressures of customer led changes to the design as we moved through the project.
Guy Winstanley, COO, Caldera
The Outcome
- Cross-functional team at MTC harnessing skills in manufacturing, assembly, welding, and automation
- Heat cell design(s) were optimised through application of DfMA principles, enabling a leaner and more efficient assembly process.
- Production-appropriate manufacturing and assembly sequencing was proposed for each key heat cell component.
- MTC harnessed relevant expertise in welding & automation to identify suitable methods-of-manufacture for heat cell components.
- MTC liaised with its network of industry contacts to identify suitable partners for manufacture and assembly.
- MTC utilised expertise in capacity analysis to generate key metrics for volume production: process time, facility footprint, and CapEx.
Benefits to the Client
- Optimised heat cell design(s) with corresponding process times for manufacture & assembly.
- Increased design features considering DfMA in the manufacturing processes and final assembly.
- Detailed manufacturing and assembly sequence for the heat cell design(s), with a breakdown of required equipment and manufacture/assembly ‘stations’.
- Development of the equipment and facility footprint requirements to achieve desired volume production targets
- Development of an appropriate lifting and handling strategy for the large heat cell components.
Since its establishment, the MTC has developed and applied capabilities, methods, and technologies to facilitate the industrialisation of emerging technologies. Through collaboration with Caldera on their innovative heat battery technology, the MTC has expanded on their existing design & manufacturing approach, and developed a design for an appropriate production phase manufacturing system to reduce time to market.
Thomas Driscoll, Technology Manager, The MTC
