Javier Diaque Final DVR submission

KAUIL STOVE. “TOOLS, STOVES AND ALTERNA-TIVE COOKING FUELS FOR INDIG-ENOUS COMMUNITIES IN MEXICO.”

JAVIER DIAQUE SUAREZINDUSTRIAL DESIGN

RMIT UNIVERSITY MAJOR PROJECT

A:

Mi Papá por creer en mí,Mi Mamá por impulsarme,Mi hermana por apoyarme.

Gracias.

Contents.

Designer Bio. * Who I am. -1- * Where I am moving to. -1-

Introduction. -2-

Background/ historical review. -3-

The context. -4-

Facts. -10- Design methods overview. -11- *Mind maps. -12- *Related relevant works. -13- *Surveys -15- *Experimentation -18- *Sketches -19- *Photos Analysis. -23-

Problem Statement. *Recognition of need. -25- *Defi nition of the problem. -28-

The project. *Summary -30- *Conclusion -31- *Summary of work compeled. -31-Learner testimonial. -32-

References. -33-

A woman cooks and prepares the food for the family. Breathing the toxic smokes released indoors by the burning timber. Bending down into an uncomfortable and tyring position for her back.

Designer Bio.

Who I am. My name is Javier Diaque, I was born in 1985 in Mexico, a country of contrast, a heavy cultural baggage and an amazing historical background.At the age of 4 I left my country with my family for 3 years, because of my fathers´ job. We moved into Canton Ohio, a small town in the north of the United States. This gave me the opportunity to grow up in the backyard, outdoors and all the possibilities that the fi rst world can offer to a kid. At the age of 7 we went back to Mexico city, one of the biggest cities in the world, fortunately I moved into a place where I could still have a chance to spend my time and childhood outside from home, in an open air environment and with friends… getting scars and muddy clothes. Since then I’ve always have been interested in out-door activities, from building ramps for the bike and skateboard, devices for climb-ing the trees, to testing them. As well, I’ve been lucky enough to explore places away from the city that allowed me to do adventurous activities exploring nature and the activities we can do with it, gaining a strong interest and concern for the environ-ment.On another hand, since I was a kid I grew up surrounded and driven into a humani-tarian, emotional artistic and creative environment, which has been guided and en-forced by my mother who is dedicated to it. This has taken me to gain an interest towards the social scene. I consider myself a sensitive and empathic person; this is refl ected through my human relationships. My family has always shown a big inter-est in social responsibility and that has planted a thought and strong feeling in my life about working with people, helping to improve others life and taking advantage of the opportunities life has given me to help others. Since young I have always been involved in social service programs back home, going to indigenous communities and working with them in different ways, such as teaching computing to children whose access to a computer is not as easy. I have a competitive personality and have always been committed to challenges, community ones and individual ones. I have always liked to be different between the others and stand out for my abilities, I like to propose innovative ideas and confront in able to get out of the “normal” parameters and the already established thoughts, and this has made a rebellion character in me.

Where i am moving to.Even though I like stability, I am a person who constantly is looking for changes in life, such as schools, cultures, countries… this has given me an ability of quick adaptation towards different circumstances. As well, I think it has made me sensitive towards people’s different styles and ways and given me an ability to approach and intimidate more with people. Even though I am quite easy going I am really loyal towards what I believe in. I have become a person who is committed towards his passions, but as well a dream-er and idealist, an adventurer looking for what has not been written yet.I am a creative thinker and like to know and understand what I am doing. I am good recreating or evolving and iterating from an original idea, concept or situation.I consider myself a good advisor because I am good at listening to people and detect-ing problems, I am perceptive and very analytic and introspective, and I like to have an objective point of view towards situations in order to get a bigger perspective and panorama. I am a theorist in some aspects but like to see the effects of what I am doing which makes me a “hands on” and practical person more than a methodologist. I really believe in our natural mortise abilities and like to use them, more than technological ones. Therefore, my aim is to be able to aproach peoples lives throughout my design skills in order to make it easier or better in any aspect. I will be working or designing for indigenous communities and my interest is to have a positive impact in their lives by bringing in simple designs that can create an op-portunity for them to come out of poverty.it is a heavy challenge, but a satisfactory and life experience opportunity.

-1-

Introduction.

My fourth´s year project is about engaging with the indigenous communities from the south east of Mexico, that are established in the mountains and in many cases away from the towns and villages and do not count with many of the main services we take for granted in our everyday lives such as water, adequate sanitation, electricity and medical services. The objective is to use design in their everyday’s life in order to improve their standards of living.

I will be researching through different sources, about their lives in order to identify design solutions within the problems they confront every day. These indigenous communities live in the toughest, most rudimentary and poor con-ditions of life, where they struggle every day with no medical access, limited food because of their really low income. “According to statistics from the world bank and other NGO´s their income is lower than 2 dollars a day” Smith [2007].

This project is more than just a challenge, it has become an opportunity to fi nd new ways of working, taking advantage of the communication facilities that we have these days. It is hard to think you can design something for someone without knowing him/them, contacting the client, or immersing your self into the fi eld you are trying to tackle. Therefore, this project not only is driven by my knowledge or awareness from the past visits and continuous contacts I have experienced with these communities, but also using internet and other facilities like emails and video conferences, to be in contact with a group of friends and an organization called “No Puedo Callar!” (I Cannot Be Silent!). Which are in constant contact and working together with these communities.

The research and information gathered together in this document, is a com-pilation of the work and investigation I have done, case studies, surveys ap-plied, testimonials form people in these communities and the voice and re-search from my friends over there.

All this, with the purpose of creating a real panorama and scene of what is going on and what the opportunities are as a designer, to create or design something that has a positive change and impact in their lives.

I believe there is an opportunity and a need for stoves designed to be made with the local materials. My aim is to reduce the amount of fuel needed for cooking, that generate alternative possibilities for healthier and more sustain-able cooking fuels and devices to produce it, the stove should also include a chimney or escape for the fumes produced in order to reduce these health is-sues. The design will be required to reduce or prevent completely, if possible, the accidents caused by the fi re, all of these of course including ergonomic and design factors that suit the customer which in this case are the Mexican indigenous communities.

-2-

Framed by the Isthmus of Tehuantepec, the Sierra Madre Oriental and the Sierra Madre Occidental, is this rugged region of mountains, highlands, val-leys and tropical rainforests.

In general you fi nd a humid, tropical climate. Rainfall can average more than 3,000 mm (120 in) per year. The abundant rainfall of the high valleys is used for fi elds of corn, beans and other agricultural and ranching products. Rainfall decreases moving towards the Pacifi c Ocean, but it is still abundant enough to allow the farming of bananas and many other tropical crops.

Separated by the mountains, this region has the highest concentration of in-digenous people among the country; People who came here on foot a long time ago. There are many indigenous communities which are culturally di-verse themselves, and that don’t even speak Spanish as their fi rst language. Within the blood of these Mexicans run the civilizations of Olmec and Maya and Aztec. All share the fact that they live from the land.

Background/ Historical Review.

-3-

Context.

These communities live in little huts “casitas” made from materials com-monly found around them like “techo de laminas” sheets of metal as a roof and pieces of wood and ply, with the most basic structures and spaces inside for a whole family to live in.

They lack a basic physical infrastructure, with little clean water or paved roads, poor sewage systems (if any), no local schools or governmental sys-tems, and other serious problems.

Many of these families get their income through agricultural products such as corn which they sell for $3.50 pesos per kg which is more or less $30 cents of a US dollar, coffee for $19 pesos kg ($1.9 US dollars), beans, honey and some few from animals which they rise and sell once they are grown up. They sell a goat for about $600 to $700 US dollars. These prices are not competi-tive to the bigger agricultural corporations, and since their income is so low, many family members have to migrate to the cities and the U.S. to be able to bring in more money.

These communities use wood, charcoal or dung for their cooking and heat-ing needs, “and while the total energy demands of the developing world are much smaller than in industrialized regions, the dependence on these biofuels as an energy source has dramatic health, economic, and environmental con-sequences” -Amy Smith [2007], Simple designs that could save millions of children lives-.

-4-

Dirt road to “Chorros” one of the communities in Chiapas.

Families with many children, a low income, and small indoor places.

-5-

A typical “casita” made out of wood and “techos de lamina” that shelter the families.

-6-

Mother and Daughter outside of their “casas”, where they realize part of the agricultural work.

-7-

A little kid guards his humble home. cooking tools, pots and pans hang from the walls inside, leaving some space inside to move around.

A whole family who relies on wood burning as an energy source for cooking and heating. More than a quarter of their income is spent on wood.

-8-

Facts.

Extremely poor conditions, These families live with lessThan $2 USD. a day.

No easy access to the main services, such as water, electricity, or health serv-ices.

They live from their agricultural products, such as corn, coffee, honey, fruits and animals like goats, cows and chicken.

They use wood to meet their energy needs, such as cooking and heating.

The dependence on timber as an energy source has dramatic health, econom-ic, and environmental consequences.

In the world, the leading cause of death in children between the age of 1 and 5 is not malnutrition, diarrhea, or malaria, but respiratory illness, caused in large part by breathing smoke from indoor cooking fi res. “PovertyNet, [2006] Understanding Poverty“.

Above, the mothers bring water to their homes from a long way out. Bellow, a cow that provides food and income from its products, for the families

-9-

A young boy and his machete bringing the timber home for his familyThe kids gathered together to heat up during the cold nights. Girls breathing smoke from the fi re.

-10-

Design Methods Overview.

This project has been driven by different methodologies applied in order to obtain the best result possible.it includes: * Case studies: this allows me to know what has been done, who are the competitors and analyze the market position. This gives me the chance to use the information obtained with other similar projects. Analyze what has been succesfull and what has failed, what could have been improved to come up with a succesful design. * Understanding the social group: in order to design I have to be aware of who is the customer to fi t their necestities, this will include read-ing relevant literature and communicating with these people through mails, friends who are constantly visiting the communities and the organization “No Puedo Callar” through internet. and video conferences. * Quantitative: a survey applied in the communities, to have accurate information of the context and sensible to the problem. Information gathered through cuestionaries fi lled and sent by people in these communities. * Experimentation: recreating scenarios, getting in context and im-mersing myself in the process of cooking and charcoal briquettes making. * Concept Development: sketches, mind mapping, representation of different scenarios, idea generation, analyzing photos,z brainstorming, model making and rapid prototyping, turning this into an iterative process that feeds the design.

-11-

design

stoves/ovensaternative cooking fuels

tools for charcoal production

tools for agricultural products

local materials

local manufacturing process

return on investment

income generating

affordability

cultural acceptability

available manufacturing capacity

strenght and durability

ease of instalation and use

portability

ergonomics and safety

energy - efficiency

environmental sustainability

succsessful outcome

design

idea problem identification research

problem statement

case studies

understand social group.

qualitative/quantitative data.

specifications and constraints

develop concept

sketches model making iterative process

final design and manufacturing.

product outcome

Process maps.

-12-

Related relevant works.

Fuels from the fi elds: Amy Smith.Creating alternative cooking fuels from their agricultural waste such as corn and other materials.This is a project conducted by Amy Smith, an MIT engineer who has de-veloped a method to produce charcoal briquettes out of sugarcane and other agricultural wastes.The dried bagasse is burned in a kiln, carbonized, mixed with a binder and compacted using a press to turn into briquettes. This technology is great since it reduces the fumes created by burning timber, but the problem is that the process is not intuitive, therefore it needs to be dif-fused and taught to each community. Amongst this, is the fact that you need the tools (kiln, press), which many communities don’t have or cannot manu-facture. A new technology is still being developed by using corncobs, which do not need further processing after burning.It has been used in Haiti, Ghana, Brazil and India.

Kenya Ceramic Jiko.This is a portable charcoal stove which, with proper use and maintenance, can reduce fuel consumption by 30-50%, saving the consumer money, reducing toxic gas and particulate matter, and resulting in better overall health for the user. The stove is used now in many urban homes and a lower average in rural homes in Kenya and it is spreading along in other African countries.Materials: ceramic and metal.This is a good design but the manufacturing process is not available to rural communities, it still creates toxic gas emotions for the user and does not suit traditional or conventional cooking styles from some places.

-13-

Fuel Briquettes.The briquettes are made out of the agricultural waste, compressed in a press and further on let to dry for days in the sun. once they are dry, they are used instead of wood. This has great results, not only in health issues by not re-leasing toxic smokes, but it also becomes an opportunity for the families to generate an income by selling these. This is being spread through out com-munities in Africa and Central America, the problem is that the user needs a press to be able to produce them.

Solar Dish Kitchen.This was designed by the University of Texas and University of Washington for two informal poor urban settlements in Mexico. It is built from bicycle parts, and small vanity mirrors which concentrates the energy of the sun on a pot or stove in the kitchen. The problem is that it relies 100% on solar energy which does not suit the geographical conditions of the communities I am working with; besides, the design is quite big and heavy, not easy to build and install.It uses aluminium, steel and mirrors. It has been applied in Mexico and India

Peterson PressThis press has been designed to compress the carbonized agricultural waste in order to produce charcoal briquettes. It is used in many communities already but the manufacturing process is still not available for rural communities, besides, it is big, heavy and not intuitive.

Onil Stoves.These stoves are designed and applied in communities un central America, their design includes a chimney and a semi closed chamber to concentrate the heat and guide the smoke out from the house. It allows families to do their traditional cooking, but still crashes with some cultural facts. The proc-ess to make them is not quite clear to the communities, therefore people are needed to come and explain or aid the construction process.

-14-

Surveys.The following are a series of questions and simple data that will be useful for the research, documentation, planning process for the project, which aims to identify the problems within these communities, and generate ideas and possibilities of design in order to improve the life quality, health, economi-cal and environmental issues in the communities, bringing the possibility of sustainability.It is important that they are fi lled with the people of the communities, this way it does not become the perceptions of an outsider, but the voice of who lives these problems and limitations every day.If it is possible, complement the information gathered with photos and video clips. Apply this survey with different persons within the community, e.g. children, young people, middle aged and the elder.Please do not alter or modify any results, and try to be as specifi c and detailed as possible.

Name:Name of the community and date:Name and age of the person interviewed:

IDENTIFICATION OF PROBLEMS AND DIFFICULTIES IN THE EVERYDAY LABORS.

1. - Which are the everyday labors? Describe a normal day in their lives.2. - what problems are identifi ed in their everyday labors?Agriculture:Preparation of food:Kitchen and cooking:Recollection of goods:Access to water and food:Others:

Surveys. 3. - Which are the problems or diffi culties the face while doing their everyday labours?4. - What stops them from being able to realize these labors?

FOOD.

1. - What do they eat? What is the basic diet?2. - Where does this food come from, how do they get it, how much does it cost, and how do they cook it?3. - What is the life cycle of their agriculture? (Time it takes to grow, where does the product end, and time it takes for them to consume or sell it)4. - What happens with the products they grow? Do they sell them, in which form?5. - How do they consume it and what happens with what is not consumed?6. - How do they sell them and what do they do with what they did not sell?7.- What is wasted?

IDENTIFICATION OF LOCAL RESOURCES.

1. - Which are the local materials? What can you fi nd within the environment? E.g. tipe of ground, clay sand… Plastics, waste and garbage bags, bottles… Metals, cans, varillas, concrete…2. - What materials can you fi nd for construction? E.g. Concrete, cement, steel, bricks…

3. - Which and how accessible are the materials from the other close com-munities or villages?

WASTE.

1. - Which are the organic wastes produced? What happens with it, where does it end?2. - Which are the inorganic wastes produces? What happens with it, where does it end?

-15-

ENERGY

1. - which is their main source of energy?2.-which sources of energy can you fi nd in the place? E.g. timber, gas, char-coal, oil.3. - which one do they use, for what and why? E.g. timber, for cooking be-cause it is cheap.4. - How accesible is it? How much does it cost? How much do they need/use? Where do they get it from and how do they bring it in?5. - which alternative energy generation resources can you fi nd? E.g. wind, water fl ow (rivers), solar, lakes, organic waste…

TOOLS

1. - Which tools do they use to prepare their food? E.g. harvesting, peeling, desgranar, etc. 2. - Which tolos do they use for cooking? Describe.3. - Which tools are used for the agricultura? Describe.4. - Which tools are used for farming and ganaderia? Describe.5. - Which defi ciencies and limitations con you see in them? (economic, ergo-nomic, functionality, materials)6. - what could be changed to improve them?

¡¡¡thank you very much for your help!!!

These surveys have been analysed and fi ltered to gather all the relevant details and the common problems identifi ed throughout all the different communities they where applied to. The following is just a summation of the important facts that the communities share and that are relevant to this project. For the complete results, individual and particular information, the documents are available.

Their economy is based on their sales of what they obtain from the fi elds (beans, corn, coffee, oranges, lemons, amongst others.) the government helps them with $500 pesos a monthly to the mothers and the elders as well. Chil-dren get a scholarship from third grade, they get money for food. There are a few plans to bring investments to work on the fi elds.

The women wake up at 4 am to start cooking and preparing the food, men wake up at 5 to work on the land and fi elds.Later, they have breakfast; they go back to their duties and come back for lunch. Depends on the person, but some go back to work the fi elds, but gener-ally the heat is too strong to keep on working, that’s why they do it so early. They have dinner later on at night, and the day is over. The rhythm of life is easy as in any rural community, but the work and labor is heavy.

Preparation of food: They don’t boil the water, they just ad chlorine into the wellKitchen and cooking: a lot of smoke in the kitchen, they burn everything. (plastics, aluminum, etc.). They have Access to wáter and food, they just add clorine to the wáter in their tanks but it is not really clean, they dont boíl it and they drink it directly.The fi re releases to much smoke. The water is free so they waste it.There is no ecological awareness.A draught has generated limited food (corn and coffee).They eat tortilla, beens, corn products, a lot of fruits and vegetables, coffee, chicken, fi sh and potatoes. Generally it comes from their land. Their fi elds, trees and animals. They grow it. There is also a little store, but what we notice that a lot of things are missing. The main things are bottled water and fl ower. Sometimes people come in bikes and cars to sell cooked chicken ($50 pesos) and corn $5 pesos. Most of it is personal consumption, but they also sell it.They consume the food cooked, nothing raw besides from the fruits.There is a lot of garbage and litter, they throw it to the fl our, the grass, any-where… if not, they burn it.There is a lot of fruit and vegetables (banana, mangoes, coffee, corn, fi sh, chicken, cows) there is plastic waste and litter.

-16-

Dung, fruits and animal wastes. They are left around anywhere.Plastics, they are thrown to the ground, left anywhere or burnt.Wraps and cans from chips and cookies, gum, they also end up in the streets or burnt.

Since 5 years ago, they began building with blocks and bricks, they have ce-ment, electricity and water. All this is provided by the government.

They use timber to cook and heat up because it is the cheapest.Timber is really accessible, they go to cut it down personally from the moun-tain or their lands.They peel the corn by hand; they have rudimentary tools for the agriculture and the fi elds.

For the coffee: they grow it, they cut it, toast it, crus hit and consume or sellFor the corn: grow it, cut it, peel, desgranan, make “masa” for tortillas, po-zol, atole and other products made out of it.Vegetables: they are cut and consumed.

Fireplace inside the kithcen, which produces a lot of smoke that remains inside, where they cook and eat. They use comales, grinders and tripie de cantera

Necessities of the community: from the perspective and voice of the habit-ants of the community.Medical serviceGasPavementSchoolsWaste, trash and garbage recollectionFunds from the government for the fi elds and agricultureEmployment resources and opportunitiesReunion places for young peopleFinish the cathedralSecurity, the one available is from the woods and it takes about 20 minutes to get to the communities.

Health, hygiene and ecological campaigns (water and electricity is wasted since it is not an additional cost for them)Family planifying

Diffi culties:They don´t have a way to get to the high school so they don’t fi nish their studies.Lack of hygiene.AlcoholismDivision because of religionDifference of gender, women only cook and clean.

Proposals:Medical services. Doctors /drug stores – there is no one prepared or with the knowledge to medícate.Gas tanks or biogas. STOVES or OVENS-their fi res release to much smoke.Water- they don´t boíl it, only add clorine and drink it dirty.Schools, Environmental awarenes- they waste the wáter and create litter which ends up in the streets.Alcoholic recovery groupsSustainability, create business within the community in which the prime ma-terial doesn’t cost and it can be sold to other communities or cities. Create an economy- they sell their products through other people and don´t win much from them. Ej: the shirts they make are paid for only $8 and sold later by $150.Organitation/union

The community has welcomed and opened the doors to the people that have gone to work with them, they are opened to changes and willing to work in new things and new proposals.

-17-

Experimentation.

wood burning cooking in a ceramic oven. cooking in a ceramic oven. using a chimny for fumes..

burning corncobs to create charcoal burning fruits to create charcoal

trying out differen methods. Attempt to make briquettes-18-

recreating scenarios.

Sketches.

rough and quick sketches for brain-storming and idea representation.

-19-

taking the ideas further and developing concepts.

-20-

-21-

creating and representing scenarios and processes.

Refi ning concepts, creating scenarios and representing materials and pos-sibilities.

Specifi cations and possible mechanisms/processes.

-22-

Photos Analysis.

-23-

Problem Statement.

Recognition of need.

For these communities in Mexico, it costs approximatly $700 pesos ($60 USD.) to buy timber for cooking and heating. This would last around a month for a family, and they have to walk many kilometers to collect it and carry it back home. Timber fuel consumption causes severe deforestation and short-ages of fuel in many areas. As deforestation grows, besides from the ecologi-cal impacts, these people have to walk further away to meet their needs.Some other problems identifi ed, and where I believe there is an opportunity are the following.

When women have to cook for their family´s food, besides from having to get the wood used as a cooking fuel, families get many health problems caused because of the smokes released while cooking in closed spaces (inside their homes) where all the family waits, eats, plays… this brings severe breathing diseases not only to the person who cooks, but also to the rest of the family, primarlilly to kids, causing cough, emphysemas, cancer and similar diseases to those caused by smoking, as well as problems to their sight, amongst many others.

“Compared to gas stoves, wood burning stoves release fi fty times more particulate matter, carbon monoxide, and hydro-carbons during cooking” World Health Organization. And “the leading cause of death in children between the age of 1 and 5 is not malnutrition, diarrhea, or malaria, but respiratory illness caused in large part by breathing smoke from indoor cooking fi res” Smith [2007], design for the other 90%

It is also a typical situation for kids to have accidents with the fi re and get burnt as the fi re is in the middle of the place where the family does everything

thing. Kids play around and occasionally hit or stumble with the unstable and fragile casseroles or stoves made by them.

Another big problem within these communities is the amount of waste they have, both organic and inorganic, which ends up being burnt.

In one hand, the organic, that comes from all their agricultural products, and on the other hand the inorganic, like plastics, aluminium, polyproppelene, and waste which they do not produce, but how ever, comes from producers that have great distribution lines and reach those places, such as coca-cola.They don´t have a recycling culture or proper waste recollection systems. which brings them to just burn all the waste (organic and innorganic) in the fi elds to get rid of it, not only polluting the air, but also the soil in which they grow their products and the water they drink.

-25-

Doing the tortillas in the “comal”, toxic emitions from fi re.

Long walk carrying timber. Timber stacked up and storage.

Rhe rural agrigultural tools. Dried and burnt agricultural waste in the fi elds.

-26-

Kids play and wander around the fi re and cooking place breathing the toxic emitions, under the risk of having an accident.

-27-

• Really low income.• Lack of basic services: water, electricity, health institutions.• Health, issues: 1) Injuries from carrying wood from long distances. 2) Respiratory illness, from breathing the smokes emited by these fu-els in indoor places. 3) Accidents with the fi re in reduced spaces.Environmental damage such as deforestation and carbon emitions. • Cost of wood for cooking and heating. • Dependence on wood as a source of energy for cooking and heating.Some attempts to attack the previous problems have been followed by a large amount of organizations, where they had developed stoves and alterna-tive cooking fuels to improve the conditions. These have had little success throughout the communities; some of the reasons are the following: • Because the stoves are not thought to be made with local materials and the people can´t be bothered going to source it, since they don’t know or realize the gravity of using their actual ones. • It is not clear for the locals how to build them, and if there is no one from the organizations to explain, they can´t do it. • The stoves that are already made, these people don’t understand properly how they work and lift up the lids and steel plates to get access to the fi re and turns out useless. • Some people use it as tables, benches or places to put their things and other belongings on top of it since they don´t have other places for stor-age. • Ergonomic factors are not considered and they are either to high or to low for them to use comfortably. • Cultural reasons, some stoves where designed so the woman who cooks isn´t near the fl oor since it is contemptuous and positions women be-low, but they would be to high and would become uncomfortable for them to use. • Or, simply because they fi nd it occupies way to much space in their little places, and it is not worth sacrifi cing space for that.

-28-

Reduced spaces, wrong ergonomics, lid lifted up. Children around fi replace.

Defining The Problem.

Behind the jaws and claws of the fi re and smoke, this boy waits for his meal.

-29-

The project.

Summary The approach with the communities is part of the key to the success of this project, historically these communities have been receiving “help” to im-prove their lives but it has never really happened and it becomes more of a way to dominate and exploit them, such as the Spanish conquest.This project is not about bringing western or modern lifestyle into their cos-tumes and traditions, it is about adapting to their way of living and creating a solution that improves their life in that way.

The intention of this project is to use the strategic process of a designer, which in this case is me, for the investigation, documentation, identifi cation of prob-lems and generation of possibilities and solutions of design within the com-munities.The creative process of design is used for the formulation of questions and methods that help to awake the eye of those who are not aware, or those who simply don’t have a critical view.Along with this, the aim is to realize a project to improve any aspect of living conditions in poor communities in the southeast of Mexico.The information obtained through different organizations located in Mexico, together with the research I am doing here, is gathered together and analyzed for the generation of ideas and alternatives of design that can help people in the communities, presenting the opportunity to bring sustainability for these people.

This year long project has different stages, starting from researching, docu-menting, problem identifi cation, generation of alternatives and possible solu-tions, concept developing and fi nally a product that can be manufactured. The idea is to use local materials so that the people them selves can make it and it can become a source to generate money.

Each community has its own conditions and different contexts so it is impor-tant to focus on a specifi c place or group with similar conditions in order to obtain the best results. From all the research and documentation, I have identifi ed an opportunity and a need for stoves designed to be made with the local materials, which aim to reduce the amount of fuel needed for cooking, and that generate alterna-tive possibilities for healthier and more sustainable cooking fuels, which are worth exploring, along with the devices to produce it, These stoves should also include a chimney or escape for the fumes produced, in order to reduce these health issues. Another aspect as well included is to reduce or prevent completely, if possible, the accidents caused by the fi re, all of these of course including ergonomic and design factors that suit the customer which in this case are the Mexican indigenous communities.For this project it will be necessary to have a clear idea of what is being done around the world in this area, what could be included in my project and what material is of relevance.

Addressing the health issues caused by indoor cooking fi res in the communi-ties from the south east of Mexico.

Improving life standards by bringing sustainability to these communities.

Reducing the environmental impacts.

Use of local resources, materials and waste to create alternatives for wood-burning.

Use design as a tool to improve the cooking process and safety, without com-promizing cost, and respecting the traditional methods for cooking.

-30-

Conclusion and summary of work compeled.

The long road through research has opened many cards to work on in order to improve the life standards in these communities. There are many problems that need to be tackled and worked on, but the opportunity of design that I have found comes up to the design of stoves, that reduce the health, economic and environmental issues that are a consequence of using timber as a fuel for cooking and heating indoors, along with tools that can aid and facilitate the process for production of charcoal briquettes out of the agricultural waste (predominantly maize). This has two purposes, one is to stop the health end environmental consequences from burning timber, and the second is to be-come a possibility for the users to generate a product that can be sold and therefore an income. creating a sustainable cycle between the food, which then turns into waste, then into charcoal (fuel) for cooking, and so on. In order for the design to be successful, it must include the following princi-ples, which are crucial for a sustainable and victorious design: * Be an income generating. the people should be able to create an income by using the design in order for it to become sustainable. * Return on investment. they should recover their investment in less than six months for it to become viable. * Affordability. affordability should rule the design, as cheap as pos-sible. * Energy-effi ciency. human powered tools that can be easy to use and powered by human force. * Ergonomics and safety. it must not include risks to the user as well as the maximum comfort to guarantee usability and effi ciency. * Ease of instalation and use. must have a clear and easy use. * Strenght and durability. it will be used in the roughest conditions so it must guarantee a long life. * Available manufacturing capacity. with available materials and tech-nologies to the communities. * Cultural acceptability. these communities have cultural traditions and beliefs which much be respected and included for them to accept the de-sign and use it. * Environmental sustenability. it must improve conditions and have a positive impact on the environment.

-31-

Learner testimonial.

Along the semester I have learned various valuable things. First of all, it has been a great challenge to develop a project situated so far away from the communities that I am working or designing for. This has en-hanced my skills to communicate, both with the people here who where not aware and unfamiliar to the group which I am treating, and also with the people back home helping me out with the fi eld information. At the beginning it was frustrating in a way, not to receive the information that I wanted from the people back in Mexico, but that forced me to try differ-ent methods, encouraging friends to help me out and convincing people of the organization “no puedo callar!” to take my surveys along with them in their visits to the communities. Another aspect which I feel has improved is my confi dence to talk about the context, my ability to expose and present the problems identifi ed. This course has been an opportunity as well, to learn how to use digital re-search tools such as Delicious, Wordpress, Scribefi re, Issuu, Blogs, mind maps, InDesign, audio recordings, and other programs we have used to condense all the information we have come through along the research process.While this semester was more about being able to conduct the research towards the identifi cation of a problem and the recognition of a need, it has also included concept development and decision making for the next semester, where I will be focusing on all the technical aspects of my de-sign, which will be framed and backed up by the work that has been done so far.I have identifi ed what and how I want to intervene as a designer and the “product” I will be creating next semester, and even though the idea is clear about what needs to be done, there is still a long path to go with model making, iterations and manufacturing processes.

Indoor and outdoor possible spaces for cooking and charcoal briquette pro-duction.

-32-

References.

BIBLIOGRAPHY.•Smith, design for the other 90%, Smithsonian, New York. 2007•Bruce, N., R Perez-Padilla, and R Albalak, the health effects of indoor air pollution exposure in developing countries (Geneve: world health organiza-tion,2002)•Alastair Fuad-Luke, Eco design the source book, 2004, Thames and Hudson Ltd., London.•Architecture for Humanity, ed. Design Like You Give a Damn: Architectural responses to Humanitarian Crises. New York: metropolis books 2006.•Easterly William. The White Man’s Burden: why the west’s efforts to aid the rest have done so much ill and so little good. New York. 2006•Bornstein, David. How to Change the World: Social Entrepreneurs and the power of New Ideas. Oxford. 2004•Farmer, Paul. Pathologies of power. Berkeley, 2005.•Papanek, Victor. Design for the real world: human ecology and social change. Chigaco, 1984•Prahalad, C.K., The fortune at the bottom of the pyramid: eradicating pov-erty through profi ts. upper Saddle River, 2005.•Sachs, Jeffrey D. The end of poverty: economic possibilities for our time. New York. 1999.•Povertynet “Overview: understanding poverty.” world bank. http://web.worldbank.or?wbsiteexternal/topics/expoverty•www.Ted.com - http://www.ted.com/index.php/talks/amy_smith_shares_simple_lifesaving_design.html•www.nopuedocallar.org•National Geographic, Emerging Mexico: a special issue. •World Health Organization: http://www.who.int/en/•Wikipedia.com/surestemexicanoPHOTOGRAPHIC CREDITS:Ana Zarak.

-33-

Semester II.

Contents.

Kauil Stove introduction. -1- Context; Immersing into the users lives. -2-

What can be used. -6-

The Problem. -9-

Design opportunities. -10- Challenge. -11-

Constraints. -12-

My Design Process: -13- * Sketching -14- * Experimentation -23- * Function and components analysis -24- * Prototyping -26- * Final Model -30- * CAD. -31-

Finished working model. -32-

The Solution. . -33-

How it works -34-

Why it works -35-

How to make it -36-

Laser Cut. -39-

Technical Drawings -40-

Costs of production. -41-

How to use it -42-

How to make charcoal -43-

Videos. -45-

Conclusion -46-

Learner Testimonial. -47-

Bibliografy -48-

Kauil Stove

An effi cient stove for rural indigenous communities in Mexico.

Made from locally available materials and processes, this low cost stove has the potential to combat deforestation and diminish the dangerous ef-fects of indoor cooking fi res.

The Kauil (Mayan god of fi re) stove not only reduces the fuel consump-tion for cooking, but creates boiled water for the household utilising the heat generated.

This self-suffi cient design runs on, and produces, its own clean burning fuel yielded from agricultural waste (predominantly maize).

-1-

Context; Immersing into the users lives.

Town close to the communities. 40 min to one hour drive. They count with the necesary tools for manufacture.

Road to the communities, you have to get into the mountain, through dirt tracks.

The communities, are in the middle of the moun-tain. They are not paved roads but are accsesible by car.

People in these communities live together and have a strong community sense. some don’t speak spanish, but they have cummunity lead-ers that represent them.

These homes are built by them, out of local re-sources and help from the government.

A two bedroom house, where they cook, eat, sleep...live..

-2-

Timber they use for cooking and heating, cut from the mountain or bought from other com-munity members.

The timber they use is either cut by them from the surrounding forests, or bought from other people who go and cut it.

Stacks of wood they use for cooking. this has a strong impact on their economy, important part of their income is spent in fuel.

Deforestation, this is one of the environmental consequences of using wood for cooking.

Inside their homes, several other consequences arise as a result of using timber.

Spending their income o n timber for cooking eliminates the possibility of saving or using the money for improving their daily life

-3-

The fi re is on all day to keep coals, which is a waste of wood. and a constant toxic emition of smoke.

This is grease and pollutants in the ceiling of the house as a consequence of the indoor fi res.

There is not enough not enough venitlation and many times they keep it closed.

health conditions are not the optimal. Burning wood creates very toxic smoke and fumes, there are also accidents because of the open fi re and the long logs sticking out.

This is a family cooking the dayly meal, corn, fruits, rice and beens. All they use is a grid, a “comal“ (iron cooking plate), and pots.

-4-

The smoke is captured inside, the eyes hurt, you cough a lot. It makes it hard to breath and re-main inside

Black walls inside a house, from the smoke. A peace of cloth hanging from a rope divides the rooms from where they cook and sleep.

There is not much space inside, they sit around in chairs or the fl oor to eat.

They are religious, and even though the major-ity has turned into Catholics, but they still con-serve ancient rituals and traditions.

Strong family links, even though each time they separate more since they have to go to the cities in search for work opportunities.

-5-

They count with cooking tools, and have acces to materials.

Food and agricultural products, which can be turned into charcoal which reduces the impact of indoor smokes.

Vegetables and fruits that need to be cooked, boiled or steamed.

Bagase, and dry agricultural waste which they burry and goes back to the land, but can be used for charcoal making.

Corn cobs “olote“ and food remains are col-lected in 50 kg. rice bags and then given to the stock.

Clay, pottery and “adobe” which are great insu-lative and lightweight matterials.

What can be used.

-6-

Maize is their main diet, they eat it in several dif-ferent ways and use it to make tortillas amongs other meals.

They have water acces, but not clean. they don’t boil it, they add clorine to clean it and drink.

This is the water supply for the household.

Cooking tools to prepare their meals. Corn grinders to make dough and tortillas. A small Kettle to heat up water for coffee.

-7-

The “olote“ (corn cob) is thrown away or given to the animals.

Help from government and NGO’s, who bring in tools, capacitate them and help them to create merchandise and sell it.

Ther is manufacturing capacity. stove can be manufactured there, brought in and assembled in the communities.

In some other homes, there are attempts to im-prove, this is a home made stove, made out of a car rim.

There are tools to cut steele, weld and manufac-ture my stove.

There is cultural acceptance towards new suge-tions that can improve the life standards.

-8-

The problem.

Health:

* Breathing toxic smokes and emitions of burning wood indoors

* Accidentss with open fi re, and logs sticking out in the midle of the house.

* Drinking dirty water without boiling or sterilizing it.

* Injuries from carrying wood to their homes.

Environmental:

* Deforestation,

* Air polution.

Economic:

* Cost of wood, more than a a quarter of a family’s income is spent on fuel.

* No possibility of generating an income.

-9-

Design opportunities.

Health:

* Alternative cooking fuels that are harmless,

* Enclose the fi re to optimize heat generated and eliminate the pos-sibilities of accidents.

* Creating boiled water while cooking to sterilize it.

* Use what is available to them as a fuel (agricultural waste)

Environmental:

* Prevent deforestation by reducing or eliminating the amount of wood for cooking.,

* Clean burning fuels.

Economic:

* Sustainability

* Produce charcoal which can enable them to sell it and make profi t.

-10-

Challenge.

To encourage users to buy and use the stove, it responds to the fol-lowing:

* Income generating: the stove enables the people to produce clean burning bricketes made out from their agricultural waste, which can be sold to the other people in the communities or nearby towns.

* Return on investment: the stove is low cost and they can recover their investment in less than 6 months by selling charcoal made out of maize.

* Energy effi ciency: the stove can be made, operated and used by a single person.

* Ergonomics and safety: it encloses the fi re inside the drum prevent-ing users and others as well from touching it and burning, it is stable and also holds the stove which makes it “stumble free”.

* Intuitive: the visual language of the stove indicates the way it oper-ates, and the graphics give a readable language of how to use it, using local icons and fi gures to explain.

* Cultural acceptability: it is fabricated locally and is named after their ansestors god of fi re “Kauil“ including simbols and colors makes them feel part of it.

* Environmental sustainability: it improves the conditions and has a positive impact on the enviromment creating a sustainable cycle be-tween food, waste and fuel.

-11-

Constraints.

To be able to produce charcoal out of maize and other agricultural waste in the stove, it must have the option of sealing it from oxygen and air fl ow, so that the fi re extinguishes inside the drum. Without fi re, the material inside burns at high heat and carbonizes.

Many of the people in these communities don’t speak Spanish, the stove is introduced to the communities via their community leaders (they do speak Spanish) who can then pass the knowledge to the rest of the people in the community.

The manufacturing process has been reduced to the simplest and cheapest. It is designed with the less amount of pieces as possible and has been simplifi ed so that the only part that needs welding is the copper coil to the pot.

The air must go through the combustion chamber, this way it heats up and burns the toxic particles of the smoke in case timber is used in the stove.

A higher combustion temperature decreases the emissions made from the burning biomass.

-12-

My design process.

Design ideation, brainstorming, rough and detailed sketching, rapid form de-velopment, experimentation, materials, prototyping, production processes, as-sembly and international manufacturing have been covered and explored along this semester.

The prototyping iterations where the most helpful for my design, since it al-lowed me to represent the conditions of whom i was designing for and recreate the space and environment.

With the information presented from the prototypes, I created different hypoth-esis which I then researched on. This research was sketched and mapped so I could include it into the next prototypes

-13-

Sketching.

As a tool to represent, un-derstand and recreate spaces, scenarios, components, me-hcanisms, functionality, form, materials.

-14-

Experimentation; Hot Water Flow.

In order to understand the physics of hot water fl ow I realized a couple of ex-periments.

I placed two bottles and fi lled them, one with hot water (painted with red colo-rant) and the other one with cold water; I connected them with a tube and placed the cold water one above the hot water one.

The hot water is lighter than the cold water, and therefore goes up (painting the cold water above in red).

This experiment was to prove if i could use the same principle and apply it to my design.

The second iteration was to connect the bottles with two tubes this time, to see if the hot water would mix up with the cold water faster, rising up the temperature of the water in both containers.

the second tube increased the effi ciency by the double by letting the hot water fl ow through one, and the cold water descend through the other one.

This experiment was made it clearer and the theory behind it was applied into my prototypes of the stove to make the most effi cient way for boiling water in the pot.

experiment #1

experiment #2

my prototypes of the stove to make the most effi cient way for boiling water in the popot.

-23-

Prototypes. This is the fi rst working prototype. It was all made in my backyard using only basic tools (hand saw, hammer, screwdriver, kitchen knife). the inten-tion of this was to immerse myself in the situation of the user and this way realize and explore the possibilities of it being made by local reused materi-als and simple fabrication.

-26-

The result was good, I was able to get hot food and boiled water, but there where many things to be changed to improve its ef-fi ciency. This took me to make a new model.

-27-

Iterations.

-28-

From the last prototype, there where many things that needed to be improved, tested and changed.

Experimenting, the vesto stove, the plastic bottles model (built to see hot water fl ow), and sketches where used to visualize some of the following iterations which where applied and included now to the new design.

Fixed legs.

“t“ joint in copper tubes to create cycle of hot water fl ow.

Ventilation holes, with nob to control oxigen fl ow into the kiln.

Combustion basket, sepparate and removable.

fi xed legs.i added 3 legs, these lift the stove up from the ground, creating more stability for uneven surfaces (tripod is the most stable system).

they also lift it up from the ground, allowing oxygen to go through the holes drilled to the bottom. the air coming in through the bottom elevates the tem-perature in the kiln by increasing combustion (+oxygen + combustion + heat).

They are pointing towards the inside to avoid pointy edges keeping the round edge of the drum, and are pop riveted.

“t joint“Creates another “channel“ for the hot water to circulate. when the hot water expands it goes up to the pot, while the colder water in the pot, goes down through the other pipe, where it then heats up and completes the cycle.

the water got really hot in a short lapse of time, i believe the “T” section looses some energy with all the connecting points. next is to try only “elbow joint” and move the water key up to the kiln.

Knob and oxygen fl ow holes.i added this knob, which allows to control the fl ame. This was made in two pieces, now i have to make it out of one piece and bended sheet of steel, for manufacturing terms. I had to add to nails to guide it, this also has to be improved for next iteration.

Combustion basketThis was added in order to make it easier to clean, remove, start the fi re.it has two handles that hold it to the top of the drum. it was sitting to high for the fi rst test and the heat did not hit the whole copper coil so i had to bend the handles for it to sit lower in the drum. for the next itera-tion I need to make it more stable, because when i added wood to the fi re, it would move and swing a little bit.

-29-

Final Prototype.

This is the last prototype I made before the fi nal one.

The “T bar” in the copper tube was replaced by an “elbow joint” creating a closed circuit for the water, increasing the effi ciency by reducing the time needed to boil water.

a stand was created for the pot, to eliminate the possibility of it falling down and spilling hot water.

The copper coil diameter was reduced along with the fi re grate, and the space between the oil drum walls and the copper tube was fi lled with rocks and sand as insulators. This created a higher temperature inside the stove, eliminating the smoke caused by burning wood.

Combustion happens in a relative small place and therefore the heat gener-ated is transferred directly to the coil and the cooking plate. Increasing the effi ciency.

I added holes and a strap at the bottom so that there was more possibility for air to go through. This allows a primary and secondary air fl ow con-trol, which are used to control the temperature of the stove.

-30-

CAD.This was my last phase for the design process, allowing me to get a real representation of what the model would look like, and at the same time permit me to make the last adjustments before making the fi nal model.Being able to play around with the components without having to make them saved me some time and gave the opportunity to refl ect on the pieces and how they could be done and assembled.The technical drawings defi ne the dimensions and manufacturing processes that would be used in order to create each piece of the stove.

-31-

Finished working model.

Flame changes as you open (above) or close (bellow) the oxigen fl ow. Boils water in aprox. 40 min.

-32-

The solution.

The outcome of this year long project is the Kauil Stove.The stove I have designed and made is a full working model; it is made out of reused materials that are available to the people in these communities. A 25 lit-ter oil drum, sheet metal or scrap steel, ½ inch annealed copper tube, a pot and a “comal” (cooking plate) made out of cast iron, which are commonly used for cooking. Vermiculite, sand, clay, water and sawdust are used to make an insula-tive refractive “brick”, this contains and entraps the heat generated while hold-ing everything together.

Along with this I have designed alternative plans of production, so that the stove can be made industrially and mass produced with machinery that is available in the close towns and that keep the cost reasonable for the end user.

This device provides people in the developing world who face fuel wood short-ages with the means to sterilize water and have hot food.

The design is immediately more effi cient by reducing (or eliminating) the amount of wood needed to cook by using the heat generated for cooking, to boil water separately.

It is also a tool that enables the possibility of creating charcoal out of their ag-ricultural waste (maize), using a process developed by MIT D-Lab, where the corn cob is burned at a high temperature and then turned into a briquette that produces minimal levels of carbon monoxide and can be used indoors.The briquettes can be produced for own use and to sell, allowing the families to make profi t out of it.

-33-

How it works.

A) Cold primary air enters the from the bottom window, and is preheated as it goes up to the combustion chamber where it mixes with fuel and fl ame, increasing the temperature of the fi re.

B) The secondary air suply controles the amount of oxigen that enters to the combustion chamber, rising or diminishing the fl ame.

C) The combustion happens in a relative small place, therefore the hot gases immediately con-tact the cooking plate which cooks the food, and the copper coil which boils the water.

D) The cold water goes down the copper tube and fi lls the coil because of the pressure and gravity. As it heats up, the water exopands, forc-ing the fl ow up in the spiral and coming out of the upper pipe. This cycle is repeated until the “whole” water has boiled.

E) Clay, water, sawdust and vermiculite make a lightweight fi ll which works as an insulator. the sawdust burns leaving air holes that increase the insulative value.

The higher combustion temperature decreases the emissions made from burning biomass. Combustion tends to be very complete and almost smokeless due to re-ignition of the pri-mary combustion products. While smoke, air, and fi re mix together inside the drum, which diminish or cut the pollution that is harmful for human health.

-34-

Why it works.

The stove: Small, light fuel burns faster and with a higher heat output than large heavy fuel, that is the reason for the diameter of the fi re grate, which in case of using wood to fi re the stove, it only fi ts small twigs and sticks that burn ef-fi ciently and at a very high temperature.Having a small combustion chamber, where the air that enters is restricted, in-creases the temperature which as a consequence burns the toxic particles that an open or common fi re would have.The Kauil stove burns wood and most other bio fuels so cleanly that they can be used indoors without a chimney, which makes it cook similar to a gas fl ame, but conserving the traditional cooking stile of the families that has been passed on from generation to generation.

Cold primary air enters the from the bottom window, and is preheated as it goes up to the combustion chamber where it mixes with fuel and fl ame. The hot fl ow gases immediately contact the cooking plate. Combustion happens in a relative small place and therefore the heat generated is entraped, creating a higher combustion temperature that decreases the emissions made from burn-ing biomass, smoke, air, and fi re mix together which decreases the pollution that is harmful for human health.

A 12 mm gap between “comal” (cooking plate) forces fl ame to touch sides as well as bottom, this signifi cantly increases the effi ciency of the stove.

The corn charcoal: Instead of ending as landfi ll, the waste from their agriculture can be transformed into a clean and effi cient burning fuel. When the corn cobs are carbonized they produce minimal levels of carbon monoxide and particulate matters, and can be used indoors. The stove works as a tool in the process, since it allows to seal the oxygen en-trance while the corn cobs are burning, creating the best conditions for the cob to carbonize and not over burn.

The boiled water: Water, like most other materials, expands when heated so cold water is denser than hot water and is therefore heav-ier. As initial temperature of the water placed in the pot is even, it fi lls the copper coil that is connected to the pot. When the fi re transmits heat to the coil it heats up the water, making the particles expand and there for go up the spiral and into the pot. This cycle is repeated until the water reaches its temperature equilibrium.

The effi ciency of the stove is measured with the thermal effi ciency formula N stove = Q water / Q fuel. This means that it is calcu-lated by the amount of fuel burned till the time when the water boils. Kauil stove is more effi cient than others, since it reduces the amount of fuel needed and boils water in approximately 40 min, while primary heat can be used for cooking.

Insulation: the fi ll which is made out of sawdust, sand, water and clay or “adobe” is highly effi cient, since it holds together all the pieces of the stove, the insulation value of this materia is that with the fi rst burn, the little pieces of sawdust and straw in the fi ll, are burnt, this creates small holes of air which entrap the heat, similar to the volcanic rocks.

-35-

How to make it. The kauil stove can be constructed in many ways with different materials, it can either be made from reused materials (oil drum, scrap metal, existing pots and copper tube), laser cut, or made by a blacksmith.These are the steps on how to make your own stove out of reused materials.

1) drill the holes in the oil drum, remov-ing the lids,

2) drill the holes in the straps, then roll them around the drum and weld them.

3) roll the annealed copper tube around your fi re grate to get the right diameter and height.

4) drill the holes in the sheet steel when it is fl at, then roll it and weld it.

3) take a used pot and drill to holes to conect the copper tube, weld it and make sure it is water proof.

2) Make for boxes out of the steel or tin cans.

DRUM STRAPS

FIRE GRATE COPPER COIL POT AIR BOXES

Materials:

25 L oil drumSteel or ceramic pot.1.2 mm scrap sheet steel.Vermiculite (volcanic rock)1000 g Dry sawdust or straw1800 g moist clay2500 g water

-36-

A) The oil drum is the main body of your stove.

B) The primary air strap goes inside the drum, make sure the windows match and that you can turn it once it is inside.

C) The secondary air strap sits outside and is tightened with a nut and bolt. make sure the holes are aligned with the drum ones.

D) Place your copper coil in the center inside of your drum; it should sit fl at with the lid inside.

E) Put the fi re grate inside the coil so the coil doesn’t loose shape when you add the fi ll.

F) Weld the pot with the copper tubes. Make sure you get the right height.

G) Place the air boxes inside the drum, aligned with the sec-ondary air windows.

Fill the space between the copper coil and the oil drum with the vermiculite (volcanic) rocks.

Mix the dry sawdust or straw with the moist clay and water and stirr it well to make the light wight fi ll that will hold and secure everything.

Now everything is in place and ready for you to add the fi ll (“Adobe”) that will hold everything together. When you do it, wrap the fi re grate with a plastic bag to prevent it from being fi xed to the copper coil, take it out from time to time while the fi ll dries, but put it back in so the copper coil doesn’t loose its shape.

Once the fi ll is dry, your stove is ready to be used.

-38-

Laser cut.

kauil stove laser cut drawings These drawings are made in AutoCAD and ready to be laser cut. This version of the stove can be mass produced, fl at packed and then sent to the communities, where they can be rolled and assembled.This version eliminates the welding part (except from the copper coil to the pot) which makes the design really cheap to produce, easy to assemble by anyone (it is rolled and has slots to hold it together) and cheap and easy to send because of its fl at volume.

The design is fi tted on to a 91 X 244 mm bed, which is the size in which they sell 1.2 mm sheet steel.It is fi tted so that from one sheet 2 stoves can be made, the fi re grate is laser cut from another sheet, and 8 pieces come out of it.

Drum, air straps, lid, air boxes and holders.

Fire Grate and holders.

-39-

Technical Drawings.

The stove can be done by a blacksmith or a small steel manufacurer with theses drawings.They contain all the pieces, materials, dimensions, processes and spe-sifi cations for the manufacture of the stove.

-40-

COMMENTS:

Kauil Stove

SCALE:1:20

SIZE DWG. NO.

AREV.

MATERIAL

FINISH

SHEET STEEL 1.2 MM

--

DO NOT SCALE DRAWING

Javier Diaque Suarez

PROPRIETARY AND CONFIDENTIAL

TWO PLACE DECIMAL

PROHIBITED.

THREE PLACE DECIMAL

BEND PIECE:

WEIGHT:

NAME DATE

DRAWN

CHECKED

SHEET 1 OF 12

DIMENSIONS ARE IN MMTOLERANCES:FRACTIONALANGULAR: MACH

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFJAVIER DIAQUE SUAREZ. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFJAVIER DIAQUE SUAREZ IS

KAUIL STOVE

DIAM: 348 mm is for inside lid

DIAM:168 mm

1


KAUIL STOVE

SHEET 2 OF 12

27.10.09

27.10.09JDS

JDS

UNLESS OTHERWISE SPECIFIED:

SCALE: 1:10 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

JAVIER DIAQUE SUAREZNAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

1.2MM SHEET METALFINISH

MATERIAL

2

TOLERANCING PER:INTERPRET GEOMETRIC

3

BEND

45

TWO PLACE DECIMAL

PROHIBITED.

THREE PLACE DECIMAL

PROPRIETARY AND CONFIDENTIAL

DIMENSIONS ARE IN MMTOLERANCES:FRACTIONALANGULAR: MACH

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFJAVIER DIAQUE SUAREZ. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFJAVIER DIAQUE SUAREZ IS

"DRUM"37

015

5

50

50

526

350

2

A

A

350

331

348

168

SECTION A-A

12.70

370

155

131

MADE FROM 20L OIL DRUM OR,

1.2 MM STEEL SHEET CUT, ROLED AND WELDED

50 MM CENTER HOLES ARE ALIGNED AT SAME HEIGHT AND SAME DISTANCE BETWEEN EACH2 MM HOLE IS FOR NAIL TO GIDE THE SECONDARY AIR STRAP.

DETAIL A SCALE 2 : 5

4A

100

50

2

50

205

"DRUM"DO NOT SCALE DRAWING

KAUIL STOVE

SHEET 3 OF 12

27.10.09

27.10.09JDS

JDS


SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

HIGH TEMP. PAINT

1.2MM SHEET METALFINISH

MATERIAL

INTERPRET GEOMETRICTOLERANCING PER:

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONALANGULAR: MACH BEND TWO PLACE DECIMAL THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIALTHE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFJAVIER DIAQUE SUAREZ. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFJAVIER DIAQUE SUAREZ IS PROHIBITED.

5 4 3 2 1

holes in strap must match with drum center holes

350

28

29

"SECONDARY AIR STRAP"


KAUIL STOVE

SHEET 4 OF 12

27.10.09

27.10.09JDS

JDS


SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

HIGH TEMP PAINT1.2MM SHEET METAL

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

STRAP MUST WRAP AROUND DRUM AND MATCH WITH THE AIRFLOW HOLES

58

352.40

50

TRUE 10

4

60

348

348

30

50

100


"PRIMARY AIR STRAP"

SHEET 5 OF 12


SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

HIGH TEMP PAINT1.2MM SHEET STEEL

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

KAUIL STOVESTRAP MUST GO INSIDE DRUM AND SLIDE TO OPEN/CLOSE PRIMARY AIR FLOW

70


"BLOCKS"SHEET 6 OF 12

27.10.09JDS


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

1.2MM SHEET STEELFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

KAUIL STOVECAN BE EXISTING OFFCUT WITH SIMILAR DIMENSIONS

70

70

This component is to prevent the secondary air flow holes (in drum) from getting blocked when drum is filed with insulator.

160

240

1020

10

20

144

20

B

B

220

160

10

14

SECTION B-B


KAUIL STOVE

SHEET 7 OF 12

27.10.09JDS


SCALE: 1:5 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

HIGH TEMP PAINT2 MM SHEET STEEL

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

"FIRE GRATE"DISTANCE BETWEEN HOLES IS NOT TO IMPORTANT.

170


KAUIL STOVE

SHEET 8 OF 12

27.10.09JDS


SCALE: 1:10 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

ANNEALED COPPER TUBE 1/2 INCH, ELBOW JOINT WELDED AND ALSO WELDED TO POT

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

"COPPER COIL"COPPER TUBE 1/2 INCH

12.70

DETAIL C SCALE 1 : 5

elbow jointwelded

R16.50

C 253

400

450

210

264

381

264.40

DETAIL D SCALE 1 : 5

26

D

12.70

408


KAUIL STOVE

SHEET 9 OF 12

27.10.09JDS


SCALE: 1:10 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

1.2 MM SHEET STEELFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

"POT & STAND"LEGS OF STAND ARE MADE IN 2MM SHEET STEEL.POT IS DRILLED FOR COPPER PIPE TO FIT IN.


KAUIL STOVE

SHEET 10 OF 12

27.10.09JDS


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

BRUSHED

STAINLESS STEEL.FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

"TOOL"

E

212.17

23

110

23

3

sharpen SCALE 1 : 1DETAIL E

sawhand sharpen

R3

R7.19

28

R2.24

this piece is ionized to strenghten.

INSULATION LIGHT WEIGHT FILL

COMPONENTS ARE HELD TOGETHER BY LIGHTWEIGH FILL.500G OF DRY SAWDUST900G OF MOIST CLAY1200G OF WATERDO NOT SCALE DRAWING

"ASSEMBLY"SHEET 11 OF 12

27.10.09JDS


SCALE: 1:20 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

KAUIL STOVE


KAUIL STOVE

SHEET 12 OF 12

27.10.09JDS


SCALE: 1:20 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY


5 4 3 2 1

"EXPLODED VIEW"

QUOTE OF MATERIALS

material dimension cost in $ M.N cost in $ AU.Steel sheet 0.7 mm 91 X 244 mm $172.00Steel sheet 1.2 mm 91 X 244 mm $290.00Steel sheet 2.0 mm 91 X 244 mm $350.00Steel sheet 2.5 mm 93 X 244 mm $550.00

annealed copper tube 1/2 in 12 m $400.00

MANUFACTURE

Piece qty. material process cost $ M.N* cost $ AU.

Drum 1 steel sheet 1.2 mm punch, cut, roll and weld $500.00 $41.45Fire Grate 1 steel sheet 2.5 mm punch, cut, roll and weld $400.00 $33.20secondary air strap 1 steel sheet 1.2 mm punch, cut, roll and weld $170.00 $14primary air strap 1 steel sheet 1.2 mm cut, roll, weld and bend $100 $8holders 3 steel sheet 2.5 mm cut, bend $60 $5copper spiral 1 annealed copper tube roll, weld joint $50 $5water pot 1 stainless steel punch holes, weld to tube $30 $3water pot stand 1 steel sheet 1.2 mm cut, bend, spot weld $100 $8tool 1 stainless steel bar 3 mm cut, sharpen, brass???

*cost $ M.N stands for mexican pesos, and the equivalence to the $ AU dollar is 0.083

manufacturing cost decreases with quan ty.total $1,410.00 $117.30

Costs of production.This is the quote given by a local blacksmith from San Cristobal de las casas, a town 40 minutes away from the communities. This is considering that it would be made in a small workshop with no industrial machinery.The cost of the laser cut version depends directly on the amount of stoves ordered.

-41-

How to use it.

1) Fill the fi re grate with charcoal and small pieces of timber to start the fi re. Do not fi ll it any higher than the line marked with smaller circles.

2) Light it up from the bottom, as this will pre-vent it from smoking. Wait for it to catch on fi re.

3) Once the fi re is going, take the fi re grate and place it inside the drum. Make sure the air win-dows of the drum are open.

4) Fill the pot with water allowing the pipes to fi ll as well. Place the lid to concerve the heat and get the water boiling faster.

5) If you need to move the coals or add more fuel you can remove the grate with the hooks.

6) Control the temperature of the fi re by open-ing/closing the air fl ow. Closing primary and secondary will extinguish the fi re.

-42-

How to make charcoal.

1) Place a stick in the centre of the gate to keep an air vent through the centre of the cobs and husk when the burn be-gins.

2) Fill the fi re grate with a layer of corn husks followed by a layer of corn cobs. Repeat until you fi ll the grate, then re-move the stick.

3) Light the husks from the bottom of the fi re grate. allow it to burn until it stops smoking.

4) Allow the fi re to burn for 20 min. then place the fi re grate into the dreum using the hooks.

5) Close the primary and secondary air win-dows turning the knobs. The lid should then be placed on the top of the stove sealing it com-pletely from air.

6) Keep it closed for 2 hours aprox. untill it is completely off. Do NOT leave unattended.

5) Remove the lid. The cobs inside should be carbonized and ready to use. Those that are not fully carbonized can be thrown into the next burn.

-43-

Making the charcoal.

The stove is used as a kiln to make charcoal, and it must be done outdoors, since the process produces some smoke.

It counts with the primary and secondary air windows in order to allow air to fl ow through the drum. The top os open for fi lling it with cobs, or other agricul-tural material. A small lid is needed to cover the top hole, this can be a piece of sheet metal or other fl at scrap.

It is important that before the fi rst charcoal burn, any oil residue is burned away. Make sure no extremely hazardous chemicals were used in the oil drum, as this can be dangerous when burning.

The fi rst thing is to open the primary air window so that air can fl ow in through the hole at the bottom. The next step in the process is to fi ll the fi re grate with about fi ve centimetres worth of corn husks. A stick held in the centre of the drum can help to keep an air vent through the centre of the cobs and husk when the burn begins. After the husks, an alternate layer of corn cobs can be placed in the fi re grate. An alternate layer of corn husks can then be placed followed by corn cobs again, and so forth until the fi re grate is full, then the stick can be removed.Light the fi re grate at the bottom hole that was formed by removing the stick. For an even and effective burn, it is best to light the husks from the bottom of the oil drum in four places, the centre, and three surrounding points. After ten minutes, the smoke should be hot enough that it can be ignited for a cleaner burn. The fi re should be allowed to burn for another ten minutes before cover-ing.

To cover the oil drum, and deprive the fi re of oxygen, close the primary and secondary air windows turning the knobs.. The lid should then be placed on the top of the stove. Sand can be placed at the edges of the bottom of the drum

and around the top of the lid to create an airtight seal. This causes the fi re to extinguish itself inside the drum. Without fi re, the material inside burns at a high heat and carbonizes.After two hours, brush the sand off the top of the stove, and remove the lid. The cobs inside should be carbonized and ready to use. Those that are not fully carbonized can be thrown into the next burn, though there is risk that they will fully burn off. Carbonized cobs will weigh much less than dried cobs, and snap quite easily when pressure is applied to them at both ends.

-44-

Videos.

The videos on how to use the stove, and how to make one can be found in youtube.

these are the links to the videos.

http://www.youtube.com/watch?v=T2I8_BhmZgM

http://www.youtube.com/watch?v=Bpr0rH7X71A

-45-

Conclusion.

-46-

The Kauil stove is an opportunity for families in rural areas and the developing world to continue with their traditional cooking methods without the dangerous health risks that indoor open fi res have. The stove is low cost but also an income generator, which encourages the users to buy it. By using their agricultural waste (corn) as a fuel, not only the health issues are being tackled but also the environmental ones.This design gives opportunity to have sterilized water for drinking and the household and hot food simultaneously.By enclosing the fi re, the risk of stumbling with the burning logs of an open fi re is eliminated, creating with this an easy, safe and intui-tive stove that improves the health, environmental and economical conditions of families.

Learner Testimonial.

-47-

This year long project has been a challenge in many different ways and has brought me to learn much more than what I expected. Doing this self directed project has given me much confi dence on my design methods and ability to determine and re-focus a design project. The need to lay out properly my ideas and get the group in the studio to understand what I had in mind with the restriction of a second language has potentiated alternative communicative methods such as quick sketch-ing, CAD, videos and portographies. Several decisions made through the design process had to be done using my past experiences with this com-munities which I believe have increased and enforced my observational and refl ective abilities towards the environment and the surroundings, not only with past experiences, but more of a way of thinking through every-day. Driving this project away from Mexico, has also allowed me to have an “outside” panorama of the picture and to compare many things with a completely different world and way of doing things. I believe the way this course has been taken along has helped me to make clearer and lucid connections between research and the design outcome, by analysing and taking in consideration many other aspects than a com-mon design project, such as cultural differences, traditions, costumes, etc. This year has also made me realize of my weaknesses and areas I need to improve for further projects, stop speculating or procrastinating and getting things done at the moment, even though the fi rst attempt will not be perfect, the iterations will always improve and open the opportunity of development and improvement.

The prototyping process has been the most aid full for my design proc-ess, I believe it is the most informative and complete way to identify the problems and what can change to make it better.

Not having the CAD program I learned to work with, forced me to get into solid works, which was totally new for me, even though I have not

mastered it, I am now more familiar with it and am able to design with it. This is one of the great challenges o found when I got here since a great part of the design process here is made in CAD. This gives me the confi dence that I am capable of adapting to different styles and methods, making me an adaptable and fast learner.On another hand, It was a great opportunity to expand on the manufac-turing and prototyping processes. Even though my stove is meant to be done with very simple manufacturing processes and tools, I explored the different ways in which it can be made and this opened many thoughts for getting it produced and sold back home. It has been really interesting to see how it can be produced in such a long distance from where it was designed; this has enforced my international design capability. I am very pleased to know that with the work I have done, the stove can already be produced and released back home at such a low cost. Many things can be improved which is exciting because it means that the project has the potential to become a reality.Working in a small but so diverse group has been a gratifying experi-ence, allowing me to learn not only in design terms, but socially and culturally.At the start I found it a bit hard to engage with some tools such as the blog, but at the end I realize the potential this tool has and therefore managed to get into it to communicate where I am standing, where my project is going to and to create an online presence.

References.

-48-

BIBLIOGRAPHY.• Manufacture processes for design profesionals, Rob Thompson.• Smith, design for the other 90%, Smithsonian, New York. 2007• Bruce, N., R Perez-Padilla, and R Albalak, the health effects of indoor air pollution ex-posure in developing countries (Geneve: world health organization,2002)•Alastair Fuad-Luke, Eco design the source book, 2004, Thames and Hudson Ltd., Lon-don.•Architecture for Humanity, ed. Design Like You Give a Damn: Architectural responses to Humanitarian Crises. New York: metropolis books 2006.•Easterly William. The White Man’s Burden: why the west’s efforts to aid the rest have done so much ill and so little good. New York. 2006•Bornstein, David. How to Change the World: Social Entrepreneurs and the power of New Ideas. Oxford. 2004•Farmer, Paul. Pathologies of power. Berkeley, 2005.•Papanek, Victor. Design for the real world: human ecology and social change. Chigaco, 1984•Prahalad, C.K., The fortune at the bottom of the pyramid: eradicating poverty through profi ts. upper Saddle River, 2005.•Sachs, Jeffrey D. The end of poverty: economic possibilities for our time. New York. 1999.•Povertynet “Overview: understanding poverty.” world bank. http://web.worldbank.or?wbsiteexternal/topics/expoverty• http://www.newdawnengineering.com/website/stove/singlestove/vesto/* http://www.turbostove.fi /englanti/turbostove.php3 * www.dutchtub.com/* http://en.wikipedia.org/wiki/Rocket_stovePHOTOGRAPHIC CREDITS:Tereza Diaque.

Javier Diaque Final DVR submission

Documents

Transcript of Javier Diaque Final DVR submission