Wollo University[KIOT]

K I
O T
Prepared By- Rezene Muruts

Tadesse Mezigebu

Melese Fantahun

Edomias Aself

A Thesis Submitted to Department of ‘mechanical engineering’ of

Kombolcha Institute of Technology in Partial Fulfillment of the
Requirements for the Degree of Bachelor of Science in manufacturing
and industrial engineering

Bachelor Science Thesis

Wollo University
Kombolcha Institute of Technology
Department of mechanical engineering
MED-2015-026BSC

SOLAR BOX COOKER

 Wollo University[KIOT] 2007E.C

K I Bachelor of Science Thesis: MED-2015-

026BSC
O T
Title: Solar Box Cooker

Rezene Muruts ID.NO ITR 762/03

Tadesse Mezigebu ID.NO ITR 846/03
Melese Fantahun ID.NO ITR635/03
Edomias Aself ID.NO ITR1135/03

Approved: Examiner: Advisor:

Habtamu Mulatu
Date: Chairperson: Co-advisor:

12/10/2007E.C
 Wollo University[KIOT] 2007E.C

ABSTRACT
The overall aim of this thesis project is to use solar box cooker, so as to avoid the Problems that
are caused due to un conformability of cook food temperature to customers especially kids and
make the temperature of cook food to a suitable condition that can give more satisfaction. In this
project flat plate collectors are designed in order to have good energy input when it is cloud and
clear sky.

This thesis includes the design and analysis of flat plate collector components, material selection
for each component of the collector, with respect flow rate, losses appear in the collector.

The main goal of this study was to improve the design of the solar box cooker to make it more
relevant, intuitive, and user friendly to the emerging middle class, rural households in
kombolcha. This goal was aimed at spurring adoption of the solar box cooker so that these
households can reduce their reliance on nonrenewable fuels, but not substantially change their
way of life.

The project is focus on input data’s and this section is described the input data was used to carry
out this project. The project is conducted by mechanical engineering students at Wollo
University and the location is suitable to run the project because kombolcha receive sufficient
amount of sun radiation.

The project is focus on desiring the main elements of solar cooker and it includes material
selection and the design is based on thermo siphon principle and a choice focus on simplicity,
installation and maintenance cost as well as durability.

The remaining parts of the project are installation and manufacturing.

Page I
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

ACNOWLEDGEMENT
First of all we would like to thank god for giving us the sprit do this project. Next to this we
would like to express our deepest thanks to advisor Mr. Habtamu Mulatu for his support and
invaluable comments. Finally we would like to express that we are great full to pour parents for
their encouragement. Patience and unfolding support in our academic career.

Rezene Muruts ITR/0762/03

Tadesse Mezigebu ITR/846/03

Melese Fantahun ITR/635/03

Edomias Aself ITR/1135/03

Bsc. Mechanical Engineering;

kombolcha institute of technology 2015 G.c

Page II
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Table of content

Contents
ABSTRACT..................................................................................................................................... I
ACNOWLEDGEMENT ................................................................................................................. II
Table of content ........................................................................................................................ III
List of Figures ........................................................................................................................... VI
List of tables ............................................................................................................................. VII
Acronyms ............................................................................................................................... VIII
Chapter One .................................................................................................................................... 1
1. Introduction .......................................................................................................................... 1
1.1 Advantage of solar energy ................................................................................................ 2
1.2 Back ground of the study .................................................................................................. 2
1.3 Statement of the problem .................................................................................................. 3
1.4 Objective ........................................................................................................................... 4
1.5 Significance of the study................................................................................................... 4
1.6 Scope of the study ............................................................................................................. 4
1.7 Methodology ..................................................................................................................... 4
1.7.2 Research Methodology .................................................................................................. 5
Chapter Two.................................................................................................................................... 6
2. Literature Review....................................................................................................................... 6
2.1.1 Solar oven or box type cooker:- ..................................................................................... 7
2.1.2 Parabolic- type solar cooker: - ....................................................................................... 7
Chapter three ................................................................................................................................. 10
Result and Discussion ................................................................................................................... 10
3.Design and analysis of solar cook box ................................................................................... 10
3.1 Conceptual design ........................................................................................................... 10
3.2 Overall Dimension .......................................................................................................... 11
3.3 Thermal analysis ............................................................................................................. 11

Page III
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
3.4 Solar angles ..................................................................................................................... 14
3.4.3 Declination (δ) ............................................................................................................. 16
3.4.9 Solar radiation on an inclined surface .......................................................................... 22
3.4.10 Estimated energy load calculation ............................................................................. 24
3.4.11 Heat loss from solar box cookers ............................................................................... 26
3.4.12Heat loss from the wall and floor ................................................................................ 28
3.4.13 Efficiency calculation ................................................................................................ 29
3.5 Geometrical analysis ........................................................................................................... 30
3.5.1 Material selection ......................................................................................................... 30
3.5.1.1 Material selection for the transparent cover.............................................................. 30
3.5.1.2 Material selection for the reflector plate and the collector ....................................... 30
3.5.1.3 Material selection for insulation ............................................................................... 31
3.5.2 over all area, mass, volume, and weight calculation.................................................... 33
3.5.3 Design of leg ................................................................................................................ 42
3.5.4 Design of hinge ............................................................................................................ 43
3.6 Working principle of solar cook box .................................................................................. 44
3.7 Cost analysis ....................................................................................................................... 45
3.7.1 Engineering Cost .......................................................................................................... 45
3.7.2 Pay back ....................................................................................................................... 45
3.8 Manufacturing ..................................................................................................................... 46
3.8.1 Glass cover ................................................................................................................... 46
3.8.2 Absorber ....................................................................................................................... 46
3.8.3 Insulation..................................................................................................................... 46
3.8.4 Leg ............................................................................................................................... 46
3.9 Safety .................................................................................................................................. 46
3.9.1 Cleaning ....................................................................................................................... 46
Chapter Four ................................................................................................................................. 47
4.1 Conclusion .......................................................................................................................... 47
4.2 Recommendation ................................................................................................................ 48

Page IV
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Reference .................................................................................................................................. 49
Appendix ................................................................................................................................... 50

Page V
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

List of Figures
Figure 2.1:box type cooker ............................................................................................................. 7
Figure 2.3: geometric analysis of box cooker ................................................................................. 9
Figure 3.1 Conceptual design ....................................................................................................... 10
Figure 3.2: Over all dimension ..................................................................................................... 11
Figure 3.3: conceptual design ....................................................................................................... 12
Figure 3.4: angles of solar radiation ............................................................................................. 17
Figure 3.5: heat transfer though ash well ...................................................................................... 26
Figure 3.6:Outer cover of cook box .............................................................................................. 33
Figure 3.7:Internal part cook box of the solar............................................................................... 37
Figure 3.8: Leg .............................................................................................................................. 43
Figure 3.9: Hinge .......................................................................................................................... 43
Figure 4.1: developed outer part ................................................................................................... 50
Figure 4.2: developed internal part ............................................................................................... 51
Figure 4.3: the reflector................................................................................................................. 52
Figure 4.4: the hinge ..................................................................................................................... 53
Figure 4.5: the leg ......................................................................................................................... 53
Figure 4.6: overall sectioned cook box ......................................................................................... 54

Page VI
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

List of tables
Table 3.1: Area covered by the reflector ...................................................................................... 12
Table 3.2:Time usage per day ....................................................................................................... 14
Table 3.3:Maximum Mean Monthly Temperature ....................................................................... 15
Table 3.4: Minimum Mean Monthly Temperature ....................................................................... 15
Table 3.6: Summary of 12 month critical value of different radiation ......................................... 22
Table 3.7: Material selection for transparent cover ...................................................................... 30
Table 3.8: Material selection for the reflector plate and the collector .......................................... 31
Table 3.9: Material selection for insulation .................................................................................. 32
Table 3.9: solar box cooker dimensions ....................................................................................... 33
Table 3.10: Area for the aluminum plate ...................................................................................... 39
Table 3.11: area of the foam ......................................................................................................... 41
Table 3.12: solar box cooker cost analysis ................................................................................... 45

Page VII
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Acronyms
Nomenclature units

N = average day of the month [days]

Φ =latitude constant [degree]

G sc = solar constant [W/m2]

ω s = sunset hour angle [degree]

δ = declination [degree]

I = solar insulation [W/ m3]

AC = collector area [m2]

Q1 = input energy [m/s]

V = wind velocity [W/m2 k]

U t = top loss coefficient [W/m2 k]

U e = edge loss coefficient [W/m2 k]

R b = geometric factor -

Q = volume flow rate [m3 /s]

ṁ = mass flow rate [kg / s]

η c = collector efficiency [%]

Ac = collector area [m2]

hw = wind heat transfer coefficient [W /M2ᵒc]

N = no of glass covers -

Ta = ambient temperature [ᵒC]

Ne = no of pass -

UL = total heat loss coefficient [W/m2 k]

Ρ =density [kg / m3]

Page VIII
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
ε = emissivity -

τ = transmittance -

α = absorpivity -

Kb= thermal conductivity of insulation [W/m ᵒ c]

Lb= thickness of insulation [m]

QL = rate of heat loss [Watt]

K e = edge thermal conductivity of insulation [W /m ᵒc]

T e = thickness edge insulator [m]

Qreq = energy required [watt]

Qpas = passive solar gain [Watt]

Page IX
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Chapter One

1. Introduction
Energy is one of the most fundamental parts of our universe. We use energy to do work. Energy
lights our cities. Energy powers our vehicles, trains, planes and rockets. Everything we do is
connected to energy in one form or another.

Energy is defined as: "The ability to do work."

There are many sources of energy. In The Energy Story, we will look at the energy that makes
our world work. Energy is an important part of our daily lives. The forms of energy we will look
at include:

 Electricity
 Biomass Energy - energy from plants
 Geothermal Energy
 Fossil Fuels - Coal, Oil and Natural Gas
 Hydro Power and Ocean Energy
 Nuclear Energy
 Solar Energy
 Wind Energy

The majority of renewable energy technologies are directly or indirectly powered by the Sun. It
is the indirect source of nearly every type of energy used today. The exceptions are geothermal
energy, and nuclear fission and fusion. Even fossil fuels owe their origins to the sun; they were
once living plants a solar energy

Our monthly fuel and utility bills are constant reminders of the cost of America's standard of
living. And the "experts" warn that the crisis is here to stay and also today’s climate of growing
energy needs and increasing environmental concern, alternatives to the use of non-renewable and
polluting fossil fuels have to be investigated. Of the alternatives to conventional forms of energy,
the one receiving most serious consideration--at least for home, farm and small business heating
needs--is solar energy.

Page 1
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

1.1 Advantage of solar energy

 Heat foodstuffs, through solar ovens.
 Heat water or air for domestic hot water and space heating needs using solar thermal
panels.
 Heat and cool air through use of solar chimneys.
 It needs no fuel and produces no waste or pollution.
 In sunny countries, solar power can be used where there is no easy way to get electricity
to a remote place.
 Handy for low-power uses such as solar powered garden lights and battery charger.

 We've used the Sun for drying clothes and food for thousands of years, but only recently
have we been able to use it for generating power.

1.2 Back ground of the study

As much as air and water, human beings require energy for existence. Now a days in the most
advanced countries the cleanness of the air the people breath, the water they drink, and the type
of energy consumed measure the level of development.
In the last century even though the global development solely depend on non renewable energy
sources, there have been significant effort to utilize renewable energy sources: hydro, solar,
biomass, geothermal, wind and ocean waves.
The sun is indirectly responsible for the cycle generation of energy resource .renewable energy
resources such as hydropower potential, wind and fuel are generated by a process that utilizes
soar energy. The energy produced and radiated by the sun, more especially the term solar energy
refers to the suns energy that reaches the earth. Solar energy, received in the form of radiation
can be converted directly or indirectly into other forms of energy, such as heat and electricity,
which can be utilized by man. Since the sun is expected to radiate at an essentially constant rate
for a few billion years, it may be regarded as an inexhaustible source of useful energy. The major
drawbacks to the extensive application of solar energy are:

1. The intermittent and variable manner in which it arrives at the earth's surface and

2. The large area required to collect the energy at a useful rate.

Energy is radiated by the sun as electromagnetic waves of which 99% have wavelengths in the
range of 0.2 to 4 micrometers. Solar energy reaching the top of the earth’s atmosphere consists of
about 8% ultraviolet radiations [short wave lengths, less than 0.39 micrometers], 46% visible
light [0.39 to 0.78 micrometers], and 46% infrared radiation [long wave length more than 0.78
micrometers]. (Reference: [1])

Page 2
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
To better inform our approach to this project alternative review was performed to determine back
ground information in our target population in Ethiopia including fuel usage traditional `foods,
cultural practice and more.

Using heat from the sun to cook food and produce hot water represents the simplest most
practical application of solar energy.

In most parts of the world using solar energy for day to day domestic cooking is not feasible
because of the climatic conditions, however the use of solar energy for recreational cooking
seems to be a far more viable option.

Ethiopia because of its proximity to the equator country enjoys receiving adulate sun shine
throughout the year. Ethiopia has 7466232 Tera joule potential reserve of solar energy, from that
7432 Tera joule (Reference: [2]) is exploitable resource. This energy can be used for cooking
foods, heating water which is used for different purpose. Solar cooking foods are widely used in
countries like Israel and Australia while the experience of these countries shows solar energy can
be competitive with conventional source of energy in certain area of application in sunniest art of
the world.

1.3 Statement of the problem

As we know in our country most people use electricity , wood, gasoil as power source to cook
foods this power source are non renewable. This project is designed to improve the habit of using
natural and renewable resource which helps to protect our planet mother Earth from being
polluted and destroyed.

This project has good reasons to design

1.3.1Environmental hazard
The power sources are no renewable and most of them are the reasons for global warming which
is the current burning issue of our planet. Black carbon is generated by composition of fossil
fuels; biomass has recently emerged as the second largest contributor to reasoning global
temperature after carbon dioxide. Black carbon is responsible for 18% of global warming.

1.3.2 Economical issue

The vision of this project is to introduce the technology to the society and to state the advantage
of solar cooker from different aspects with fair price.

In fact solar cooker in foreign country is widely used , in most area of our country there is
electric system to boil the water. In order to substitute this electrical system by renewable system
the only way is using solar energy.

Page 3
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
1.3.3 Safety
Cooking and heating with solid fuels on open fairs or traditional stoves results in high levels of
indoor air pollution. In particular, biomass composition contains in many health damaging
pollutants such as particulate matter and carbon monoxide. Particulate matter has long been
associated with increased risk for serious respiratory and cardiovascular health problem.

1.4 Objective

1.4.1 General objective

The main objective of this project is to design solar cooker.

1.4.2 Specific objective

 To make with locally available material
 To comparing the different types of solar collectors
 To determine the amount of heat required to temperature rise
 To design the solar collector area
 To determine the losses occur by different sources
 Determining energy balance

1.5 Significance of the study

The main significance of the study is:-

It replaces and reduces the cost of electricity using non conventional energy
It creates a safe and emission free energy utilization for environment
Slows deforestation

1.6 Scope of the study

The study of this project seeks to apply the alternative of solar energy by using box type cooking.

We are doing this project only the design part. Are this research paper is going to be done in
kombolcha because it is suitable receive sufficient amount of sun radiation.

It is going to be finished in the middle the month i.e. may.

1.7 Methodology

1.7.1 Method of data collection

 By assessing many literature reviews.
 By collecting solar data from different books and sources.
 By conducting with metrology agency.
 Conceptual design on solar cooker.
Page 4
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
 Using Google site.

1.7.2 Research Methodology

To better inform our approach to this project, a literature review was performed to determine
background information on our target in konbolcha Wollo, including fuel usage, traditional
foods, cultural practices, and more. To better understand the experience of current and past
atmospheric condition, solar radiation, we conducted to metrology data.

Secondary data

Secondary data of this project is to reference the site area about the wither condition such as
atmospheric temperature; wend pressure, time of season from measuring and observation site.
Tools and Equipment required (secondary data)

 Data document
 Data recorder (pencil, data sheet)

The data record that was carried out was the following:

 Minimum atmospheric temperature

 Maximum atmospheric temperature
 Wend effect of cloud covers (speed)
 Hooting time per day

Page 5
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Chapter Two

2. Literature Review
Solar energy is a well proven technology that directly substitutes renewable energy for
conventional energy. There is considerable potential for using these technologies at federal
facilities in the south western United States or other areas with high direct bean solar radiation.
Facilities such as jails, motels and barracks that consistently use large volumes of hot water are
practically good candidate.

Solar energy uses for many applications like cooking, water heating using heat from the sun to
cook food and produce hot water is the most simplest, most practical application of solar energy

There are many types of solar energy for cooking from these classifications exist:-

Page 6
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

2.1.1 Solar oven or box type cooker:-This is an insulated box with a transparent glass
window on the side exposed to the sun. Additional radiation reflected in to the window by flat
reflectors arranged around it results in a solar intensification of two of four. The concentration of
the radiation combined with green house effect traps the heat within the space where the food is
placed which is slowly cooked. The box should be insulated and be air tight.

Figure 2.1:box type cooker(reference:[3])

2.1.2 Parabolic- type solar cooker: - here parallel sun rays are made to reflect on a parabolic
surface and concentrated focused in to the underside of the cooking pot. The temperature
obtained is very high but the lost due to convention and conduction are considered.

Page 7
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 2.2: parabolic type solar cooker (Reference: [4])

Page 8
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 2.3: geometric analysis of box cooker (Reference [5])

Page 9
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Chapter three

Result and Discussion

3.Design and analysis of solar cook box

3.1 Conceptual design
The essential features of the cooker are illustrated in Fig. 1. The features introduced to enhance
the overall performance of the design over the traditional solar-energy box cooker include, a
steam-relief line which helps to let off steam from the cooking chamber thus keeping the cooker
tidy and inhibiting corrosion of the absorber plate, a secular plane mirror reflector, which
increases the magnitude of solar radiation incident on the cooker surface.

β
θ
θ

Figure 3.1 Conceptual design

The cooking vessels are cylindrical in shape and have flat bases so as to ensure good thermal
contact with the absorber plate. The major mode of heat transfer to the vessel is by conduction
via the absorber plate.

The vessel covers are flat and each has a provision made for plugging a steam-relief hose.

A steam relief hose is provided for exit (from the cooking chamber) of steam, which, when
condensed in the chamber, reduces transmissivity of the cover, renders the equipment untidy and
may corrode the absorber plate. The hose is passed through the sidewall and it relieves steam
into the atmosphere.

Page 10
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Access to the cooking chamber is by raising the hinged lid. Solar radiation that impinges on the
glazing consists of three components, namely, direct and diffuse insulations and reflected
radiation from the plane reflector.

3.2 Overall Dimension

11144mm

Figure 3.2: Over all dimension

3.3 Thermal analysis

2.3.1 Light ray controlling

To calculate maximum radiation in the box first calculates the angle between the sun and the
reflector and the angle between the sun and the horizontal line.

Page 11
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
The sun ray:-

Where θ =the angle between the sun ray and the horizontal line

β =the angle between the sun ray and reflector

β
θ

Figure 3.3: conceptual design

Let's say the angle between the reflector and the box is 900 first calculate the angle between the
sun ray and the reflector that is, β by assuming the angle between the sun rays and the box (
horizontal line)

Table3.1: Area covered by the reflector

Θ A, (m) Area covered in the reflector, (m2)
15 0.2m 0.13m2
30 0.44m 0.27m2
40 0.64m 0.4m2
45 0.76m 0.5m2
60 1.3m 0.8m2

When θ= 150

Tanθ = = , a= 0.76tan 150

a = 0.2m

When θ =600 , a= 0.76tan 600

Page 12
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
a=1.3m

Then we conclude that θ could not be more than 450 because a cannot be greater than 0.76but it
will not be same as 0.76 because the sun is not in a fixed place since it is movable it will not be
always the same in one fixed degree but from 300 -450 , we choose 400 as the maximum a
distance then we can have maximum area of a maximum a distance we chose a= 0.64m

Then, Area = 0.64 * 0.6

= 0.4m2

3.3.2 Angle between adjacent lines

Then the angel between the reflector and the box θ + β in variable hours will be but θ= 400 then
β= 500 angel between the sun ray and the reflector.

Page 13
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Table3.2:Time usage per day
Daily hour Angle between sun ray Angle between sun ray Angle between
and reflector and horizontal box ,θ reflector and
horizontal box ,β + θ
1 15 40 55
2 30 40 70
3 45 40 85
4 60 40 100
5 75 40 115
6 90 40 130
7 90 40 130
8 75 40 115
9 60 40 100
10 45 40 85
11 30 40 70

3.4 Solar angles

The earth makes one rotation about its axis every 24h and completes a revolution about the sun
in a period of approximately 365.25 days. This revolution is not circular but it follows an ellipse
with the sun at one of the foci. The eccentricity, of the earth's orbit is very small, equal to
0.01673. Therefore the orbit of the earth round the sun is almost circular. The sun earth distance,
R, at perihelion (shortest distance at January 3) and aphelion (longest distance, at July 4) .

R=a(1 ± e) ................................................(*)

Where a = mean sun distance = 149.5985 * 106 KM.

The plus sign in Eq. (*) is for the sun-earth distance when the earth is at the aphelion position
and the minus sign for the perihelion position. The solution of Eq (*) gives values for the longest
distance equal to 152.1 * 106 KM and for the shortest distance equal to 147.1 * 106KM,The mean
sun earth distance a is defined as half the sum of perihelion and aphelion distance. Rif [17]

The sun´s position in the sky changes from day to day and from hour to hour. It is common
knowledge that the sun is higher in the sky in the summer than in the winter. The relative motion
of the sun and the earth are not simple they are systematic and thus predictable. Once a year the
earth moves around the sun in an orbit that is elliptical in shape. As the earth makes its yearly
revolution around the sun, it rotates every 24 hours about its axis, which is tilted at Angele of 23º
27.14min (23.45º) to the plane of the elliptic, which contains the earth´s orbital plane and the
sun´s equator.

The most obvious apparent motion of the sun is that it moves daily in an arc across the sky,
reaching its highest point at midday. As winter becomes spring and then summer, the sunrise and
sunset points move gradually northward along the horizon.

Page 14
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
3.4.1Thermal Model
The following section is describes the input data that was used to carry out this project. This
project is conducted by mechanical engineering students at Wollo University. And the location is
suitable to run the project because of two reasons those are, Kombolcha area receive sufficient
amount of sun radiation and easy to access the data.

Table 3.3:Maximum Mean Monthly Temperature (in degree centigrade)

JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
25.6 26.0 27.7 28.7 28.3 30.9 29.6 27.1 26.7 25.7 25.8 24.8

Table 3.4: Minimum Mean Monthly Temperature

JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
9.9 13.3 13.6 14.5 14.8 15.2 15.3 14.9 14.0 11.5 10.6 7.9
……………………………………………………………..Reference.[ 6 ]

The thermal model solves for the temperature inside the solar box cooker by solving the

Energy rate equation:

Q˙in- Q˙out= Q˙acc

Where Q˙in is the heat gain term [W], Q˙out is the heat loss term [W], and Q˙acc is the heat
accumulation within the SBC term [W].

The heat gain term is calculated as

Q˙in = (Arefl + Awindow) * H* sin (β)

Where H is the solar radiance [W/m2], β is altitude [º] and Arefl and Awindow [m2] represent the
amount of solar radiation (indirect and direct, respectively) the window of the SBC is exposed to.
The solar radiance is multiplied by the sine of the altitude to take into account the amount of
radiation that falls normal to the window.

First calculating the solar insulation per day

H= * Gsc(1+0.033cos ( ))*⦋cos(ϕ )cos(δ )(sin(ωs)) + sin(ϕ)sin(δ)

Where

n=average day of the month

ϕ =latitude angle (for Konbolcha = (11.08): is the angular location north or south of the equator

Page 15
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
GSC =solar constant = 1367 W/m2: is the energy from the sun, per unit time, received on a unit
area surface perpendicular to the direction of propagation

ωs =sunset hour angle: is the solar hour angle cross pounding to the time when the sun sets.

3.4.2 Solar Hour Angle and Sun Set hour Angle

The solar hour angles (ω),the angular displacement of the sun east or west of the local meridian
due to rotation of the earth on its axis at 15º per hour ,morning negative , afternoon positive [Rif;
[7] The solar hour angle is equal to zero at solar noon and varies by 15 hour angle degrees per
hour from solar noon.

The sun set hour angle (ωs), is the angle solar hour angle corresponding to the time when the
sun sets and it is given by:-

ωs= cos-1(-tan(ϕ)tan(δ))

Where ϕ, is a latitude which is the location of kombolcha from the equator is 11.08º[refrence
:[8]]

3.4.3 Declination (δ)

δ=declination: the angular position of the sun at solar noon (when the sun is on the local
meridian) with respect to the plane of equator, north positive :-23.45º≤ δ ≤23.45º.[reference :[9]]

To calculate the declination

δ = 23.45 sin {360( )}

Then to calculate the declination angle (δ) the value of average day of month (n) must be known.

Page 16
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Table 3.5: Recommended average days in months and average values of n by month

For the average days of the month

month n for ith

day of Month Date n, Days of year δ, Declination
January I 17 17 -22.48
February 31 + i 16 47 -22.85
March 59 + i 16 75 12.10
April 90 + i 15 105 -7.92
May 120 + i 13 135 4.02
June 151 + i 11 162 13.95
July 181 + i 17 198 22.3
August 212 + i 16 228 22.97
September 243 + i 15 258 17.65
October 273 + i 15 288 7.73
November 304 + i 14 318 -4.21
December 334 + i 10 344 -13.78

Figure 3.4: angles of solar radiation

3.4.4 Extraterrestrial Radiation

A solar system frequently needs to be judged on its long term performance therefore, knowledge
of long term monthly average daily insulation data for the locality under consideration is
required. Daily mean total solar radiation (beam plus diffuse) incident on a horizontal surface for
each month of the year is available from various sources, such as radiation maps or a countries

Page 17
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
metrology crevice. In this source data such as 24 hr average temperature, monthly average daily
radiation on a horizontal surface H (MJ/m2-d),and monthly average clearness index, KT, are
given together with other parameters, which are not of interest hear. The monthly average
clearness index KT, is defined as

KT =H/H0

Where

H = monthly average total insulation on a terrestrial horizontal surface (MJ/m2-d)

H0= monthly average daily total insulation on an exterritorial horizontal surface (MJ/m2)

The bar over the symbols signifies a long-term average.

Use n = 17 for January, the declination will be

δ = 23.45 sin {360( )}

= 23.45 sin {360( )}

= -22.48

Calculating sunset hour angle in degrees

Cosωs = -tan (ϕ) tan (δ)

= -tan (11.08˚) tan (-22.48˚)

=0.0810

ωs =85.35ºC

Then the insulation will be

Ho= *GSC (1+0.033cos ( ))*⦋cosϕ cosδ (sinωs) + sin (ϕ) sin (δ)
= *1367 (1+0.033cos ( ))*⦋cos11.08˚cos-22.48˚ (sin85.35˚)+ sin11.08sin-
22.48˚

=30749483.02J/m2 or =30.74948302MJ/m2 per hour

=355.896 W/ m2

Page 18
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
3.4.5 Prediction of monthly average daily global radiation on horizontal surface
Several empirical models have been developed to calculate global solar radiation using various
parameters. Angstrom (1924) developed the earliest model used for estimating global radiation,
in which the sunshine duration data and clear sky radiation to clear day radiation at the location
in question and average fraction of possible sunshine hour.

A basic difficulty with above Equation lies in the ambiguity of the term n/N and Ho. The
former is an instrument problem (sunshine records are open to interpretation).The latter stems
from uncertainty in the definition of clear day. Solar engineering of thermal process book and
other has modified the method to base it on extraterrestrial radiation on a horizontal surface
rather than on clear day radiation. The ratio H/Ho is termed the monthly average clearness
average clearness index.

KT = H/Ho= a + b (n/N)

The coefficient a and b can be determined from

a = -0.110 + 0.235cosɸ + 0.323(n/N)

b = 1.449 - 0.533cosɸ - 0.694(n/N)

Then for the first month January when n = 17

N= ∑

= 16

Then KT =H/Ho= a + b(n/N)

a = 0.10 + 0.235 cosϕ + 0.323 (n/N)

= 0.1 + 0.235 cos11.08˚ + 0.323( )

= 0.4738 and

b = 1.449 -0.533 cosϕ - 0.694 (n/N)

= 1.449 - 0.533cos11.08˚ - 0.694 (1.0625)

=0.18856

KT = a + b(n/N)
Page 19
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
= 0.4738 + 0.18856 (11.0625)

= 0.674

But KT =H/Ho, H = KT * Ho

H = 0.674 * 35.16

= 23.7W/m2

3.4.6Prediction of monthly average daily diffuse radiation on a horizontal surface

3.4.6.1Diffuse radiation:-The solar radiation received from the sun after their directions were
changed by scattering by the atmosphere. (Diffuse radiation is referred to in some metrological
literature as sky radiation or solar sky radiation: the definition used here will distinguish the
diffuse solar radiation from infrared radiation emitted by the atmosphere.)

The daily diffuse radiation, (Hd, W/m2) depends on the hour angle and the cloudiness ratio.

For ωs and 0.3 its possible to get from the equation:-

Hd/H = 1.311-3.022KT+3.427KT2-1.82KT3

For ωs and 0.3

Hd/H = 1.391-3.0560KT+4.18KT2-2.137KT3

Then we need the first equation:-

Hd/H=1.311-3.022KT+3.427KT2-1.82KT3

=1.311-3.2022(0.674)+3.427(.674)2-1.8(0.674)3

= 0.279848208

Then Hd = 0.279848208 * H

=0.279848208 * 23.7

= 6.6324W/m2

3.4.6.2 Beam radiation: The solar radiation received from the sun without having been scattered
by the atmosphere. It is often referred to as direct solar radiation, to avoid confusion between
subscripts' for direct and diffuse we use the term radiation.

Hb = H-Hd

Page 20
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
=23.7-6.6324

=17.0676W/m2

3.4.7Prediction of monthly average hourly global radiation on a horizontal surface

The monthly average hourly global radiation on the horizontal surface can be calculated from the
knowledge of the monthly average daily global radiation on a horizontal.

I/H = ω)(cos ω-cos ωs)/sin ωs- (cos ωs)

The coefficient a and b is given by :

a=0.409+0.5016sin (ωs-60˚)

=0.409+0.5016sin (85.35˚-60˚)

= 0.9106

b= 0.6609-0.4767sin (ωs-60˚)

=0.6609-0.4767sin (85.35˚-60˚)

=0.4568

In these equations, ω is the hour angle in degrees for the time in the day is given as

ω = (ST-12) * 15˚

where ST is standard time from 1 to 24 hour or time of sun gives light to earth , ST = 11

Then ω = (11-12) * 15˚

= -15˚

I=( ω)(cos ω-cos ωs)/sin ωs- (cos ωs))*H

= ( (0.9106+0.4568cos-15˚)(cos-15˚-cos85.35˚)/sin85.35˚- (cos85.35˚)) * 23.7

= 23.6511W/m2

3.4.8 Prediction of monthly average hourly diffuse radiation on horizontal surface

The ratio of monthly average hourly diffuse radiation on a horizontal surface to monthly average
daily diffuse is as a function of time of the day and the day length. It can be used to estimate
hourly average of diffuse radiation if the average daily total radiation is:-

Page 21
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Where, Hd= 6.6324

Id = (6.6324

= 0.84W/m2

After estimating the hourly values of global and diffuses radiation, monthly average hourly beam
radiation is calculated by the following relation:

Ib = I - Id

Ib = 23.6511-0.84

= 22.81W/m2

Table 3.6: Summary of 12 month critical value of different radiation

Mont Δ ωs N Ho a b KT H Hd Hb I Id
h (˚) (˚) (MJ/ (MJ/ (MJ/ (MJ/ (MJ/ (MJ/m2)
m2) m2) m2) m2) m2)
Jan -22.4 85.35 16 35.58 0.4 0.18 0.67 23.7 6.632 17.06 23.65 0.84
9 4
Feb -22.8 86.8 16. 36.35 0.45 0.22 0.67 25.4 6.91 18.96 23.88 0.88
2
Mar 12.1 88.6 16. 37.57 0.45 0.2 0.66 26.74 7.3 19.87 23.3 0.87
4
Apr -7.9 90.6 16. 37.67 0.46 0.18 0.66 27.2 7.6 29.1 24.33 0,93
8
May 4.02 92.3 17 37.05 0.47 0.18 0.65 26.7 7.58 19.65 23.99 0.94
Jun 13.95 93.2 17. 36.03 0.47 0.17 0.65 26.2 7.4 19.25 24.53 0.904
2
July 22.3 92.8 17. 37.44 0.46 0.16 0.65 26.3 7.49 19.36 23.22 0.918
1
Aug 22.97 92.4 17. 37.72 0.46 0.18 0.66 26.8 7.55 19.8 24 0.942
1
Sep 17.65 89.4 17 37.01 0.45 0.19 0.67 26.7 7.42 19.86 24.2 0.882
Oct 7.73 87.4 16. 36.31 0.45 0.21 0.67 25.7 7.02 19.16 23.66 0.872
3
Nov -4.21 85.7 16. 35.72 0.44 0.22 0.67 24.1 6.52 18.1 23.44 0.854
5
Dec -13.7 84.9 16 34.11 0.44 0.23 0.66 23.2 6.25 17.43 23.23 0.813

3.4.9 Solar radiation on an inclined surface

The most favorable orientation of a collector, for heating only , is facing due south at an
inclination angle to the horizontal equal to 15˚.
Page 22
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
(β = 11.08˚ + 15˚) = 26.08˚

Hence, the inclination angle of the reflector solar cooker box should be 26.08˚.The general form
of total hourly solar radiation energy incident on inclined surface it is given by Liu and Jordan
formula,

It = IbRb + IdRd + ρRr (Ib + Id)

Where are known as conversion factor form beam, diffuse and reflective components,
respectively is the reflection coefficient of the ground 0.2 and 0.6 for non-snow-covered and
snow-covered ground respectively for this site select. Expression for these conversion factor
are:-

1, Rb defined as the ratio of flux of beam radiation incident on an inclined surface to horizontal
surface.

Rb =

Angle of incident: - means the angle between the beam radiation on a surface and the normal to
that surface.

CosѲi = cos (ф-β) cosδcosω + sin (ф-β) sin (δ)

= cos (11.08˚-26.08˚) cos (-22.48˚) cos (15˚) + sin (-22.48˚-26.08˚) sin (11.08˚)

= 0.72

CosѲi = cos (ф) cos (δ) cos (ω) + sin (ф) sin (δ)

=cos11.08˚cos (-22.48˚) cos (15˚) + sin (11.08 ) sin (-22.48˚)

= 0.802

Therefore Rb =

= 0.8973

2, Rd defined as the ratio of the flux of diffuse radiation falling on the tilted surface to the
horizontal surface. This conversion factor depended on the distribution of diffuse radiation over
the sky and on the portion of sky seen by the surface. But a satisfactory method of estimating the

Page 23
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
distribution of diffuse radiation over the sky is yet to be found. It is however, widely accepted
that the sky is an isotropic source of diffuse radiation.18W/m2

Rd =

= 0.949

3, Rr the reflected component, which comes mainly from the ground and other surface, and is
given by

Rr =

= 0.0509

For the collector modeling, the flux collected per unit time is given by

It = IbRb + IdRd + ρRr (Ib + Id)

= 23.3(0.8973) + 0.878(0.949) + 0.6(0.0509)(23.3 + 0.878)

= 24.178

3.4.10 Estimated energy load calculation

In this design and manufacturing of solar cook box the fluid we use to cook is water so that water
starts evaporate at, 100˚C and totally changed to steam at 170°C this shows 135°C is the average
of two values, and it can cook meal.[Reference:[10]] Depending on this reality the energy gain
from solar radiation can be calculated by using this equation.

Qload = CpρVt (T2 – T1)

Where, Ρ = density (1Kg/i)

Cp of H2O= 4200

T1 = cold water (ambient temperature) Equal to 26°C which is yearly average value taken from
metrology agency shown in proposal.

T2 = required water 135°C

Page 24
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
V = required amount of water volume which is assumed to be 7L, this assumption depends on
the size of box and volume.

To find the solar energy on the above assumption;-

Qload = CpρVt (T2 – T1)

= 4200 * 1 * 7(135-26)

= 3204600

Page 25
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
3.4.11 Heat loss from solar box cookers
A). Convection heat transfer

B) Conduction heat transfer

3.4.11.1 Convection heat transfer

Qconv = hA (Ts2 – T1)

Where h = 25 w/m2k

K = 1 W/M

L = 0.76m

Then =

= =

TS2= 304.45 K

Figure 3.5: heat transfer though ash well

Page 26
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Qconv = hA (Ts2 – T1)

= 25W/M2.K *0.456m2 (304.45 -299) K

= 62.13W

3.4.11.2 Radiation heat transfer

Q rad = ԑΔa ( T24 – T14)k4

Where: - = is the Stefan Boltzmann constant = 5.67*10-8w/m2.k4

= 5.67*10-8w/m2k4*0.456m2*1 (4084-2994) k4

=50.981 w

The losses occurring along the way are mainly due to:-

Optical radiation through partial reflection for and absorption by the cover glass in combination
with incomplete absorption inside the cooking box/ pot, with the remanded being reflected,. The
radiation given off by all warm to parts of the solar cooker- Box-type solar cookers exploit the
thermal radiation given off by the inside of the box and the cooking pot by trapping it under a
glass cover that does not let the thermal radiation pass through, but instead absorbs it, heats up
and then radiates heat itself;

Heat conduction, despite careful thermal insulates: through the insulation in the cooking box
through its transparent cover glass.
Convection by, either circulating within the cooker due to differences in temperature at
different points of the cooker, or due to cooling effect of wind on the outside cooker. with
outstanding consideration of the said transfer and loss, the active thermal power, Qeff(heat loss)
inside a solar cooking box can be described by:-

Optical gain through radiation, transmission and absorption (including reflection loses )

Qopt = G*A*ԑ*α
=where Q opt = optical power gain
G = irradiance =1367w/m2

A = Aperture of solar cooker = 0.456m2

ԑ = transmittance through the cover =0.8

α = mean absorption inside the cooker =1 for black material

Q opt = G*A*ԑ*α

Page 27
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
= 1367w /m2 *0.456m2 * 0.8 * 1

= 498.68W

Heat loss through transparent cover, summarized by coefficient of heat transmission for the gap,
UA including heat conduction, radiation, and convection, and which, to be precise, is a function
of temperature;

QL, A=Ut*T*A*∆T
Where QLA=thermal power loss through gap
Ut=Heat transfer coefficient of cover (gap)
T=temperature transfer through the glass to cook pot 135ᵒ

∆T=temperature head between the inside, and outside of the cooking box

The absorber plate temperature increase the top heat loss coefficient increase due to higher
losses at higher temperature .Therefore it is important to place the cooker in a sunny spot out of
the wind in the cooking area .

UA=12w/m2 ᵒC

QL, A=UA*T*A*∆T

QL, A=12w/m2ᵒC*0.66m2*109ᵒC

=863.28W

3.4.12Heat loss from the wall and floor

Heat loss from the wall and floor (the floor of the cooker is treated the same as the wall) consists
of conduction, convection and radiation.

q₺=T1-T2/R

Where q₺ is the heat flux (W) and R is the thermal resistance in units of (ᵒC / W). T1and T2is Cᵒ
the temperature of the opposing walls of the cooker (in absolute Kelvin).

An empirical equation [Reference:[11]] predicts a thermal resistance of 0.39 units for the 5.0 cm
thick wall (with only air in between ), when T1=299K (26ᵒC), T2 =408 K (135ᵒC) and. Doubling
of the wall to 10.0 cm results in only about a 6% increase resistance R.

Since the wall of absorber is the value of R become

R = (0.06*0.39) + 0.39

= 0.413M2W/ᵒC

Page 28
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Q eff = (G’*A*T*α) + (Ut *A*∆T) + (Ub * A * ∆T) + (T2-T1)/R

= (1367 W/m2 *0.66m2*408K*1) + (12W/m2*0.66m2*109K) +

(2.78W/M2K*0.66M2*109K)+(135-26ᵒc)/0.413M2W /ᵒC)

= 369.2kW

Sum of all heat loss =Q eff +Qconv + Q rad

=369.2 kW +0.5098kw + 0.06213 kW

= 369.8 k w

3.4.13 Efficiency calculation

Based on the of thermodynamics:

Energy input = energy output + energy losses

Ei = H * ASC

H = total solar energy occurrence upon of the solar air being heated in W/m2 which is
calculated in solar in solar radiation to 23MJ/ m2 (surface energy)

ASC = is the surface area of the solar cooker in m2 equal to 1.71 m2. Almost half of this total area
is useable (0.855) m2 depend on light direction.

Ei = 23.7 MJ/M2*033m2

= 7.821 MJ

Energy output = Energy input - Energy losses

= 7.821MJ – 3.698MJ

= 4.123MJ

Energy efficiency of the solar cooker can be found as shown below

η=

= 0.52*100%

= 52%

Page 29
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

3.5 Geometrical analysis

3.5.1 Material selection
 Density
 Availability/Manufacturability
 Cost
 Appearance

Based on the above property there are a list of materials choose for all components.

3.5.1.1 Material selection for the transparent cover

A transparent is needed in solar collector to help provide the „green house effect‟ necessary to
cook. A good transparent cover should have:
 High transmittance to ultraviolet radiations.
 Low transmittance to infra-red radiation in order traps the radiated heat from the absorber
plate.

Table 3.7: Material selection for transparent cover (reference[12])

Material Thickness(m) Density(Kg/m3) Specific Thermal

heat(J/KgK) capacity(Whr/m2
K)
Glass 3.175*10-3 2.489*103 0.754*103 1.659
Fiber glass 6.35* 10-3 1.399*103 1.465*103 3.61
Acrylic 3.175*10-3 1.189*103 1.465*103 1.534
Polyester 1.27* 10-3 1.394*103 1.046*103 0.051
Polycarbonate 3.175*10-3 1.199*103 1.193*103 1.260

Low cost glass is preferred because it has high transmittance to infra-red radiation and it is
stable.
The main disadvantage is that it has a low resistance to shatter.

3.5.1.2 Material selection for the reflector plate and the collector
For both reflector and collector bottom, and side plates we use same material. Copper,
aluminum, mind steel, and galvanized iron are alternative materials. Among those material
copper is best material for absorber plate because it has high thermal conductivity but it has one
constraint that is it is coasty.

Page 30
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Table 3.8: Material selection for the reflector plate and the collector (reference[12])
Material Density(Kg/m3) Specific heat(KJ/Kg ) Thermal
conductivity(W/m )
Aluminum 2707 0.996 204
Iron 7897 0.452 73
Steel 7833 0.465 54
Copper 8954 0.383 386
Brass(70/30) 8522 0.385 111
Silver 10524 0.234 419
Tin 7304 0.226 64
Zinc, pure 7144 0.384 112

Aluminum is used as absorber plate because relatively cheap, it has a good means of attachment
with other material, and it has good thermal conductivity.

3.5.1.3 Material selection for insulation

Several thermal insulating materials which can be used to reduce heat losses from the absorbing
plate and case are commonly available.

The desired characteristics of an insulating material are

Low thermal conductivity,

Stability at high temperature (up to 200 )

No degassing up to 200
Self-supporting feature without tendency to settle,
Ease of application,
No contribution in corrosion and low cost

 Insulation used to reduce heat loss in the collector in order to improve efficiency.
 Alternative materials are glass wool, sawdust, wood shaving, and Styrofoam.

Page 31
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Table 3.9: Material selection for insulation (Reference[12])
no Name of material Thermal Densit Out aging Color Remark
conductivity( y gassing change
w/m )
1 Crown white 0.034 48 No Yes No Good but
wool expensive
2 Crown bonded 0.066 48 Yes No Yes Not good
3 Spintex 0.975 48 No No No Good,
300industrial reasonable
4 Glass wool 0.044 48 No Yes Yes Good
5 Calcium silicate 0.017 251.6 No No No Good, but
component
system become
very heavy
6 Expanded poly 0.017 32 Yes No Yes Not good
stryrene
7 Isocyanurate 0.020 32 No No Yes Under testing
8 Foam 0.017 32 No No No Good

Among these alternatives Styrofoam is used because

 Relatively cheap.
 Easily available.
 Low thermal conductivity.

Page 32
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
3.5.2 over all area, mass, volume, and weight calculation

Table3.9: solar box cooker dimensions

Dimension (m)

height of reflectors H=0.76

width of outside box, wo =0.60

length of outside box Lo =0.25

width of inside box wi =0.60

length of inside box Li =0.71

depth of box D=0.25

3.5.2.1Outer Cover Of The Cook Box

Figure 3.6:Outer cover of cook box

We choose material for this outer part stainless steel because of the above stated physical
properties.

Page 33
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
To calculate the mass of the reflector and the bottom side:-

Thickness= 0.00635m

Length = 0.76m

Width =0.6m

To calculate the volume, V1

V1= t * L * W

= 0.00635 * 0.76 * 0.6

=0.002895m3

Since we are calculating for the reflector and for the bottom side

2*V1=2 * 0.002895m3

= 0.00579m3

To calculate volume for the right side, V2

Thickness = 0.00635m

Page 34
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Length = 0.76m

V2= t * L * W
= 0.00635*0.25 * 0.76
= 0.121m3
Since we have two sides with the same dimension
2 * V2= 0.121m3=0.242m3

To calculate the volume of the left side, V3

Thickness =0.00635m
Length = 0.6m

Width = 0.25m

V3= t * L * W

= 0.00635 * 0.6 * 0.25

= 0.0009525m3

Page 35
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Since we have two sides with same dimensions:-

2 * V3= 0.001905m3

Therefore the total volume of the outer box is:-

Vt= V1+V2+V3

= 0.00579+ 0.242 + 0.001905

=0.25m3

To calculate the mass of the outer container we need density, then for sheet metal

Density = 7.85 g/in3.

Then mass = volume * density

= 0.25m3 * 7.85 g/in3

= 4.9 kg = 5 kg

3.5.2.2 Internal Part of the Cook Box

Construction

Important general considerations in the selection of materials for construction of the cooker
Included, local availability, low cost, easy handling during fabrication, lightness of weight for
easy, handling during use, weather ability and long service life (i.e. ability to withstand
environmental and operating conditions) and non-toxic effects. Commercially available 0.001m
(l mm) thick aluminum plate was used as absorber plate. This was painted matt black to improve
its absorptive. Aluminum satisfies the absorber plate desirable characteristics of good thermal
conductivity and high resistance to corrosion [Reference [13] and aluminum plate thickness of
between 0.0056 in has been determined previously to give optimum results [Reference [14]]
Copper, which is a better material is expensive and not readily available. The glazing material
was commercially available 0.004m (4mm) thick tempered glass. Glass satisfies the cover
desirable properties of high optical transmittance, low reflectivity, low transmittance to heat and
low absorptance of solar radiation. The solar cooker thus consists of a 0.0056in [Reference [15]]
thick aluminum tray shaped in the form of an inverted square-based pyramid. Its base is 26 in *

Page 36
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
20 in and the slant height is 5.09 in. The top consists of an aluminum-framed, glazed lid with a
transparent surface area of 0.73m *0.58m. The tray is enclosed in a 0.76m * 0.6m * 10in sheet
metal box. The gap between the tray and the box is filled with foam insulator. The reflector
consists of a stainless steel framed commercially available aluminum, which is sized to form a
cover for the box when not in use. Provision is made for four cooking vessels each capable of
holding up to l.5Kg of water.

Figure 3.7:Internal part cook box of the solar

The dimension is in meter. To find the total mass of the internal part cook box first calculate the
area of the aluminum plate

Calculate the mass of the aluminum plate

the area of aluminum plate is more than that of the calculated area because we need some
clearance cover for hook the foam perfectly.

Page 37
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
To the length part

Then we have two triangles with the same dimension then we make it one rectangle to calculate

Then area of rectangle length * width

A1 = 0.18 * o.11= 0.0183m2

Page 38
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Total area =A2 = 0.0183m2 + 0.154m2

= 0.172m2

Total = A1+A2

=0.156 +0.172

=0.33m2

 Since we have two faces with the same dimension.

= 2 *0.33m2
=
0.66m2

Table3.10: Area for the aluminum plate

Internal sides of the cook box Area of each sides in (m2)
1, side to the length part 0.2245m2
2,sides to the width part 0.22m2
3, side to the length part 0.2245m2
4,sides to the width part 0.22m2
6,the reflector 0.57m2
7,the bottom side 0.465m2

AT = 0.2245m2 + 0.22m2 + 0.2245m2 +0.22m2 +0.57m2 + 0.265m2

= 1.71m2

The thickness of aluminum = 0.00014m

Volume = area * thickness

= 1.71m2 *0.00014m

= 0.00024m3

Page 39
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Then the density of aluminum = 0.0442kg /in3

Mass = volume * density

= 0.00024m3 * 0.0442 kg /in3

= 0.74 kg

Calculate mass of the foam

We have also mass of foam calculate total area of foam to the length part.

To calculate first add the two triangle ass one rectangle, then the area of rectangle = length *
width

= 0.13m * 0.025m

= 0.33m2

The rectangle itself will be

0.66 *0.13 = 0.086m2

Then A1 = 0.33m2 +0.086m2= 0.42m2

A2 =0.71m * 0.13m =0.0923m2

AT =0.42 + 0.0923 =0.52m2

Page 40
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
Then we have two sides with same dimension then

2AT = 2 *0.52m2

=1.03m2

Table 3.11: area of the foam

Sides of the foam Area of each sides in (m2)

1,side to the length part 0.175m2

2,side to the width part 0.14m2
3,side to the length part 0.17m2
4,side to the width part 0.14m2
5,The reflector 0.47m2

6,the bottom side 0.34m2

Then the overall area will be

= AT1+AT2 + AT3 + AT4 + AT5 + AT6

=0.175 + 0.14 + 0.17+ 0.14 + 0.47 + 0.34

=1.44m2

 Density of the foam which is extremely porous solid foam with connectivity and has a
density between 0.0011 to 0.5 g/cm3 with a typical average of around 0.02g/cm3.

= 0.02g/ cm3*16.387cm3/in3 * 1/1000Kg/g

= Kg/in3

= 0.00032774Kg/in3

Then mass of foam will be = volume * density

But volume = Area * thickness

=1.44m2 * 0.05m

=0.073m3

Then mass will be = 4420in3* 0.00032774Kg/in3

= 1.3 Kg

Page 41
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C
3.5.3 Design of leg
The leg of the cook box is made of steel in order to with the cook box by welding .

But to know the stress in the leg we have to know the overall weight of the box. i.e.

Total mass = 7.04Kg

Total weight = mass * gravity

= 7.04Kg * 9.81 m/s2

= 69.0624N

But we have four legs in each corner of the box, then the stress on one leg will be :-

Stress = =

Area = 0.05m * 0.05m

= 0.0025

Then stress = = = = 6906.24

Since the stress is very small we choose for this , a material used for simple things like tube,
rivet bars and wire which is Fe 290, that has minimum tensile strength of 290 .

Page 42
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 3.8: Leg

3.5.4 Design of hinge

The hinge is made from wood but the hinge locker is made from the sheet metal that we choose
for the cook box in order to attach simply by welding b0th the hinge and the locker.

Figure 3.9: Hinge

Page 43
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

3.6 Working principle of solar cook box

The solar radiation directly strikes the reflector and reflected back in to the box cooker through
glazing and causes the box very hot. Then the insulation causes to insulate or to catch the heat
and the glazing protects the ray in order to not exit out of the box so the stew or other meals gets
cook.

Page 44
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

3.7 Cost analysis

3.7.1 Engineering Cost
The project is free of engineering cost. Engineering cost is a cost of assuming each part of the
machine body.

This budget was designed to be within a range

Table3.12: solar box cooker cost analysis

No Part Name Quantity dimension Unit cost Total cost
1 Glass cover 1 0.76m*0.6m 340birr/m2 142birr
2 Insulation 3 0.67m*0.6m 250birr/m2 301.5birr
3 Welding work - - - 400birr
4 Labor cost 2 - 1200birr/m2 2400birr
5 Aluminum sheet 3 2m*1m 170birr/m2 510birr
6 Stainless steal 3 0.76m*0.6m 950birr/m2 1300birr
Total cost 5053.5birr

3.7.2 Pay back

Since its material is very simple and locally available its pay back will not be that much huge,
and also we have labor cost, generally the total cost of that cook box is 5053birr. Then we ask for
mothers and they spend averagely per day 17 Birr for 12Kg of wood. That means per year will
be

= 6205birr

Then, Pay back = *365days

=298days

Page 45
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

3.8 Manufacturing
With the dimensions that we obtain from our analysis of the design the following are going to be
ready with the following manufacturing processes to several parts to satisfy the main target of
the project.

3.8.1 Glass cover

A 0.76m *0.6m glass is going to be prepared for the fulfillment of the requirement heating effect
of the above mentioned volume of meals to the required temperature. These are then to be
supported by the side frames of the box frame.

3.8.2 Absorber
An aluminum sheet plate will be prepared according to the designed dimension value and will be
corrugated and painted with black paint...

3.8.3 Insulation
All insulations are made of Styrofoam.
Back Insulation
A two (0.76mx0.254 m) is going to be prepared.
Bottom insulation one (0.8m) * 0.7m
Side Insulation
A two o.6m x 0.254 m and one for the reflector (0.76m * 0.6m) going to be prepared.

3.8.4 Leg
These are standard beam materials of 50x 100 mm and 50 mm thickness square cross section.
These are needed to support the box itself.

3.9 Safety
3.9.1 Cleaning
The contaminants either in solid, liquid or gaseous state may harm the cook box. As
contaminants can affect the performance and life of the cook box in many ways cook box must
thoroughly cleaned prior to assembly. If the cook box is subsequently exposed to air, smoke, dust
or other contaminants, then the cook box must be reclined after assembly.

Page 46
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Chapter Four

4.1 Conclusion
Running out of energy resources such as petroleum and coal have led the world community to
find feasible alternatives. in addition to this using biomass energy such as wood resulted in harsh
deforestation which threatens the existence of human being . Solar energy is one of the
renewable energy resource i.e. environmentally it is beneficial adding no harmful by product to
the globe.
Most Ethiopian people are using wood as a source of energy for cooking and water heating
purpose. This is causing serious deforestation in the nearby regions. As a result finding possible
solution is necessary to minimize the rate of deforestation.
Solar box cooker is one of the possible solutions to overcome this problem. Consequently,
gathering the necessary data, the design was performed. For our case it is proposed to heat more
than30 liter per day of water to satisfying the members of the house, the temperature being 60 oc.
And controller can be adjusted whatever the temperature of the water is decreased. When the
cost analysis is observed it is advantageous to use solar energy since it saves significant amount
of money after one year in addition to reducing the rate of deforestation. More ever, it minimizes
labor cost.
1. Generally on the basis of the results obtained in the book of solar cook box it is clear that
solar cooker at fixed position gives minimum thermal efficiencies at maximum solar
intensity of the day around 11-12 AM with an average over all efficiency around 27%
where as box cooker with internal reflecting mirrors installed on a sun tracking system
higher thermal efficiency from 29.3%-53.1% with average overall efficiency 40.6% Ref
[16]. And we get in our project with overall thermal efficiency of 52%, and then it is
acceptable.

Page 47
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

4.2 Recommendation
Cooking and heating with solid fuels on open fairs or traditional stoves results in high levels of
indoor air pollution. In particular, biomass composition contains in many health damaging
pollutants such as particulate matter and carbon monoxide. Particulate matter has long been
associated with increased risk for serious respiratory and cardiovascular health problem. But
Solar energy is a well proven technology that directly substitutes renewable energy for
conventional energy.

Based on the investigation carried out the following recommendation are made:

 Dimension and geometry of cook box should be studied in more detailed in order to
optimize the performance.
 Solar cooking should be encourage and popularize through mass production and
distribution to students, rural areas and low income earners to supplement to high cost of
convectional fuels such as kerosene, cooking gas and fuel wood.
 Solar cooker is more safe than other cooking or heating with solid fuels on open fairs or
stoves through their simplicity for use, low cost to purchase or to manufacture, and
maintenance.

Page 48
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Reference
1. G.D.RAI,” Energy Resources”, 4th Edition, KHANNA, NEW DELHI, 2004. )
2. proceeding of energyconference2002
3. WWW.Fix.com/blog/Solar-Cooking/...
4. WWW.Solar cooker-at -cantinawest.com/...
5. WWW.Solar box cooker at -cantinawest.com/...
6. Kombolcha metrology
7. Solar engineering thermal process page 16.
8. http://WWW.Wikepedia.com.
9. http //solar engineering thermal process pdf .
10. http://frontiers_day.
11. http;// Incropera and dewitt, 1985,eq. 9.38
12. Solar energy fundamental approach H.P.Gorg
13. Eggers-Lsura, A., Solar energy in developing countries, in The Pergamon
seuropean Heliostudies, Pergamon Press, New York, USA, 1979.
14. Thulasi-Das TC, Karmakar S, Rao DP. Solar box-cooker: part II - analysis and
simulation. Solar Energy 1994; 52(3): 273 – 282.
15. en.wikipedia.org/wiki/sheet-metal.
16. Algifri AH, Al-Towaie HA, 2001 EFFICIENT Orientation Impacts of box type
solar energy

Page 49
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Appendix

Figure 4.1: developed outer part

Page 50
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 4.2: developed internal part

Page 51
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 4.3: the reflector

Page 52
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 4.4: the hinge

Figure 4.5: the leg

Page 53
SOLAR BOX COOKER
 Wollo University[KIOT] 2007E.C

Figure 4.6: overall sectioned cook box

Page 54
SOLAR BOX COOKER