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Zeecol Zero Impact Process

/YEAR

$2390

$650 $550

$440
$1410
$6100
$2015

Food Waste $0

$1500 $235
$295
$1410
COST PER COW $1000

Unprecedented rates of return are achieved in waste treatment by producing multiple revenue
streams from a single approved waste stream. By combining several proven technologies from
quality vendors that today work independently rates of return rise from the traditional 0% to 5%
range requiring subsidy to an astounding 40% range and more using this approach.

Engineers look at potential failure modes and eliminate them before they become problems. They
are perfectionists. They have to be if we are to enjoy the benefits of complex systems. Ask
yourself, how often do you want the brakes in your car to work? 90% of the time? 99% of the
time? The answer is obvious, you want your brakes to work in your car 100% of the time. Nothing
less than perfection is acceptable in this application. Otherwise, your automobile is an
unacceptable hazard. At the same time, the brakes must be reasonably priced. The same is true
in nearly everything you use today.
The list of possible failure modes in complex systems is endless over their life cycle. A combined
total of 40,000 parts in a large system of liquids containing a variety of cell cultures, describe the
Zeecol system. It is like a fish tank on steroids. Containing costs while maintaining perfection is a
critical factor to significant economic success. The good news is that systems containing millions
and even billions of parts routinely achieve perfection today.

Businesses maintain perfection at finite cost by


implementing an Open Issues and Project
Tracking (OIPT) management methodology in
combination with Lifecycle Management (LM)
software tools to support project management.
This allows for detailed project management
and the attainment of perfection at reasonably
predictable costs even in a changing
competitive environment.

Tuleap Open ALM is a project management


tool Zeecol currently uses. It is an application lifecycle management tool which includes support
for agile development and project management. Tuleap received the InforWorld.com Bossie Award
in 2013 and is used by Fortune 500 companies, small and medium businesses, and open source
projects.

Tuleap allows for agile, traditional, hybrid, or custom processes for project management. It
supports planning, sprints, tasks, reports, and more. This tool is very suitable for open source
development companies, as the tool also integrates with Git, SVN, Jenkins, and more making it
well suited to work across many vendor teams.

Tuleap is licensed under a GNU Public License and is available on GitHub. The open source
version contains all features and allows for unlimited projects and users. In addition to professional
support, there is an active community for support and documentation. Tuleap is in active
development.

Zeecol builds owns and operates facilities that


process fluids in which a variety of single
celled organisms live. We start with fluid
dynamics and use a software tool called CFD,
computational fluid dynamics. CFD is a
software modeller. CFD uses proven applied
mathematical equations and algorithms to
evaluate the effects of various interacting and
non-interacting factors affecting fluids gases
and materials. CFD results include thermal
gradient mapping, fluid and gas flow, pressure,
pressure drop, radiation effects, heat loss,
material optimisation, flow optimisation,
velocity as a result of radiation and thermal
convection and much more.

So, think about building a radiator for your car. Your engine runs, water heats up, it flows through
the radiator. The engine has to be kept cool under a wide range of conditions. The metals expand
and flex, and a large number of details have to be gotten right in order to build reliable effective
radiators that have long life and low cost. The same goes for the system we need to produce
multiple revenue streams.

Zeecol uses OpenFOAM (for "Open source Field Operation And Manipulation") software.
OpenFOAM is a C++ toolbox for the development of customised numerical solvers, and pre-/post-
processing utilities for the solution of
continuum mechanics problems, including
computational fluid dynamics (CFD). The code
is released as free and open source software
under the GNU License. The fluids in the
system are built out of materials. To select the
most effective material FEA software is used,
Finite Element Analysis. FEA is a Software
Solid Modeler. FEA uses proven applied
mathematical equations and algorithms to
evaluate the effects of various interacting
forces affecting structures, materials and
mechanisms. FEA results are used in design
optimisation, fatigue analysis, predicting
structural life times and much more.

If you put your fingers on the edge of your


desk and press down, your fingers will stretch
as you press down, thats called displacement.
The stretching of your muscles in your arm,
thats called stress. FEA computes the stress
and displacement of material objects and
helps specify design details for producing
components possessing superior performance
at low cost.

Components are assembled into systems to


carry out specific tasks and functions to
achieve performance goals. Interactions are
computed and system performance is
optimised. Once the process is perfected, the
result is engineering schematics for the
system to be built. Those schematics are
reduced to three dimensional models. Those
models are subjected to further analysis,
theyre not just renderings, they are computer
models that can be analysed. These result in
engineering drawings that are submitted to
vendors and that results in cost quotes.

Zeecol uses the integrated open-source tools


of CAELinux, to simulate incredibly complex
physics with the open-source FE & CFD
solvers Code_Aster, Code-Saturne,
OpenFOAM & Elmer: non-linear thermo-
mechanics, coupled fluid-structure dynamics,
seismic / non-linear explicit dynamics,
contacts, visco-plasticity, fluid dynamics, heat
exchange, convection heat transfer and radiation in other words nearly all physics problem can be
addressed with the integrated solvers! Then reload our results files in post-processing applications
like Salom, GMSH or Paraview to visualize our data in 3D. All these features are based on open-
source / free softwares, so we don't have to pay for any expensive licenses and because its open
source, we can improve things when we want and build significant IP.

CAELinux is based on the open-source CAD/CAM software such as Freecad, LibreCAD, PyCAM
and Cura and CAE softwares like Salom, Code_Aster, Code_Saturne, OpenFOAM and Elmer
Zeecol designs CAD geometry, performs multiphysics simulations to optimizes design, generates
G-code for 3D printing and milling, and even develops custom PCBs & microcontroller based
electronic circuits for automation.

For example, using Freecad, you can design your parametric CAD geometry with ease, generate a
computation mesh and setup your simulation problem in Salome_Meca in a few minutes. After your
design is checked you can go on preparing a G-Code for CNC milling a prototype with PyCAM or
3D printing it with Cura.

With detailed designs and specifications Zeecol is then ready to go to vendors to obtain quotations
for pricing and delivery. Performance is then tracked with the same project management software
used at the beginning. We use this to work with vendors in order to detail expected pricing.

So, here is a schematic that details the processes required for automated algae production. Using
CAE processes outlined above, a digital model is prepared from the schematic. From that model a
working prototype is completed. Operation of the prototype results in engineering data from which
a larger production prototype is prepared. That prototype is built and tested. In this case a 38,000
litre algae system that fits inside a 40 foot shipping container. Here the design is optimised and
pricing reduced for production units.