{
  "id": "water-bench-01",
  "status": "Proposed experiment — not built, tested or potable",
  "objective": "Measure whether fixed folded conductive cassettes plus explicit vapor/thermal interfaces can deliver repeatable low-humidity collected water with lower service burden than an unstructured sorbent box.",
  "proposedDimensions": {
    "skidM": [
      1.6,
      1.45,
      0.9
    ],
    "cassetteM": [
      0.16,
      0.21,
      0.16
    ],
    "beds": 2,
    "drySorbentKgPerBed": 0.15,
    "finCountPerBed": 16,
    "finActiveFaceM": [
      0.13,
      0.15
    ],
    "copperThicknessM": 0.00015,
    "coatingPerFaceM": 0.0005,
    "finPitchM": 0.0055,
    "clearGapBetweenCoatedFinsM": 0.00435,
    "coatedAreaBothBedsM2": 1.248,
    "nominalDryCoatingDensityKgM3": 480,
    "storageLitres": 1
  },
  "baselineMaterial": {
    "name": "AQSOA-Z02 / SAPO-34 reference class",
    "procurementBoundary": "Identify a current supplier, batch composition, particle size, binder compatibility and safety data before ordering; historical manufacturer sources are not a live quote.",
    "massBoundary": "150 g is a target for dry active sorbent per bed. Binder/retention mesh are extra mass; nominal geometric density is a sizing assumption.",
    "regenerationBoundary": "90°C is an initial test setpoint, not a guarantee of full dehydration. Measure partial working capacity. Packed SAPO-34 in W01 needed higher temperatures for complete dehydration; do not transfer thin-fin W02 results without testing."
  },
  "bom": [
    {
      "item": "Pre-formed copper lamellae with folded contact feet",
      "quantity": 32,
      "specification": "130 × 150 mm active face, 0.15 mm sheet; form before coating; no repeated bending of coating"
    },
    {
      "item": "Active AQSOA-Z02",
      "quantity": 0.3,
      "unit": "kg dry active sorbent",
      "specification": "Two weighed 150 g loads; characterize binder and extra carrier mass separately"
    },
    {
      "item": "Hollow hot-fluid plates and removable cassette housings",
      "quantity": 2,
      "specification": "160 mm square proposed 12 mm hollow plate envelope; two 2 mm covers, perimeter and serpentine ribs; leak/pressure qualification required"
    },
    {
      "item": "Bypass seals, binder and particle-retention layer",
      "quantity": 2,
      "unit": "sets",
      "specification": "Temperature-rated, low-migration materials selected by coupon adhesion, air permeability and leaching tests"
    },
    {
      "item": "Replaceable particulate filters / fans / isolation shutters",
      "quantity": 2,
      "unit": "complete ambient-air branches",
      "specification": "Proposed shared UI assumption 30 m³/h per active branch; select from actual pressure-drop/fan measurements"
    },
    {
      "item": "Temperature-rated vapor supply/return isolation, circulation blower and relief",
      "quantity": 1,
      "unit": "two-bed manifold set",
      "specification": "Low-pressure assembly reviewed before energizing; independent mechanical protection, not only firmware"
    },
    {
      "item": "Thermal vessel, circulation pump, selectors and trim heater",
      "quantity": 1,
      "unit": "isolated loop",
      "specification": "Proposed maximum 200 W controlled heater for bench characterization, hard cutoff; external certified heater preferred to improvised mains wiring"
    },
    {
      "item": "Inspectable drainable condenser and coolant pump/radiator",
      "quantity": 1,
      "unit": "loop",
      "specification": "Condenser is sized experimentally; log coolant heat balance and droplet hold-up"
    },
    {
      "item": "Optional external recirculating chiller",
      "quantity": 1,
      "unit": "laboratory utility",
      "specification": "Only for active-mode trials; meter at wall; capability and rating chosen after load measurements; outside skid envelope"
    },
    {
      "item": "Raw receiver, reject vessel and accepted-batch tank",
      "quantity": 3,
      "specification": "Raw and reject labeled nonpotable, cleanable 1 L accepted-batch bench tank kept isolated"
    },
    {
      "item": "Sample tees, particulate/carbon housings and monitored UV interface",
      "quantity": 1,
      "unit": "conditional barrier train",
      "specification": "No generic media-size claim; select only after contaminant/hazard analysis and relevant validation"
    },
    {
      "item": "RH/T, temperature, flow and pressure instrumentation",
      "quantity": 1,
      "unit": "measurement suite",
      "specification": "Four ambient RH/T stations; six bed thermocouples; hot and coolant inlet/outlet temperatures; two loop flow meters; differential-pressure taps; gas pressure/relief verification; raw/product mass scales"
    },
    {
      "item": "Meters, controller and safety chain",
      "quantity": 1,
      "unit": "set",
      "specification": "Separate heater, auxiliary and optional chiller electrical meters; thermal calorimetry; valve-position feedback; hardware high-limit; local fault log"
    },
    {
      "item": "Mounting rails, drip tray and segregated service docks",
      "quantity": 1,
      "unit": "skid",
      "specification": "No farm-nutrient, graywater, potable and coolant interconnection; caps and spill capture for service"
    }
  ],
  "planningCost": {
    "currency": "USD",
    "range": [
      1800,
      5500
    ],
    "basis": "Authored planning allowance for an instrumented two-bed fixture, not supplier quotes or a commercial water price. Obtain current sorbent, fabrication and barrier quotes before commitment.",
    "excludes": [
      "engineering labor",
      "outsourced fabrication beyond allowance",
      "laboratory chiller purchase",
      "calibration reference instruments",
      "microbiological/chemical laboratory analyses",
      "certification",
      "solar collector/PV/battery",
      "shipping/taxes"
    ]
  },
  "assumptions": {
    "water": "0.30 kg × 0.10 kg/kg × 6 cycles/bed/day × 0.70 = 0.126 L/day. These inputs are assumptions, not device performance.",
    "finLoading": "32 fins × 2 faces × 0.13 m × 0.15 m × 0.0005 m × 480 kg/m³ = 0.29952 kg nominal dry coating; active fraction must be measured.",
    "thermal": "At 25°C ambient, 90°C regeneration, effective heat capacity 1.2 kJ/K/bed, 12 regeneration events/day, 3200 kJ/kg assumed desorption enthalpy, 10 W loss for 12 h: 0.26 sensible + 0.16 desorption + 0.12 leakage = 0.54 kWh_th/day, or 4.29 kWh_th/L. All thermal properties are test inputs.",
    "electric": "An illustrative 0.20 kWh_e/day auxiliaries gives 1.59 kWh_e/L at the assumed yield. If heat is resistance-generated, heater electricity is also measured and reported; thermal and electric ledgers are not independent free supplies.",
    "activeCooling": "Assumed 0.24 kWh/day cold load and COP 2 adds 0.12 kWh_e/day and rejects 0.36 kWh/day hot-side heat. No heat-recovery credit is taken; its temperature may be too low for 90°C regeneration."
  },
  "ports": {
    "bedA": {
      "ambientIn": [
        -0.46,
        0.87,
        0.08
      ],
      "ambientOut": [
        -0.46,
        0.87,
        -0.08
      ],
      "vaporOut": [
        -0.46,
        1.014,
        0
      ],
      "gasReturn": [
        -0.46,
        0.82,
        -0.08
      ],
      "hotIn": [
        -0.54,
        0.786,
        0.025
      ],
      "hotOut": [
        -0.38,
        0.786,
        -0.025
      ]
    },
    "bedB": {
      "ambientIn": [
        -0.13,
        0.87,
        0.08
      ],
      "ambientOut": [
        -0.13,
        0.87,
        -0.08
      ],
      "vaporOut": [
        -0.13,
        1.014,
        0
      ],
      "gasReturn": [
        -0.13,
        0.82,
        -0.08
      ],
      "hotIn": [
        -0.21,
        0.786,
        0.025
      ],
      "hotOut": [
        -0.05,
        0.786,
        -0.025
      ]
    },
    "condenser": {
      "vaporIn": [
        0.33,
        1.105,
        0.014
      ],
      "gasReturnOut": [
        0.43,
        0.88,
        -0.03
      ],
      "coolantIn": [
        0.43,
        0.91,
        -0.055
      ],
      "coolantOut": [
        0.43,
        1.11,
        -0.055
      ],
      "liquidOut": [
        0.43,
        0.85,
        0.065
      ]
    },
    "rawReceiverIn": [
      0.43,
      0.72,
      0.18
    ],
    "rejectReceiverIn": [
      0.6,
      0.37,
      0.24
    ],
    "acceptedTankIn": [
      -0.25,
      0.35,
      0.25
    ],
    "domesticDock": [
      -0.7,
      0.28,
      0.32
    ]
  },
  "operatingMatrix": {
    "ambientTemperatureC": [
      25,
      35,
      40
    ],
    "ambientRhPercent": [
      10,
      20,
      30,
      50
    ],
    "regenerationC": [
      70,
      90,
      105
    ],
    "highTemperatureBoundary": "105°C only after every seal, binder, plate, pressure relief and external heat source is specifically rated and reviewed; never simply increase power after poor yield.",
    "coolingModes": [
      "Ambient radiator with measured surface temperature",
      "Separate metered chiller, initially 17–25°C coolant if rated; never count as passive cooling"
    ],
    "timing": "Start with slow state-controlled characterization, not a six-cycle claim. Determine adsorption, release and cooldown distributions before scheduling."
  },
  "tests": [
    {
      "test": "0 · Dry blank and instrument audit",
      "method": "Run empty clean metal/retention assembly through humidity and heating steps. Calibrate mass, RH/T, flow, pressure and meter timing; recover a known water charge through condenser.",
      "target": "Proposed gate: injected-water recovery accounting within ±10% after measured hold-up; investigate larger discrepancies before any material-output claim."
    },
    {
      "test": "1 · Equal-mass folded versus flat coupons",
      "method": "At 20/30/50% RH and fixed temperature, compare identical active mass, binder, heat input and pressure drop. Record water loading versus time and coating particle loss.",
      "target": "Proposed advancement gate: folded architecture improves measured collection per total thermal-plus-electric resource or service footprint, rather than merely per visible surface area."
    },
    {
      "test": "2 · One-bed coupled cycle",
      "method": "Measure dry active mass, inlet/outlet absolute humidity, bed root/mid/tip temperatures, desorption, raw condensate and hold-up separately. Include 10% RH challenge.",
      "target": "Publish working-capacity and collection-efficiency distributions with uncertainty; 0.10 g/g and 70% are hypotheses to falsify, not acceptance facts."
    },
    {
      "test": "3 · Condenser heat-sink failure",
      "method": "Raise ambient/coolant through the matrix while recording regeneration-stream dew point, surface temperature and collected mass. Compare radiator and chiller with all electricity metered.",
      "target": "No passive-cooling claim when surface is not below measured vapor dew point. Demonstrate safe stop and retained mass accounting when collection collapses."
    },
    {
      "test": "4 · Dual-bed scheduling and heat recovery",
      "method": "Switch only on measured states. Compare recovery bypass against enabled recovery at equal ambient/input conditions; calorimetrically measure sensible heat transfer.",
      "target": "Demonstrate whether two beds suffice for declared duty. Add a third bed or reduce duty if cooling/adsorption take too long; never hide dry intervals."
    },
    {
      "test": "5 · Carryover and safety boundary",
      "method": "Collect blank, material, first-flush, aged and post-stagnation samples. A qualified laboratory selects microbiological, elemental, dissolved-organic, ionic and particle analyses from actual material and air hazards.",
      "target": "First prototype remains nonpotable. No human-use release until a documented safety assessment, appropriate independent results and validated barrier operating envelope exist."
    },
    {
      "test": "6 · Durability and service",
      "method": "At least 100 screening cycles and 20 drained cassette exchanges; weigh shed mass, inspect adhesion, seals and dead legs, trend capacity/pressure drop and repeat leachate samples.",
      "target": "Proposed screen: less than 10% collection decline against controlled reference and no undetected leaks or release faults; passing is not product lifetime qualification."
    },
    {
      "test": "7 · Fault injection",
      "method": "Disconnect/offset RH, stall fans, stop coolant, command conflicting valves, simulate full tank and lost power.",
      "target": "Heat disabled, product release closed, raw liquid safely isolated/diverted and fault reason logged; pressure protection independent of software."
    }
  ],
  "killConditions": [
    "Undetected gas/fluid cross-leak or uncontained pressure/overtemperature",
    "Coating/binder carryover or chemical/microbial hazard not controlled by a validated train",
    "Apparent yield disappears after blank, hold-up and meter corrections",
    "Two-bed cooldown cannot meet required duty without uneconomic extra equipment",
    "A safer locally appropriate water source outperforms the platform for the actual intended application"
  ],
  "scalePath": {
    "stage1": "0.30 kg / 0.126 L/day arithmetic bench: establish real data, barriers and service pattern.",
    "stage2": "Replicate a measured cassette with a third spare/regeneration lane if timing demands it; shared condenser capacity must be remeasured.",
    "stage3": "At unchanged assumed 0.42 L/kg/day, 2–5 L/day requires approximately 4.8–11.9 kg sorbent, about 32–80 of these tiny 150 g cassettes. That is a scale warning, not an attractive product size.",
    "stage4": "A separate optimization hypothesis of 0.15 kg/kg working capacity × 12 cycles × 0.80 collection would give 1.44 L/kg/day and require 1.4–3.5 kg for 2–5 L/day. Every factor must survive coupled testing, including heat rejection and quality.",
    "applicationBoundary": "2–5 L/day is a small water-supply target, not a fully autonomous household/farm water budget. Compare rain capture, delivery, recycling and local source treatment before choosing AWH."
  }
}