Mechanical Engineering Department
Design and analyze of a Solar-Powered Candle
Making Machine Using Air Heating Method
HEAT TRANSFER COURSE
Group members ID
Biruk Solomon 1501095
Amanuel Alemayehu 1500983
Beyene Gizachew 1501064
Iyader Tsedeke 1401442
Bisrat Meseret 1501087
Advisor : Mr. Dessie Gashaya
Date of submission: DEC 31 2025
TABLE OF CONTENTS
Chapter One: Introduction and Background
1.1 Introduction
1.2 Background of the Study
Chapter Two: Problem Statement and Objectives
2.1 Problem Statement
2.2 Objectives
2.2.1 General Objective
2.2.2 Specific Objectives
Chapter Three: Literature Review
Chapter Four: Concept Generation and Selection
4.1 Concept Generation
4.2 Concept Selection Criteria
Chapter Five: Design Specifications and System Description
Chapter Six: Solar Irradiance and Energy Calculations
6.1 Location and Climatic Condition of debre birhan
6.2 Average solar irradiance of debre birhan
6.3 Selection of solar collector Area
6.4 Solar collector Efficiency
6.5 Useful Solar Energy Gain
6.6 Energy requirement for melting wax
6.6.1 sensible heat requirement
6.6.2 Latent Heat requirement
6.6.3 Total Energy requirement
6.7 Feasibility Check
Chapter Seven: Design of Solar Collector and Heat
Exchanger
7.1 Solar air heater design
7.2 Heat exchanger Design
Chapter Eight: Mechanical Design and Modeling
Chapter Nine: Discussion and Conclusion
9.1 Discussion
9.2 Conclusion
References
Chapter One: Introduction and Background
1.1 Introduction
Heat transfer is one of the fundamental subjects in mechanical engineering and plays a major
role in many engineering applications such as heating systems, manufacturing processes, power
generation, and renewable energy technologies. Understanding how heat is transferred
through conduction, convection, and radiation is essential for designing efficient thermal
systems.
In Ethiopia, many small-scale manufacturing industries rely on electricity, firewood, or fossil
fuels for heating purposes. These energy sources are often expensive, unreliable, and
environmentally harmful. At the same time, Ethiopia has abundant solar energy potential that is
not fully utilized.
This project is given as part of the Heat Transfer course by Mr. Desse to help students apply
theoretical knowledge in a practical manner. The project focuses on designing a solar-powered
candle-making machine using the air heating method, which converts solar radiation into
thermal energy for melting candle wax.
1.2 Background of the Study
Debre Birhan is located in the central highlands of Ethiopia at a high altitude, which results in
relatively cool temperatures and strong solar radiation. Due to this condition, the area is
suitable for solar thermal applications.
Candle making is a simple manufacturing process that mainly requires heat to melt wax. The
melting temperature of candle wax is relatively low, which makes it suitable for solar heating
applications. Using solar air heating for candle making can reduce energy costs and promote
the use of renewable energy.
Chapter Two: Problem Statement and
Objectives
2.1 Problem Statement
Despite the high availability of solar energy in Debre Birhan, its application in small-scale
manufacturing systems is very limited. Candle-making processes commonly depend on electric
heaters or fuel-based systems, which increase production costs and cause operational
challenges during power interruptions.
Additionally, fuel-based heating systems contribute to environmental pollution. There is a need
for a clean, renewable, and low-cost heating system that can be used for candle making. This
project aims to address this problem by designing a solar-powered candle-making machine
using air heating.
2.2 Objectives
2.2.1 General Objective
To design and analyze a solar-powered candle-making machine using the air heating method
based on heat transfer principles.
2.2.2 Specific Objectives
To study the solar energy potential of Debre Birhan
To apply heat transfer principles in a practical design
To calculate the energy required for melting candle wax
To design a solar air heater and heat exchanger
To develop a simple and efficient candle-making system
Chapter Three: Literature Review
Previous studies on solar air heaters indicate that they are effective for low-temperature
heating applications such as drying and space heating. Research also shows that solar thermal
systems can be used for wax melting and candle production.
Various designs of solar collectors have been developed to improve efficiency by reducing heat
loss and improving air flow. These studies provided valuable insight into the selection of
materials, collector design, and heat transfer mechanisms used in this project.
Warning 5 previous literature with picture
Chapter Four: Concept Generation and
Selection
4.1 Concept Generation
Different heating methods were considered during the design stage, including electric heating,
fuel-based heating, solar water heating, and solar air heating. Each concept was evaluated
based on cost, safety, efficiency, and feasibility.
4.2 Concept Selection Criteria
The selection criteria included cost effectiveness, availability of materials, environmental
impact, safety, and ease of fabrication. Based on these criteria, the solar air heating method
was selected as the most suitable option.
Chapter Five: Design Specifications and
System Description
The system is designed to operate using solar radiation as the main heat source. Air is used as
the heat transfer medium. The wax melting temperature range is considered to be 60–70°C.
The system is designed using locally available materials and simple construction methods.
Component Selected specifications Engineering justification
collector Parabolic dish High concentration ratio for rapid
melting
reflector Anodized aluminum High reflectivity (ρ=0.85) and durable
Absorber Copper with black coating Maximize heat conduction and solar
absorption
Tracking Manual dual axis Low cost allows the dish to follow the
suns path in debre berhan
Chapter Six: Solar Irradiance and Energy
Calculations (Detailed)
6.1 Location and Climatic Condition of Debre Birhan
Debre Birhan town is located in the central highlands of Ethiopia at an altitude of approximately
2840 meters above sea level. Due to this high elevation, the town experiences relatively cool
ambient temperatures and good solar radiation for most of the year. These climatic conditions
make Debre Birhan suitable for solar thermal applications, especially for low-temperature
heating processes such as candle wax melting.
6.2 Average Solar Irradiance of Debre Birhan
Based on available solar data for central Ethiopia, the average daily solar irradiance of Debre
Birhan can be taken as:
G = 6 kWh/m²/day
This value represents the amount of solar energy received per square meter of surface per day.
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6.3 Selection of Solar Collector Area
For this project, a flat-plate solar air collector is selected. The collector area is assumed as:
A = 1.5 m²
This area is selected based on practical size, ease of fabrication, and availability of local
materials.
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6.4 Solar Collector Efficiency
Due to heat losses from the collector, not all incoming solar radiation is converted into useful
heat. For a simple solar air heater, the efficiency is assumed as:
η = 0.5 (50%)
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6.5 Useful Solar Energy Gain
The useful solar energy collected per day is calculated using the relation:
Q_solar = G × A × η
Substituting the values:
Q_solar = 6 × 1.5 × 0.5 = 4.5 kWh/day
Converting this energy into joules:
Q_solar = 4.5 × 3.6 × 10⁶ = 16.2 × 10⁶ J/day
This energy is available for heating air and melting candle wax.
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6.6 Energy Requirement for Melting Wax
Assume the mass of wax to be melted is 5 kg. The initial temperature of the wax is taken as
25°C, and the melting temperature is assumed to be 65°C. The specific heat capacity of solid
wax is approximately 2.1 kJ/kg·K.
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6.6.1 Sensible Heat Requirement
The sensible heat required to raise the temperature of wax to its melting point is calculated as:
Q_s = m × c × (T_m − T_i)
Q_s = 5 × 2.1 × (65 − 25) = 420 kJ
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6.6.2 Latent Heat Requirement
The latent heat of fusion of wax is approximately 200 kJ/kg. Therefore, the latent heat required
is:
Q_l = m × L = 5 × 200 = 1000 kJ
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6.6.3 Total Energy Requirement
The total energy required to melt the wax is the sum of sensible and latent heat:
Q_total = Q_s + Q_l = 420 + 1000 = 1420 kJ
Q_total = 1.42 × 10⁶ J
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6.7 Feasibility Check
The available solar energy per day (16.2 MJ) is much greater than the energy required to melt
the wax (1.42 MJ). This confirms that the designed solar air heating system can supply sufficient
heat for candle making.
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Chapter Seven: Design of Solar Collector and
Heat Exchanger
7.1 Solar Air Heater Design
The solar air heater consists of a transparent glass cover, a black absorber plate, and an
insulated air duct. Solar radiation is absorbed by the plate and transferred to the air flowing
through the duct.
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7.2 Heat Exchanger Design
A heat exchanger is designed to transfer heat from the hot air to the wax container. The design
focuses on maximizing heat transfer efficiency while maintaining simplicity.
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Chapter Eight: Mechanical Design and
Modeling
Detailed part drawings are prepared for each component using SolidWorks software. Assembly
and exploded views are created to show the overall structure and assembly sequence.
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Chapter Nine: Discussion and Conclusion
9.1 Discussion
The design demonstrates that solar air heating can effectively supply the required heat for
candle making. The system is environmentally friendly, cost-effective, and suitable for local
conditions in Debre Birhan.
9.2 Conclusion
This project successfully applies heat transfer principles to design a solar-powered candle-
making machine. It promotes renewable energy use and provides a practical learning
experience for mechanical engineering students.
References
1. Incropera, F.P., Introduction to Heat Transfer
2. Duffie, J.A. and Beckman, W.A., Solar Engineering of Thermal Processes
3. Heat Transfer Course Notes, Debre Birhan University