The Teachings of a Coffee Percolator

In the first article posted to this website, I acknowledged the coffee percolator as the device that ignited my life long fascination with machines that have no moving parts. I remember being astonished that such a simple contraption should be able to perform the miracle of making 30 cups of coffee seemingly without effort.

Today, I want to spend a little time examining the coffee percolator to see how it works and maybe determine what it is that all machines with no moving parts have in common.

The Percolator: A Simple Brewing Machine

The coffee percolator, a stalwart of kitchens for decades, stands as a testament to the ingenuity of engineering. At its core, it is a machine that achieves its purpose without the need for any moving parts. Yet, it’s a marvel of fluid dynamics and heat transfer.

A percolator is essentially a vessel with a central tube that reaches nearly to the bottom. There is a basket containing coffee grounds at the top of the open tube. Water is heated at the base, and as it vaporizes, it forces its way up the tube, lifting the water column as it goes. At the top, the water runs out over the tube and percolates down through the coffee grounds in the basket. It drips back into the main chamber, where it is reheated, and the cycle repeats. The process continues until the desired coffee strength is achieved.

There are three distinct functions involved with the operation of a coffee percolator. None of these require moving parts to be realized.

  1. Water lift:
    To provide liquid to the basket, a bubble pump lifts a column of water through the central tube.
  2. Percolation:
    The water then percolates down through the coffee grounds to extract flavors and color making coffee in the process.
  3. Filtration:
    The coffee is filtered through a porous membrane, usually a disposable paper filter. This helps retain the grounds in the basket while allowing the coffee to slowly return to the reservoir.

The Working Principles

The key to the percolator’s operation lies in the interplay of heat, pressure, and gravity.

There are no pumps, gears, or motors involved; the process is driven solely by the physical properties of water and heat.

The heat source, typically an electric coil or gas flame, provides the energy to convert water into a gas, steam.

Lifting a fluid by gasses is not unique to coffee makers. Here are some other examples:

Geysers:
These natural phenomena occur when groundwater is heated by magma, creating steam that forces water to the surface.

Bubble columns:
These are industrial reactors where gas is bubbled through a liquid, promoting mass transfer and chemical reactions.

Thermosyphons:
A related device that rarely involves a lifting gas, thermosyphons use the natural circulation of a fluid due to density differences caused by temperature variations. They are often used in heating systems and solar water heaters.

While these examples might seem vastly different from a coffee percolator, they all share the underlying principle of fluid movement driven by pressure differentials.

Perks of Percolation

Percolation too is not unique to coffee makers. While the percolator is primarily known for its coffee-making abilities, the principle of percolation itself has far-reaching applications. In chemistry.

Filter washing:
Percolation is a technique used to separate components of a mixture. A solvent is passed through a filter containing the mixture, and different substances are extracted at varying rates. This process is essential in industries such as pharmaceuticals, food processing, and environmental science.

Water purification:
Water filtration systems often employ percolation through layers of sand, gravel, and charcoal to remove impurities. We recently posted an article on this very thing. This natural filtration process is a cornerstone of many municipal water treatment plants.

Cave creation:
Groundwater naturally percolates through rock and soil. This is important for clear, freshwater springs. Over millions of years and under certain conditions, this percolation can create limestone caves. As the water flows, it removes material by dissolving it away.

A Dawning Revelation

The percolator, with its simple yet effective design, showcases the power of fluid dynamics and heat transfer. It is a reminder that complex tasks can often be achieved through elegant and minimalistic means. By understanding the principles behind the percolator, we gain a deeper appreciation for the underlying physics at work in countless other systems, from coffee brewing to water purification and beyond.

Our detailed examination of the coffee percolator has exposed hints to answer our all consuming question:

“What do all machines with no moving parts have in common?”

And the answer is simple … Fluids.

A fluid is a substance that deforms continuously under the application of a shear stress, no matter how small the stress may be.  

In simpler terms, a fluid is a substance that can flow and change its shape easily.

Key characteristics of fluids

  • No definite shape; they take the shape of their container.
  • Ability to flow under the influence of gravity or applied forces.
  • Low resistance to shear stress.

In general, we can talk about two classes of fluids.

Physical fluids:
Fine particulate matter, liquids, gases, and plasmas.

Fluidic Energies:
Electrical currents, electromagnetic waves, sound, fields and thermal gradients.

Fluids are the unseen workhorses of many machines. All machines with no moving parts rely on fluids to do work and perform their function.

Often there are multiple fluids involved. The work is accomplished through changes in pressure, flow, volume, temperature, fields, frequency and other physical phenomena.

Moving forward, every time you encounter a new machine with no moving parts, I would urge you to analyze it to identify the fluid(s) it uses and the fluidic properties employed to make it function.

Wicking Pumps

In the realm of fluid dynamics, pumps have always played a crucial role. Whether it’s pumping water, fuel, or any other fluid, traditional pumps rely on mechanical parts to transfer liquids from one place to another. However, modern advancements have allowed engineers to develop pumps with no moving parts. This can revolutionize the way we approach fluid transfer. For instance, one such innovation is the pump that utilizes wicking and capillary action.

Capillary action causes wicking forces that can be used to create a pump with no moving parts. This type of pump is simple, reliable, and can be used to pump a variety of fluids, including water, oil, and chemicals.

How it works

So how exactly does a pump with no moving parts work through wicking and capillary action?

A wicking pump works by using a porous material, typically a sponge, fabric, string or rope possessing high capillary forces. The wick is placed in the lower reservoir. Thus, through this material, the pump can draw liquid into its system and transport it to the desired location.

The capillary action of the material causes the liquid to rise up the wick and into the higher reservoir.

By controlling the geometry, surface chemistry, and porosity of the wick material, engineers can fine-tune the pumping performance for various applications.

The capillary action, caused by surface tension, pulls the liquid along the wicking material, against the force of gravity if necessary.

Capillary action is the phenomenon of a liquid rising in a narrow tube or porous material, This is due to the cohesive forces between liquid molecules and the adhesive forces between the liquid molecules and the walls of the tube or material. This allows the pump to operate vertically, horizontally, or even upside down. The liquid is effectively lifted and transported without any mechanical assistance. Think of the range of possibilities this offers in different industries, from medical devices to aerospace and more.

Applications

We often associate wicking and capillary action with phenomena like oil spreading through a paper towel or water rising in a narrow tube. These are key principles underlying this type of pump. By harnessing these natural forces, engineers have created a pump that eliminates the need for mechanical components, reducing maintenance, energy consumption, and overall system complexity.

Wicking pumps can be used in a variety of applications, including:

  • Watering plants
  • Fueling engines
  • Cooling systems
  • Medical devices
  • Chemical processing

One area where this technology has already started to make significant advancements is in the medical field. Micropumps utilizing wicking and capillary action are being developed to deliver medication to targeted areas in the body. By eliminating moving parts, the risk of contamination and failure is greatly reduced. Furthermore, the simplicity of these pumps allows for miniaturization, opening doors for implantable devices and wearables.

Beyond medicine, this pump design is finding applications in areas like environmental monitoring, chemical production, and even space exploration. In remote locations or extreme environments where access to power or maintenance is limited, these pumps offer an ideal solution. They can operate autonomously for extended periods, providing ongoing and reliable fluid transfer.

Advantages

Wicking pumps have several advantages over traditional pumps, including:

  • They are simple and reliable, with no moving parts to break down.
  • They are energy-efficient, as they require no external power source.
  • They are quiet in operation.
  • They can be used to pump a variety of fluids, including water, oil, and chemicals.

Disadvantages

Wicking pumps also have some disadvantages, including:

  • They have a relatively low flow rate.
  • They can be clogged by debris.
  • They can be affected by changes in temperature and humidity.

Examples of wicking pumps

Here are a few examples of wicking pumps:

  • Self-watering plant pots: These pots use a wick to draw water from a reservoir up to the soil, keeping the plants hydrated without the need for manual watering.
  • Oil lamps: The wick in an oil lamp draws oil up from the reservoir and into the flame, keeping the lamp burning.
  • Alcohol stoves: These stoves use a wick to draw alcohol up from a reservoir and into the flame, heating the pot or pan placed on top of the stove.
  • Vapore-Jet pump: This pump uses capillary action and phase transition to vaporize a liquid and forcefully eject it as a gas. It could be used in camping stoves and small UAVs to pump vaporized fuel-and-air mixtures.

Conclusion

Wicking pumps are a simple, reliable, and energy-efficient way to pump a variety of fluids. They have a wide range of applications, and they are becoming increasingly popular in a variety of industries.

Additionally, the absence of mechanical parts means that energy efficiency is significantly improved. These pumps require very little to no external energy to operate, reducing power consumption and making them more environmentally friendly. By embracing sustainable designs, these pumps contribute to a more efficient use of resources and a greener future.

While there is still much research and development required to optimize the performance and broaden the applications of pumps utilizing wicking and capillary action, the initial progress is promising.

As engineers continue to refine and innovate upon the design of these pumps, we can look forward to a world where the reliance on mechanical parts becomes a thing of the past. The future holds exciting possibilities as we witness the growing potential of pumps that harness the power of wicking and capillary action.

This technology has the potential to transform various industries by offering reliable and efficient fluid transfer solutions without the need for moving parts.

From healthcare to space exploration, this technology is set to redefine the way we transport fluids, making our world more efficient, sustainable, and accessible.

DIY O₂ Absorbers

Can an O₂ absorber really be considered a ‘machine’? Well, I’d say it is a device which is engineered and constructed to provide a desired, useful function based on scientific principles. On that basis I would definitely call it a machine of sorts. And furthermore, it’s a machine with no moving parts! Exactly the sort of thing we excel at around here.

Oxygen is a good thing. But what it does, that is… oxidize stuff, isn’t good for things we want to protect and save. It makes them age. Free atmospheric oxygen corrodes metals, makes oils go rancid, bleaches and fades pigments and dyes, and most annoyingly, spoils food and vitamins.

The answer is O₂ absorbers. Oxygen absorbers are highly recommended as a means of helping preserve dry goods such as fine art, firearms and most especially, food which has been stored away for use in a future emergency. Oxygen absorbers are placed inside sealed containers and are intended to do exactly what it says on the tin… absorb atmospheric oxygen to prevent it from interacting with the preserved materials. Do NOT confuse oxygen absorbers with desiccants for humidity control. Those are entirely different.

Oxygen Absorbers

Modern oxygen absorbers will come in sizes that range from 20 cc to 2000 cc. The size of the oxygen absorber refers to the amount of free oxygen that it can take out of an environment.

Therefore, a 20 cc packet can only remove 20 cc of oxygen, while a 400 cc packet can take away 400 cc of oxygen.

Recommended oxygen absorber usage based on container size is as follows:

  • 1 pint – 50 cc
  • 1 quart – 100 cc
  • 1 gallon – 400 cc
  • 5 gallon bucket – 2000 cc

Begin Nerdy Engineering Talk

One gallon equals 3.78 liters. Chemistry buffs will recognize that one gallon of a gas consists of 3.78/22.4 moles of substance at standard temperature and pressure. If 21% of that gas is oxygen then it means:
(3.78/22.4)*(21/100) = 0.0355 moles of oxygen O₂ are present. A mole is just a number, a count of molecules.

Also note that by volume:
21% * 3.78 L = 0.7938 L
(nearly 800 cc)

O₂ absorbers work by a chemical reaction that captures free oxygen. Rusting iron is just the ticket. This reaction also releases some heat energy and is commonly employed in the design of chemical hand warmers. A 400 cc oxygen absorber is considered to be sufficient to collect all the free O₂ from a gallon jar if it’s filled with product. This is roughly ½ of the O₂ in an empty jar as we have just calculated. What we are assuming is that a jar filled with product will still have up to ½ of its volume taken up by air; and 400 cc of that is oxygen. If your jar is not filled or you think more than half the volume contains air, use more absorbing capacity. There is no danger in adding too many packets.

This means we need to scale our stoichiometry to absorb at least:
0.0355/2= 0.0178 moles of O₂.

We will be forming Fe₂O₃ rust, so each mole of Fe₂ anions will capture 1.5 moles of O₂.

Accordingly, that requires:
0.0178/1.5 = 0.0119 moles Fe₂

Now, consulting the periodic table of elements we find:
The Atomic Mass of iron (Fe) = 55.845 g/mol

Therefore, we determine that we need :
2 * 55.845 *0.0119 = 1.33 g of iron to complete the absorption.

Let’s Build It

We will use steel wool instead of iron powder in our design because it is more easily sourced. Remember, more surface area is better so use a fine wool Do not use wool with soap or anticorrosion coatings.

We want:
Grade – 0000#
Grade Name – Super Fine
Typical Use – Sanding furniture

Ordinary (non-stainless) steel wool is made from a low-carbon steel and should be in excess of 98% iron by mass. To obtain the desired iron content we need:
1.33 / 0.98 = 1.35 g. steel wool.

NOTE: There is nothing wrong with oversizing our design by using “too much” iron, other than the extra expense of course. But when you think about it, wouldn’t it be foolish to risk $100 or more in food (not to mention your very life when you are depending on that food in a survival situation!) just to save a penny? Don’t do it!! Feel free to use up to 5x the requirement and be assured of safety. If you check, you’ll find that most commercially produced O₂ absorbers are made exactly this way. I think 2-3 grams of steel wool is a fine approach here.

Optional Step:
Add sufficient bentonite clay (kitty litter) or activated charcoal and work it into the steel wool. These porous materials will hold the water necessary for catalyzing the oxidizing reaction.

A pound of activated charcoal has the same surface area as six football fields. That’s a lot of crannies for storing water so you don’t need much.

A little known fact about adding charcoal is that it will cause a small amount of carbon monoxide (CO) to form inside your container. This, in combination with the reduced oxygen atmosphere will help kill any insects that might be hiding in your storage container. Not to worry though, it isn’t enough to harm anyone and will quickly dissipate when the container is opened.

Wrap this material together in a piece of paper towel or coffee filter forming a pouch. Tape or staple it closed and secure it to the underside of the jar lid. Double sided tape might be the perfect thing here.

These units may be made up in bulk to be used as needed. Unlike commercial oxygen absorbers, there are no special storage conditions such as vacuum packing necessary. They require activation before the rust reaction will start in earnest. Simply keep them dry and you should be good, although, a couple of silica gel packets couldn’t hurt here to be sure.

How to Activate and Use Your Oxygen Absorber

NOTE: Sea water is a good rust promoter. The salinity (saltiness) of the ocean is about 35 parts per thousand. This means that in every liter of water, there are 35 grams of salt.

Make a salt water solution of 3-5 g. per 100 ml. (About ½ teaspoon per ¼ cup of water.)

Before sealing the jar, moisten the packet with about an ⅛ teaspoon of this brine solution. A simple spritz with a spray bottle to dampen the paper should be sufficient.

With salt and water present, the oxygen reacts with the iron in the steel wool to form iron oxide (Fe₂O₃) and release heat.

Wait to be sure the packet is getting warm and then proceed. Remember that we mentioned CO formation? This heat is what will cause that to happen. Apply the jar lid and ring. The absorber will draw a vacuum for sealing. The lid should ping to prove it.

There is one caution you should be aware of. This is an IMPORTANT one.

When using oxygen absorbers to store foods, it is vital that the food be dry! The moisture content must be below 10%. The reason is that botulism likes to grow in moist, low oxygen environments. Be careful.

You may read on the internet that you should not use oxygen absorbers and silica gel packets together. This is because oxygen absorbers require moisture to activate them as we have seen. Silica gel packets will absorb moisture and your oxygen absorbers may not work.

I believe this shouldn’t be a problem if you’re sure to separate them from your O₂ absorber so it has a chance to work before the moisture is drawn away. Experiment a little for yourself to see what works.