Detailed DesignP13601

Bill Dullea, Garry Clarke, Jae Ho, Kelly McNabb, Mary Medino

Process Flow Diagram

Process & Instrumentation Diagram

Process & Instrumentation Diagram

Process & Instrumentation Diagram

Process & Instrumentation Diagram

Process & Instrumentation Diagram

Current Specifications: Chiller

Labview Interface Design

Current Specifications: Beaker

Heat Transfer Equations

Table 1: Data Sample Set

Data Sample Current (mA)

Sample # Peak S.S

A125A126 80.6 11.1

A127A128 100.7 24

A129A130 74.5 2

A131A132 93 25.6

A135A136 101.7 23.7

A139A140 91.3 24.1

Ave 90.3 18.416667

Ave of P & SS 54.35833

• Illustrates the sample set taken from previous tests to provide a peak current and a steady-state current

Heat Transfer Equations

Table 2.1: Beaker DimensionsD 6.8072 cm

thickness 1 mm

Table 2.2: Beaker Dimensions dependent on volume of solution in a 250ml Beaker

Volume (ml) height (cm) A (m2)1 180 5.87 0.0125532 190 6.19 0.0132383 210 6.82 0.014585

•Illustrates the dimensions of the Polypropylene Beaker

•The area of heat transfer is dependent on the amount of solution that is within the beaker

•There are three different volumes of solution provided to give a range of results

Heat Transfer Equations

Table 4: Overall Heat Transfer

Overall Heat Transfer

U (W/m2K) 90.16393443

Table 3: Properties of Elements

Ethylene Glycol

Polyproplylene (Beaker) Water

k .258 0.11 .609h 500

•Utilizing the elemental properties values, the Overall Heat Transfer Coefficient.

[Reference] Forced Convection of water http://www.engineeringtoolbox.com/convective-heat-transfer-d_430.html Thermal Conductivity http://www.engineeringtoolbox.com/thermal-conductivity-liquids-d_1260.html

Heat Transfer Feasibility

Table 5: Heat Generated due to average current

V (volt) I (current) P or Q (heat) ΔT (K)

100 0.0544 5.4358 4.8026

80 0.0544 4.3487 3.6435

60 0.0544 3.2615 2.4802

•Table 5 illustrates the Heat Generated from the electrodes

•Applied an average of peak and steady state current use

•Ultimately calculate the temperature difference from Solution to coolant, to see how effective the water bath system is at cooling.

Heat Transfer Feasibility

Table 7: Heat Generated with peak current

Calc at Peak

Initial T (oC) (Solution) 65

V (volt) I (current) P or Q (heat) T (oC) @ peak

100 0.0903 9.0300 57.02192

80 0.0903 7.2240 58.9474960 0.0903 5.4180 60.87994

Table 6: Heat Generated with Steady State current

Calc at S.S Initial T (oC) (Solution) 65

V (volt) I (current) P or Q (heat) T (oC) @ S.S

100 0.0184 1.8417 63.37287

80 0.0184 1.4733 63.7655960 0.0184 1.1050 64.15971

•Table 6• Heat Generated from the

electrodes• Average steady state current• Calculated the T of the coolant

•Initial Temperature of solution was 65 Deg C

•Temperature was calculated with the Heat Transfer Equation (Previous Slide)

•Table 7• Heat Generated from the

electrodes• average peak current;• calculated the T of the coolant

Heat Transfer Feasibility

Table 9: Time needed for chiller to change temperature from Peak to Steady State

Calc Time need for chiller

V (volt) ΔT Time (s) Time (min)

100 6.35 1134.10 18.90

80 4.82 860.38 14.34

60 3.28 585.67 9.76

Table 8: Time for Chiller to change by 1oC

Chiller Transient Time

time 0.0056 oC/s

•Table 9 illustrates the time required for the chiller to translate from the peak heat generated to the steady state heat generated.

•These results provide vital information on what needs to be done with labview.

•Table 8 illustrates the time required for the chiller to change the coolant temperature by 1 degree.

Test Plans

Specification Range Tests

Controlling temperature of solution within 1° 0-70°C

1)Cool solution to 0°C2)Measure temperature every couple of minutes until solution reaches 0°C3)Once at 0°C measure temperature every 5 minutes for an hour4)Heat up to 20°C5)Repeat the same tests6)Heat up to 50°C7)Repeat the same tests8)Heat up to 70°C9)Repeat the same tests

Control and monitor voltage 0-100V

1)Set voltage to 1V2)Check multimeter every 5 minutes for an hour 3)Set voltage to 25V4)Check multimeter every 5 minutes for an hour5)Set voltage to 50V6)Check multimeter every 5 minutes for an hour7)Set voltage to 75V8)Check multimeter every 5 minutes for an hour9)Set voltage to 100V10)Check multimeter every 5 minutes for an hour

Control and monitor current 100μA-5A

1)Set multimeter to 100μA2) Check multimeter every 5 minutes for an hour3)Set multimeter to 1μA4) Check multimeter every 5 minutes for an hour5)Set multimeter to 1mA6) Check multimeter every 5 minutes for an hour7)Set multimeter to 1A8) Check multimeter every 5 minutes for an hour9)Set multimeter to 5A10) Check multimeter every 5 minutes for an hour

Control humidity <15%1)Purge system with N2

2)With a data logger measure humidity every 5 minutes for an hour

Easy use for loading and unloading electrodes

1)Record how long it takes to load electrodes2)Record how long it takes to unload electrodes3)Repeat both steps 5 times

Risk Assessment

Risk Item Effect Cause

Likelihood

Severity

Importance

Action to Minimize Risk Owner Comment

Labview Coding of transient chiller

Wrong temperature range

Transient code's cooling rate

3 3 9 1)Code at steady state conditions; 2)Code transient chiller rate to start before reaction

Kelly

User Interface with Labview

Acquiring poor data analysis Programming Error 2 3 6 Integrate unit tests 1 at a time by weeks;

specification TBD Chief Programmer

Transient Cooling Time

Rapid cooling of solution

Chiller temperature change time is too long

3 2 6 Coding labview with timed equations for constant heat transfer

Garry/Bill

Controlling excess Humidity not purged by nitrogen

Changes concentration which ultimately changes the end product result

Undesired Reactions 2 2 4 Utilized CaCl as a hydrophilic material to control excess/ produced water (drierite) Team Leader

Run away reaction Materials become scrapTemperature becomes too high/current get high

2 2 4 Program Emergency Shutdown, increase cooling

Chief Design Engineer

Building Technique/ Machine Work

Lose of building integrity

Implementing wrong Technique 1 3 3 3 point check technique, basically double

check work with two different perspectiveChief Design Engineer

material/equipment budget

Can't buy needed equipment

Trying to fufill client's neededs 1 2 2

talk to client Procument

material/equipment wait time

can't start building design on time

Shipping time restrained by costs 2 1 2

work on other aspects as parts arrive Procument

Controlling Temperature with set specification

Becomes run away reaction Chiller/ Heater 3 3 9 Once we get specs 10/2/12; test the

machine for data by 10/9/12 or 10/11/12 Team Leader Decided not a risk after calculations of water bath concept. 10/23

Heat Transfer (Overall) at electrodes

Doesn't cool the soln effectively

the material used is not thermally conductive

3 3 9 increase the diameter of the tube to increase the surface area, while trying to decrease the plastic tubing; change the coolant

Chief ProgrammerDecided not a risk after calculations of water bath concept. 10/23

Bill of Materials

Product Description Dimension Catalog Quantiy Cost Vendor Purpose Notes

PFA Coated Thermocouple Probes with Standard

Connectors

PFA Coated Probes are the perfect solution when there is a need to measure the temperature of caustic or corrosive chemical solutions in industrial and laboratory environments. The superior corrosion resistance of PFA allows you to measure the temperature of sulfuric, hydrochloric, nitric and chromic acids, as well as caustic compounds.

1 /16 " or 1 /8 " Diameter 12" Probe Standard † ICSS-116G-12-PFA 1 $52.00 omega Temperature

Monitoring

TriCorner Beaker Plastic beaker with three dripless pouring spouts. Polypropylene (PP).

250 mL 76mm x 88mm (wxh) 3642 100 $31.10 globe

scientific Reaction Vessel

Scratch-Resistant Cast AcrylicColor: Clear, Temperature Range: 0° to 150° F, Tensile Strength: GoodImpact Strength: Poor

5" D 1' Length 8528K49 1 $307.06 McMaster Main Chamber

VWR® Advanced Digital Controller Refrigerated/Heated

Circulating Baths120V 60Hz Temp Rang: -40 to 200 C

Overall dimensions 54.1L x 22.1W x 61.7H

cm  Working Access

15.7L x 14.2W x 12.7D cm

89202-978 1 $3,903.59 VWR Chiller/Heating

Polycarbonate (1 Chambers)Color: ClearTemperature Range: -40° to 180° FTensile Strength: GoodImpact Strength: Excellent

1' x 3' (3/16" Thickness) 8574K273 2 $26.49 McMaster Reactor May Change due to size

VWR® Dylastir® Magnetic Stirrer Cast Aluminum Top Plate Large 16.5 cm (61/2") Diameter 12620-974 1 255.83 VWR Mixer

TDK-Lambda ZUP 1203.6/U Current Out:3.6A, Voltage out:120VDC 70176888 1 1,450.00 Allied

Electronics Power Supply

Agilent Technologies Test Equipment 34405A 701801169 765.00 Allied

Electronics Multimeter

Half-Mortise/Half-Surface Mount Template Hinges 1498A12 2 9.52 McMaster Hinges for Door

Exposed Latches 13435A63 2 6.22 McMaster Door Latch

Metric O-Rings 4 mm wide 9262K371 1 7.70 McMaster O Ring for cooling Chamber

Hex Nut Zinc-Plated Grade 2 Steel 99961A450 1 10.90 McMaster HingesFlat Head screws 91253A425 1 14.02 McMaster

Barbed Tube Fittings 5463K128 1 5.26 McMaster Nitrogen fittingCompression Tube Fitting 5533K499 2 6.54 McMaster Cooling fittings

Steel Support Rectangular Bases 60110-222 1 40.87 VWR Stand

Questions, Comments, Concerns??

Why are we doing this?What problem are we

solving?Is this actually useful?Is there an easier way?What’s the opportunity

cost?Are we on our critical

path?Is it really worth it?