improvements to carbete dry powder injector systemedge.rit.edu/content/p05104/public/cdr...
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Project 05104Improvements to CarBETe Dry
Powder Injector System
Multidisciplinary Engineering Senior Design
2005 Critical Design Review
May 13, 2005
Kate Gleason College of EngineeringRochester Institute of Technology
TeamEdin Sehovic, MEMitsuru Ishihara, MEMartin Kuma, ME
Sponsor: Fuel Efficiency, LLCMentor: Dr. Alan NyeAcknowledgements: Steve Kosciol
Dr. KozakDave Hathaway
Kate Gleason College of EngineeringRochester Institute of Technology
Outline
Project OverviewDesign ProcessFinal Design
Kate Gleason College of EngineeringRochester Institute of Technology
Project OverviewBackground
CarBETe Dry Powder Injector System:
Improves efficiency of industrial boilers
Transports the powdered combustion catalyst into combustion chamber of the boiler
Improves oxidation of residual oil and produces cleaner flame
Kate Gleason College of EngineeringRochester Institute of Technology
… Project OverviewSponsor discontinued production in 1986 due to clogging of powder in the system
It is unknown in what part of the system the clogging occurred
Sponsor Needs:Eliminate Clogging Increase reliabilityMake product adaptable to wider range of applications
Kate Gleason College of EngineeringRochester Institute of Technology
Design Process
Needs AssessmentConceptsFeasibility
Kate Gleason College of EngineeringRochester Institute of Technology
Needs AssessmentVisit sponsor, establish needs and draft a formal statement of workMinimize cost – Less than $1000Minimum required performance (parameters are necessary for a successful project):- Develop a design that eliminates clogging- Increase performance by designing a reliable system
- - Provide means of monitoring powder level in the holding canister
- - Must resist high temperature of the boilerDesired Performance (should be accomplished if time and schedule permit): - Incorporate an adjustable powder-delivery system- Optimize delivery adjustments and monitoring through testing
and simulation
Kate Gleason College of EngineeringRochester Institute of Technology
Concepts
‘Venturi’ Principle
Auger Feed
“Snow Blower” PrincipleAuger x 2 w/ shaft in middle
Powder
Air pipe
Kate Gleason College of EngineeringRochester Institute of Technology
… ConceptsMaterial Transfer Vacuum Pump
• Transfer of solid materials:fine powder to bulk objects
• No moving Parts, no maintenance• Requires only compressed air
Compressed Air
Air OutletSuction
Mixed Flow of Air and Material
Path of Material
Path of Compressed Air
High Velocity – Low Pressure Region
Kate Gleason College of EngineeringRochester Institute of Technology
Feasibility AssessmentAttribute Importance
Bas
e Li
ne
Snow
Blo
wer
Aug
er
Ven
turi
Mat
eria
lTr
ansf
er P
ump
Rel
ativ
e W
eigh
t
T1 sufficent skills 3.0 3.0 4.0 4.0 5.0 7.6%T2 availablity of equipment 3.0 2.0 3.0 4.0 5.0 1.5%E1 production cost 3.0 1.0 2.0 3.0 2.0 9.1%E2 Budget provided 3.0 3.0 3.0 3.0 3.0 13.6%E3 Future Prospects of the product 3.0 3.0 3.0 3.0 4.0 4.5%S1 Team's time constraints 3.0 2.0 2.0 2.0 2.0 13.6%P1 Feeding powder 3.0 4.0 4.5 4.5 5.0 16.7%P2 Monitoring powder level in the container 3.0 3.0 3.0 4.0 5.0 10.6%P3 Adaptable to other appliction 3.0 3.0 3.0 2.0 4.0 3.0%P4 Adjustable delivery system 3.0 3.0 4.0 4.0 5.0 3.0%P5 Number of moving parts 3.0 2.0 2.0 3.0 3.0 9.1%P6 Number of main components 3.0 1.0 2.0 2.0 3.0 7.6%
Weighted Score 3.0 2.6 3.0 3.2 3.6Normalized Score 82.5% 71.3% 81.5% 89.0% 100.0%
Kate Gleason College of EngineeringRochester Institute of Technology
Weighted Method
Kate Gleason College of EngineeringRochester Institute of Technology
Relative Weight
Kate Gleason College of EngineeringRochester Institute of Technology
Planned Schedule
Kate Gleason College of EngineeringRochester Institute of Technology
… Planned Schedule
Kate Gleason College of EngineeringRochester Institute of Technology
Desired Outcomes
• Fully functional prototype that transports powder from holding canister into the boiler
• No clogging of powder in the system• Powder level monitoring• Adjustable flow rate• Adaptable to wide range of applications
- Industrial use- Residential use
Kate Gleason College of EngineeringRochester Institute of Technology
Key Requirements & Critical Parameters
Eliminate clogging of powder in all parts of the system
- Minimize moisture by using a desiccant air drier- Redesign the holding canister to allow for continuous outflow of powder
- Use a reliable transfer method – vacuum pump Resistant to high temperatures
- Use of metals instead plastic Delivery tube ranging from one to ten feet in length
- Account for head-loss
Kate Gleason College of EngineeringRochester Institute of Technology
Major Design Challenges
• Dynamics of powder flow unknown
- Powder behavior had to be determined experimentally
• - Holding Canister geometryHolding Canister
Powder
Bleeder Hole
φ
• Powder Containment – Backpressure issues
Kate Gleason College of EngineeringRochester Institute of Technology
… Major Design Challenges
Bleeder hole positioning
15 20
20
Kate Gleason College of EngineeringRochester Institute of Technology
Analysis of DesignPowder Mass Flow (test results)
Supply pressure
Weight of Powder Time
(PSI) (lbs) (sec) lb/sec grams/sec
252525
avg. 25.09080120
avg. 96.710 1 N/A* N/A* N/A*
* Suction below threshold - no powder transfer
15 1 0.010 4.7
Mass Flow Rate of Powder
20 - 60 1 0.040 18.0Powder Collection Can
Material Transfer Vacuum Pump
3/4" Steel Pipe
Compressed air inlet3/8" pipe
3/4" Transparent Tube
Holding Canister
"T"
Kate Gleason College of EngineeringRochester Institute of Technology
… AnalysisHead Loss (delivery tube)
DVfLPPH L 2
21 2
=−ρ
Supply pressure (PSI) Maximum delivery pipe length (ft)
60 25.3
50 20.3
40 15.1
30 10.2
20 5.1
380000Re ==−
µρVD
D
ρ2
2Vf
pDL ∆=
Kate Gleason College of EngineeringRochester Institute of Technology
… AnalysisVacuum pump performance (@ 60 psi)
sm
sft
inftin
ft
AQV
in
inin 127418
124)58.0(
sec60min1
min46
22
222
3
==⎟⎠⎞
⎜⎝⎛
⎟⎠⎞
⎜⎝⎛
==π
Material Transfer Vacuum Pump
Vacuum
3/4" Steel Pipe3/4" Tube
Compressed Air Inlet3/8" pipe
Exhaust
sm
sft
inftin
ft
AQV
vac
vacvac 161528
124)75.0(
sec60min1
min1.97
22
222
3
==⎟⎠⎞
⎜⎝⎛
⎟⎠⎞
⎜⎝⎛
==π
sm
sft
inftin
ft
AQV
out
outout 237777
124)75.0(
sec60min1
min143
22
222
3
==⎟⎠⎞
⎜⎝⎛
⎟⎠⎞
⎜⎝⎛
==π
Kate Gleason College of EngineeringRochester Institute of Technology
… AnalysisFLUENT implementation
Air Inlet
Vacuum Inlet
Outlet
Location Mass Flow Rate (kg/sec)
Velocity Magnitude (m/sec)
Air inlet (Fixed Value) 0.02598 127 Vacuum inlet (Fixed Value) 0.05605 161
Outlet -0.08204 211.0482 Total -3.166e-08 N/A
Kate Gleason College of EngineeringRochester Institute of Technology
Final DesignContainer• 4” I.D. PVC pipe with a funnel inserted
• PVC cap – 4 holes
Kate Gleason College of EngineeringRochester Institute of Technology
Bill of MaterialsQty Supplier Price1 Vaccon $157.501 McMaster-Carr $3.771 McMaster-Carr $0.681 McMaster-Carr $0.751 McMaster-Carr $4.761 McMaster-Carr $7.001 McMaster-Carr $7.001 McMaster-Carr $16.381 N/A $2.501 McMaster-Carr $0.751 McMaster-Carr $75.191 McMaster-Carr $0.751 McMaster-Carr $52.351 McMaster-Carr $0.751 McMaster-Carr $8.321 McMaster-Carr $0.96
$339.41
N/A
44615K4434457K42
44615K465
44615K4434370K11
44615K4434910K82
Pipe size = 3/4" / Lengths = 4"(Threaded both ends)
Part #DF-7-6-TV-75-TE-75
4513K1444615K43544615K44347865K224880K584880K5948925K98
Pipe size = 3/8" / Lengths = 2"(Threaded both ends)Pipe = 3/8" / 60 scfm max
Pipe size = 3/8" / Lengths = 2"(Threaded both ends)Pipe size = 3/4" / Lengths = 36"(Threaded both ends)
Pipe size = 4" / Do =4.5" Di = 4.026" / Max. Press = 220 psi / Funnel (80 deg => 86 deg)
Pipe size = 3/8" / Lengths = 2"(Threaded both ends)Desiccant Air Dryer -- Pipe size = 3/8 "
Pipe size = 3/8" / Lengths = 2"(Threaded both ends)Pipe size = 3/8" / End-to-End Length = 1 49/64"
Pipe size = 4" / Di = 4 1/2"Pipe size = 4" / Di = 4 1/2"
DescriptionMaterial Transfer Pump
90 Degree / Pipe size = 3/4"Pipe size = 3/4" / Lengths = 1 1/2"(Threaded both ends)
container_inner_wall
air_inlet_pipe4 long_feeding_pipe
Feeding Pipe
Part Name Vaccon DF7-6
elbow connecting_pipe
Manual_valve Bottom_cap
air_inlet_pipe
TOTAL
air_inlet _pipe_3 filter
air_inlet_pipe_2 dryer
Top_cap container_body
Kate Gleason College of EngineeringRochester Institute of Technology
… Final DesignVacuum Pump• ¾” I.D. Vacuum Pump
Supply pressure
Weight of Powder Time
(PSI) (lbs) (sec) lb/sec grams/sec
252525
avg. 25.09080120
avg. 96.710 1 N/A* N/A* N/A*
* Suction below threshold - no powder transfer
15 1 0.010 4.7
Mass Flow Rate of Powder
20 - 60 1 0.040 18.0At 60 psi:
Q = 46 ft3/min (0.022 m3/s)V = 418 ft/s (127 m/s)
Q = 97.1 ft3/min(0.046 m3/s)V = 528 ft/s (161 m/s)
Q = 143 ft3/min (0.068 m3/s)V = 777 ft/s (237 m/s)
Outlet
Air Inlet
Vacuum Inlet
Kate Gleason College of EngineeringRochester Institute of Technology
… Final DesignAir supply
• Electrically activated solenoid valve
Bleeder• 3 holes (1/8”) in feeding tube• 3/4” bushing
Kate Gleason College of EngineeringRochester Institute of Technology
… Final DesignFINAL DESIGNNo maintenance
no moving partsno lubrication necessary
Long lasting because non-corrosive materials usedTransfers 18 grams of powder per second (0.04 lb/s)
Holding canister capacity is 11 lbs (5 kg)
Kate Gleason College of EngineeringRochester Institute of Technology
Desired Outcomes Actual OutcomesFully functional prototype that transports powder from holding canister into the boiler
• No clogging of powder in the system
• Powder level monitoring• Adjustable flow rate• Adaptable to wide range of
applications- Industrial use- Residential use
Fully functional prototype that transports powder from holding canister into the boiler
• No clogging of powder in the system
• Powder level monitoring• Adjustable flow rate• Adaptable to wide range of
applications- Industrial use- Residential use
Kate Gleason College of EngineeringRochester Institute of Technology
Conclusion
The Design Team met all the desired outcomes The senior design team successfully re-designed the dry powder injection systemFuture recommendations:Rugged, maintenance free design achieved but the amount of powder being transferred cannot be controlled very accuratelyFuture versions should improve on accuracy of powder transfer
Kate Gleason College of EngineeringRochester Institute of Technology
Questions ?
Kate Gleason College of EngineeringRochester Institute of Technology