john zink burn process simulator team leader: kyle davis johnny benson michael cap kyle davis van...
TRANSCRIPT
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John Zink Burn Process Simulator
Team Leader: Kyle Davis
Johnny Benson
Michael Cap
Kyle Davis
Van Mai
Dr. Wilson Merchan-Merchan
(Advisor)
Sponsor: John Zink Institute
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Objective
The purpose of this capstone project was to produce a portable burner process simulator that allows the user to manipulate the combustion process by altering multiple variables in the system. Portability is a main concern due to John Zink Institute using the unit as a teaching aide in various locations in the country.
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Desired to demonstrate with apparatus
• Burners• Varying firing rates of burners• 1 burner out of service• Varying burner spacing• Varying amount of premixing
• Heater• Varying draft levels
• Varying excess O2 levels
• Varying heater length• Tramp air leakage
• Emissions (NOx, CO)
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Desired design from John Zink
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Capstone group’s Design
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Budget
Item Description Qty Unit Price Sub-Total Total InvoiceBurner for LPG 3 $22.09 $66.27 $69.02 Flow meter 1 $139 $139 $147.68 Parts for burners testing $21.26 Adjustable propane regulator 1 $18 $18 $21 Disposable cylinder adapter 1 $9.84 $9.84 $12.83 Snap well thermometer 2 $13.95 $27.90 $37.55 Water pump 1 $59.99 $59.99 $67.98 Fume Hood 1 $50.00 $50.00 $50.00Motor (DC, gear, 12V, 60RPM) 3 $19.95 $59.85 $66.75 Flow meter 3 $160.00 $480.00 $490.94 6 Amp Linear Power Supply 1 $39.95 $39.95 $52.34 Water Tank 1 $46.95 $46.95 $60.45 Unislide 3 $273.00 $819.00 $833.69 Acquaric chamber 1 $95.45 $95.45 $99.20 Acquaric tray 1 $37.49 $37.49 $41.24 Aluminum sheet 1 $97.30 $97.30 $97.30 Cabinet 1 $471.76 $471.76 $471.76 Flexible hose 4 $150.00 $600.00 $617.26 Motor (DC, gear, 12V, 110RPM) 3 $18.95 $56.85 $63.75 Powder coating 7 $10.00 $70.00 $70.00 Camera 2 $60.00 $120.00 $135.00 Glass tubes 1 $400.00 $400.00 $400.00
Total $3927.00
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Cabinet SystemCabinet System
System Highlights
•Made from 1” x 1” aluminum profile order through Bosch Rexroth Corporation
•Easy to assemble and disassemble
•This design allows to set the piece in parts and easy transportation as JZ needs to transport the system from one state to another in a limited volume.
•Rolling bottom shelf for easy access to the water tank and fuel supply
System Highlights
•Made from 1” x 1” aluminum profile order through Bosch Rexroth Corporation
•Easy to assemble and disassemble
•This design allows to set the piece in parts and easy transportation as JZ needs to transport the system from one state to another in a limited volume.
•Rolling bottom shelf for easy access to the water tank and fuel supply
Cost: $471.76
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Necessary Items to Constrict the Cabinet
Qty Length Description Total
2 n/a3 x 3 T-junction joining plate $18.72
13 21 Profile 1"x1", - / - $134.89
4 18 Profile 1"x1", - / - $38.43
50 n/a #8 T-Nut, 1/4-20 UNC $39.50
4 n/a 3 x 3 base plate $48.32
34 n/a1"x1" Gusset with fasteners $80.58
4 n/a Cap, 1 x 1, black $4.20
30 n/a#8, 1/4-20 square nut, one $11.10
2 21 Profile 1"x2", - / - $31.50
3 20 Profile 1"x1", - / - $30.36
14 n/a8mm-to-8mm slide bearing B $34.16
$471.76
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Powder CoatingAdvantages of powder coating over
conventional liquid coating• Used to create a hard finish that is tougher
than conventional paint• Powder coatings emit zero or near zero
volatile organic compounds (VOC). • Powder coatings can produce much thicker
coatings than conventional liquid coatings without running or sagging.
• Powder coating overspray can be recycled and thus it is possible to achieve nearly 100% use of the coating.
• Powder coating production lines produce less hazardous waste than conventional liquid coatings.
• Powder coated items generally have fewer appearance differences between horizontally coated surfaces and vertically coated surfaces than liquid coated items.
• A wide range of specialty effects is easily accomplished which would be impossible to achieve with other coating processes.
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Combustion chamber & fume hood
System Highlights
•Visibility
•Able to handle high temperatures
•Easily replaceable
System Highlights
•Visibility
•Able to handle high temperatures
•Easily replaceable
Estimated Cost: $150.00
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Heat Exchanger System
System Highlights
•8-Pass glass heat exchanger
•Water as working fluid
•Fluid changes color with temperature change
System Highlights
•8-Pass glass heat exchanger
•Water as working fluid
•Fluid changes color with temperature change
Cost: $759.00
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Heat exchanger system
Danner Mag-Drive• Flow Rate: 350 GPH maximum
flow with a 10.5` shut-off
3 Gallon Maximum Tank
Leuco dye• A 5 degree change in the
temperature of the water will cause the dye to change colors.
System Highlights
•Water Pump
•Water Reservoir
•Water Dye
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Heat Exchanger System (PUMP)
System Properties
• System equation•hp =8.9X10-3(Q²)
Q (gal/hr)
hp ( in )
•Pump curve•Given in pump specifications
• System Pump can will operate in the 90 gallon per hour area.
System Properties
• System equation•hp =8.9X10-3(Q²)
Q (gal/hr)
hp ( in )
•Pump curve•Given in pump specifications
• System Pump can will operate in the 90 gallon per hour area.
0 50 100 150 200 250 300 350 4000
100
200
300
400
500
600
700
800
900
system curvepump curve
Q, Flow rate (gal/hr)
Pum
p H
ead,
hp (
in)
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Glass Tubing
•½” Glass Tubing
•Can be disassembled
•Threaded connection
•½” Glass Tubing
•Can be disassembled
•Threaded connection
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Heat Exchanger System Part Description QTY
Unit Price
Sub-Total
8-pass glass tube system 1 $500.00 $500.00
3 gallon water tank 1 $42.56 $42.56
Danner mag-drive supreme 3 water pump
1 $53.99 $53.99
1/4" barb x 1/2" MIPS 1 $3.14 $3.14
1/4" barb x 1/2" FIPS 1 $3.40 $3.40
1/4" barb x 3/8" MIPS 2 $1.65 $3.30
Clear Vinyl Tubing 3/8"id 10 $0.31 $3.10
Stainless Steel Hose Clamp - 3/8"-7/8" 6 $0.92 $5.52
Water Additive 1 $150 $150.00
Temperature Gages 2 $30 $60.00
Estimated parts and price list for the heat exchanger system
Estimated parts and price list for the heat exchanger system
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Positioning System
System Highlights
•Simultaneous movement
•Single switch control
•Precise motion
•Forward and reverse motion
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Positioning System
Part Description QTY Unit Price Sub-Total
Velmex, manual sliding system, 3.5” 3 $273.00 $819.00
12V DC electric motors 3 $20.00 $60.00
Control switch 1 $6.00 $6.00
Push button Switch 1 $6.00 $6.00
6 amp ac/dc linear power supply 1 $40.00 $40.00
Miscellaneous wiring 1 $10.00 $10.00
Mounting hardware 1 $10.00 $10.00
System total $951.00
Estimated parts and price list for positioning system
Estimated parts and price list for positioning system
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Fuel Supply System
System Highlights
• Propane fuel supply
•¾” burner flame diameter
•Up to 12” flame height
•Flexible stainless steel hose design
•Variable rate flow meters
•System is pressure regulated
System Highlights
• Propane fuel supply
•¾” burner flame diameter
•Up to 12” flame height
•Flexible stainless steel hose design
•Variable rate flow meters
•System is pressure regulated
Approx. Cost: $1500.00
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Fuel Supply System
Part Description QTY Unit Price Sub-Total
P series graduated flow meter w/valve 3 $139.00 $417.00
1/4" x 12" Flexible supply hose 5 $130.00 $650.00
1/4" x 18" Flexible supply hose 1 $140.00 $140.00
1/4" x 24" Flexible supply hose 1 $150.00 $150.00
1/4 x 48" Flexible supply hose 1 $180.00 $180.00
Adjustable propane regulator 0-15 psi 1 $18.00 $18.00
Female cylinder adapter x 1/4" male 1 $9.84 $9.84
Propane cylinder 14.1 oz 1 $2.85 $2.85
1/4" standard pressure gauge 1 $7.97 $7.97
.75" Bunsen burner 3 $24.87 $74.61
¼” female brass cross 1 $12.00 $12.00
Miscellaneous brass fittings 1 $20.00 $20.00
System Total $1632.53
Estimated materials and price list for fuel supply system
Estimated materials and price list for fuel supply system
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Construction
• Took approximately 3 weeks
• No major set-backs
• Heat exchanger is the only remaining system to be built
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Up-To-Date Project Scheduling
Task 1/18 1/25 2/1 2/8 2/15 2/22 3/1 3/8 3/15 3/22 3/29 4/5 4/12 4/19 4/26 5/3 5/10
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Concepts
Initial Design
Drawings
Order Parts
Mid-Term Presentation
Production
Final Revisions
Final Report
Poster Fair
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Special Thanks
• John Zink Institute• Dr. Charles Baukal
• AME Machine Shop• Billy Mays• Greg Williams
• Local Part Suppliers• Jennings Powder Coating• Regal Plastics• Bosch Rexroth
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Questions?