““DESIGN AND ANALYSIS OF SLUDGE DESIGN AND ANALYSIS OF SLUDGE COLLECTOR HEAD SHAFT FOR WASTE COLLECTOR HEAD SHAFT FOR WASTE

WATER TREATMENT PLANT” WATER TREATMENT PLANT”

Presented ByNITEEN MULMULE

Enrollment No. 0103ME12MT08M-Tech (Industrial Design), IV-Sem.

LNCT, Bhopal

A Presentation OnProposed Dissertation Work

Under the Supervision ofDr. V. N. Bartaria

H.O.D., Department of Mechanical Engineering

LNCT, Bhopal

CONTENTCONTENT

Introduction & Objective of Present WorkLiterature ReviewTheoretical Analysis and Data CollectionProblem Identification & MethodologyComputational StudyProposed SolutionResult AnalysisConclusion

Introduction & Objective of Present WorkIntroduction & Objective of Present Work

Water and sewage treatment systems are well known. For more than 50 years, rectangular clarifiers (rectangular concrete tanks) have been used in the treatment and purification of sewage, sewer drain, and drinking water. They are used to remove those materials which are either not biodegradable or cannot be chemically treated during the water purification process. Systems include motor-driven sprockets which move two parallel chains which have flight members attached there. The flight members scrape the floor of rectangular clarifier tank in one direction, gathering all solid waste materials which have fallen to the floor of the tank and moving them to a cross collector located at one end of rectangular tank.The power transmitted from motor to head shaft which transmitted power to follower stub shaft.

Major components in sludge collector system of waste water treatment plant.

Head Shaft

Concrete tankDriven ShaftChain

Flight

Bull Sprocke

t

Motor

Chain Sprocke

tBearing

Objective of present work: The objective of current project is to replacement of solid head shaft design to combination of solid and hollow shaft design.

Benefits of proposed new head shaft design.

-Reduction in weight.

-Better strength.

-Cost reduction.

-Manufacturing time reduction.

Literature ReviewLiterature Review

Since five decade various research and development work done on sludge collector of waste water treatment plant and few of them also patented. Under US patent US6279752 B1, Joseph R. Hannum (Aug 28, 2001) invented waste water treatment system for use in a rectangular clarifying tank using solid head shaft design.

Under US patent US5454942 A, Bertil A. Ljungberg (Oct 3, 1995) invented purification of liquids, including water, milk and the like, utilizing an air floatation basin and a skimming device for removal of floating sludge. using solid head shaft design.

Under US patent US6260716 B1, Henri Fontaine, Erick Breton(Jul 17, 2001) invented removing operation of scum, sludge or other matters floating at the surface of water, waste water, sewage or the like in a clarifying tank, and more particularly to a scum sweeper used for performing such an operation, and a system using such a scum sweeper to sweep surface floating matters into a collector channel or pipe in a clarifying tank, using solid head shaft design.

Under European patent EP0198334 A2, Joseph Robert Hannum(Oct 22, 1986) invented water clarifier and sewage treatment device comprising a rectangular tank including a floor, a pair of side walls and a pair of end walls, spindles secured to the side walls, sprockets received on said spindles, a pair of chains meshing with the sprockets, a pair of which sprockets is connected by a drive shaft and driven by drive means while the other ones are idler sprockets, and a plurality of flight members secured to the chains for scraping the floor of the tank, using solid head shaft design.

Theoretical Analysis and Data CollectionTheoretical Analysis and Data Collection

Hollow Vs solid shaft:

Section Modulus = I/c

where I = Moment of Inertia

c = Distance to extreme fiber

Hollow shaft: O.D. = 6.625”, I.D. = 5.761 (6” Schedule 40)

Weight = 28.57 pounds/ft.

Moment of Inertia for hollow shaft = 0.049087 x (OD4 – ID4) = 40.4904

Section modulus for hollow shaft = 0.049087 x (OD4 – ID4) x 2U

OD

= 12.2

4.99” dia. Solid shaft weight = 66.65 pounds/ft.

Moment of Inertia for 4.99” solid shaft = 0.785398 x R4 = 30.4349

Section modulus for 4.99” solid shaft = 0.785398 x R4 /R = 12.2

Result: 57% material saving for the same section modulus

Problem Identification & MethodologyProblem Identification & Methodology

The major problem in replacement of solid shaft is the creation of key way in long solid shaft. The key way is important feature of head shaft to mount the chain sprocket.

The identified problem can be solved by design the head shaft in to combination of hollow and solid shaft.The concept model shown below.

Solid shaftSolid shaft

Solid shaft (Dia. 4.5”)

Hollow shaft (Dia. 6.625”, Thk. 0.4325

Schematic Diagram of load on Bull sprocket and Chain Sprocket:

• Maximum torque developed at bull sprocket

= (Bull sprocket PCD/2)* Max Tangential force= (33.25/2)*1920= 31920 lb.in

• Maximum torque at by drive end and non drive end sprocket.

= (Sprocket PCD/2)* Max Tangential force= (22.23/2)*2860= 31788.9 lb.in

Note: Referring water treatment standard data.Standard Bull sprocket PCD uses in 4.5” Dia shaft = 33.25”Standard chain sprocket PCD uses in 4.5” Dia shaft = 22.225”For 15 Hp Motor & 5 Row Flight conveyer. Max load applied on bull sprocket = 1920 lb. and Max. loaad applied on chain sprocket = 2860 lb. each side.

Torque Hand Calculation: Torque Hand Calculation:

Fr

Fa

Θ = 2700

Forces Along two perpendicular axis i.e along X (Horizontal) and along Y (Vertical)

Reaction Force Fr= Applied Force Fa• Fx = Fr+Fa cos θ

Fy = Fa sin θResultant Fr = √(Fx2 + Fy2 )Angle of Resultant = tan-1 (Fy/Fx)

Fa

Fr

Θ = 1800

+Y

+X

Resultant force calculation based load angle: Resultant force calculation based load angle: Chain Sprocket Bull Sprocket

Load Case

Chain Sprocket

Force (lbf)

warping

angle (deg)

Resultant Force on sprocket

(lbf)

Resultant angle(deg)

from + X axis

Ycompon

ent force(lb

f)

X compon

ent force (lbf)

Torque (lb-in)

1 2860 90 4044.6508 315 -2860 2860 31788.9

Load Case

Bull Sprocket

Force (lbf)

warping angle (deg)

Resultant

Force on

sprocket (lbf)

Resultant angle(deg)

from + X axis

Y compone

nt force(lbf)

X component force

(lbf)

Torque (lb-in)

1 1920 180 3840 90 3840 0 31920

Loading condition for simulation: Loading condition for simulation:

Computational Study Computational Study The CAD packages Solid works is used to automate the

drafting/designing/engineering processes & technical operations.

The FEA packages Ansys 15.0 is used to analyze the head shaft design. Solid works data imported to Ansys Workbench.

For simulation Contact region created.

Patch confirming method has been used to mesh generation.

Model has been meshed using tetrahedral mesh element.

Meshed Zoom view.

Meshed Zoom view.

Meshed Zoom view.

Boundary Conditions.

Boundary Condition: Support provided on both end of the model

Boundary Condition: At both chain sprocket 4044.6508 lbf load applied at an angle of 315 degree. (Referring loading condition) table)

Boundary Condition: At Bull sprocket 3840 lbf load applied at an angle of 90 degree. (Referring loading condition table)

Material selected 316L SS. Material Properties shown below

Young's Modulus

(psi)

Poisson's Ratio

Density (lb/in3)

Yield Strength

(psi)

Shear Strength

(psi)

Ultimate Tensile

strength (psi)

Endurance limit (Stress)

(psi)

2.90E+07 0.3 0.289 24700 14079 72000 21242

Result Analysis:Result Analysis: Von- Mises stress Plot shows safe design.

After neglecting concentrated stress, Max Von- Mises Stress observed less than 12000 psi.

Maximum displacement is less than 0.08 inches.

Displacement in X-direction.

Displacement in Y-direction.

Displacement in Z-direction.

Twisting about Z axis is 0.5 degree.

Conclusion :Conclusion :

THANK YOUTHANK YOU