CONDUCTIVE HEAT TRANSFER APPARATUS

P13624

John Durfee, Ryan Murphy, Fielding Confer

Dan Unger, Katie Higgins, Robin Basalla

Group Members

Roles

• Project ManagerFielding Confer

• Lead EngineerDan Unger

• SecretaryRobin Basalla

• Mechanical EngineerJohn Durfee

• Chemical EngineerKatie Higgins

• Chemical EngineerRyan Murphy

• Team GuideDr. Michael Antoniades

Karuna Koppula and Paul Gregorius

RIT Chemical Engineering

Customers and Sponsor

Agenda

• 10:15Project Description

Concept Summary

• 10:20Design Summary

System Architecture

• 10:25System Testing Results

Project Evaluation

• 10:35Future Projections

Questions

Project Description

Top Level Function

Uninformed Student

Partial Assembly

Energy

Unknown k

Informed Student

Hands-on Experience

Thermal Energy

Known k

Demonstrate Principle of Thermal

Conductivity

Functional Decomposition

Demonstrate

Thermal

Conductivity

Creates

1-Dimensional

Heat Transfer

Minimal heat loss from boundaries

Generates heat flux

Provides proper temperature variation

Accepts multiple geometries

Accepts multiple materials/phases

Minimizes resistance at heat exchanges

Generates

Measurable

Data

Accurate

Precise

Manual collection

Digital collection (Labview)

Displays rate of heat flux

Displays temperature distribution

Enhance

Student

Lab Skills

Requires manual assembly and disassembly

Can be used within given time periods

Fits on the chemical engineering carts

Has replaceable components

Low maintenance

Durable

Project Plan II

Week

Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Review Bill of Materials

Assess Test/Assembly Plan

Order Parts

Software Development

Discuss possible design modifications

Generate testing procedures

Receive first tier of parts

Documentation

Format testing datasheets

Talk to machine shop

Draft insulation testing block

Machine specimens

Machine insulation

Receive heater and thermocouples

Construct presentation

Test thermocouples

Assemble insulation

Test heat source

Test cold side

Failure analysis on insulation

Test specimens w/o insulation

Test specimens in insulation w/ cold side

Test specimens in insulation w/o cold side

Failure analysis on housing material

Construct cold side housing modification

Form housing structure

Assemble final apparatus

Final testing

Functional and Performance Review

Functional and Performance Review

Format Lab Procedure

Final Project Review

Final Project Management Review

Upload all documentation

Review and Planning

Order Parts

Construction and Testing

Final Assembly and Testing

Documentation and Presentation

Software Development

Document Templates

Concept Summary

Subsystems and Ideas

Subsystems

Hot

Cold

Specimen

Temp. Trans.

Insulation

Liquid flow jacket

Liquid flow jacket

Rectangular prism (bar)

Thermocouples

Form-fitted Solid

Steam flow jacket

Cold air gun (vortex tube)

Cylinder (rod)

Resistance Thermometer

Form-fitting malleable

Steam flow jacket

Liquid N2

Thermistors

Wrapped

Electric heater

Thermoelectric Device

Color-changing Material

Packed

Combined Concept

Design Summary

Design as of MSD I

� Cartridge heater

� Drilled into Specimen

� Cooling water jacket

� Boxed housing

� Thermocouples

� Drilled into Specimen

� Cylindrical Specimen

� Rigid, molded insulation

� Seated closure

Cross Sections

Hot Side Cold Side

Bill of Materials

Project 13624 - Conductive Heat Transfer Demonstration Apparatus

Part Name Material Manufacturer Distributor Part # k value DimensionsQuantity Needed

Unit Price ShippingTotal Price

Rigid Calcium Silicate Insulation

Calcium Silicate McMaster-Carr 9353k43 .073 W/mK 24 x 48 1 $126.93 $8.75 $135.68

Kiln-Dried Hem-Fir S4S Dimensional

LumberHemlock Wood Lowe's

Item # - 4545Model # - N/A

.89 BTU/in 2 x 8 x 8 4 $7.35 N/A $29.40

Ready Made Insulated

Thermocouples

Nickel-Chromium/Nickel-Alumel with Glass Braid Insulation

Omega Omega 5TC-gg-k-20-36 N/A Package of 5 2 $41.00 $5.00 $87.00

Multi-Purpose Aluminum 6061

Aluminum 6061 McMaster-Carr 8974k133 167 W/mK1 in diamter by 3

feet1 $19.34 $8.75 $28.09

Multi-Purpose Copper Alloy 110

Copper 110 McMaster-Carr 8966k23 388 W/mK1 in diamter by 3

feet1 $126.22 $8.75 $134.97

Ultra Machineable Brass Alloy 360

Brass 360 McMaster-Carr 8953k983 115 W/mK1 in diamter by 3

feet1 $83.51 $8.75 $92.26

5A Variac Variable AC Power

TransformerN/A

PHC Enterprises

Parts-Express.com

120-842 N/A N/A 1 $124.50 $3.99 $128.49

Bill of Materials (continued)

Cabot Australian Timber Oil

Transparent Exterior Stain

Cabot Lowe'sItem # - 220549

Model # -140.0019400.005

N/A1-Quart

Transparent Exterior Stain

1 $16.48 $0.00 $16.48

The Hillman Group 50-Count

#8 x 2-1/2

Zinc Plated Wood Screws

The Hillman Group

Lowe'sItem # - 68356

Model # - 35058N/A 50-Count 1 $5.58 $0.00 $5.58

High Watt Density Cartridge Heater

with Incoloy Sheath

Incoloy Sheath Omega Omega CIR-2012-120 N/A1 1/4 in long by 3/8 in around

2 $42.00 $5.00 $89.00

Epoxy Adhesive E-40Ht

Hysol E-40 Epoxy

Loctite McMaster-Carr 7555A41 N/A 1.69 oz (50 mL) 2 $15.80 $8.75 $40.35

Reducing coupling

(10pk)Nylon McMaster-Carr 5463K233 N/A 1"-1/2" 2 $8.94 $5.00 $22.88

Reducing coupling Nylon McMaster-Carr 5463K225 N/A 1/2"-3/8" 2 $5.60 $5.00 $16.20

Water-Resistant

Clear TubingPolyurethane McMaster-Carr 5195T84 N/A 1" ID (1 ft piece) 2 $4.05 $5.00 $13.10

Water-Resistant

Clear TubingPolyurethane McMaster-Carr 5195T78 N/A

1/2" ID (1 ft piece)

2 $3.05 $5.00 $11.10

Water-Resistant

Clear TubingPolyurethane McMaster-Carr 5195T73 N/A

3/8" ID (1 ft piece)

25 $1.34 $5.00 $38.50

Union Tee Brass Swagelok B-1610-3 N/A 1" OD 1 $50.61 $8.00 $58.61

Totals $947.69

Issues in MSD II

The following issues will be explained further:

� Cold Side support addition

� Shipping time of heaters and thermocouples

� Received a damaged sheet of insulation

Shipping Time

� Most materials had a reasonable lead time

� Cartridge heaters were backordered by supplier

� Thermocouples and heaters both took over a month to receive

� Both pieces were critical to testing

� Lead time disrupted original process plan

Insulation

� Insulation came damaged from supplier

� Time was used to ship it back

� There was the possibility of it happening again

� Modifications were made to the design to avoid using the same sheet of insulation

System Architecture

Major Changes from MSD I

� Whole length insulation has been replaced by a protected air pocket

� Two hard points at either end provide support to the specimen

� Insulation is no longer used as a lip to seal the apparatus

� The outer housing has been connected through a hinge to allow for easier assembly

� Material changes� Structured mineral wool insulation

� High temperature Silicone fabric

� Smaller scale calcium silicate

Current Revision

Financial Status

� Current Expenditures: $905.53

� Projected Expense: $947.69

� Savings: $42.16

� Below ideal budget: $1000

LabView Interface

Additional Programming

� A Microsoft Excel file will be provided to the lab students

� It prompts them for all known parameters

� Final Temperatures

� LabView Data

�Material

� The file will automatically display graphs and values helpful to the understanding of heat conduction

System Testing Results

Thermocouples

� Purpose:To test the accuracy and precision of the thermocouple measurements.

� Procedure:Each thermocouple was placed in a beaker of boiling water at 100°C. Temperature was recorded ten times with each thermocouple.

� Results:The average and standard deviation were calculated and compared to expected values

ThermocoupleAverage

Temperature (°C)

Standard Deviation

1 99.46 0.0516

2 98.64 0.0516

3 98.63 0.0675

4 98.27 0.1059

5 98.33 0.0675

6 99.25 0.0527

7 98.52 0.0422

8 98.45 0.0527

9 98.35 0.0972

10 98.62 0.0789

Heat Source

� Purpose:To determine the rate at which the cartridge heater will be receiving power. The results will provide insight on the heating power, Qin.

� Procedure:The cartridge heater was attached to the power supply and changed periodically

� Results:The power output versus voltage dial setting was fit to a curve

0

20

40

60

80

100

120

140

160

0 20 40 60 80 100 120

Power (W)

Voltage (Dial)

Power Curve

� = � ∗ ��

Housing and Insulation

� Insulation tested simultaneously with apparatus

� Design modifications made previous plan obsolete

� Constraints made direct assembly and testing necessary

� The same testing applies to the Housing

� The cartridge heater cannot exceed 120 V

� The highest voltage tested was 110 V

� No thermal hazards were experienced

Cold Side

� The Cold Side works effectively at removing necessary heat values

� It is operational at temperatures down to 10 ºC

� Teflon tape can be used to prevent leaking from the assembled cooling jacket

Final Test Values

� The observed steady state times are different for each material

� This does not agree with the preliminary calculations projecting 20 minutes maximum

� However, temperature gradients can safely reach above 100 ºC

Material

Emperical

Value

(W/m.K)

Std

Deviation

(W/m.K)

McMaster-

Carr Value

(W/m.K)

% error

Steady

State Time

(min)

Aluminum 275 6 167 64.4 ̴60

Copper 470 6 388 21.1 ̴50

Brass 184 7 115 59.8 ̴150

Project Evaluation

Success

� Safe

� Robust

� Simple

� Precise

� Reliable components

� High temperature gradients

Failure

� Cumbersome

� Not a flexible design

� Lengthy steady state times

� Accuracy off by a factor

� Dependent on the material

� Current precision can allow for future correction

� Prototyping would have been highly beneficial

Project Plan Reassessment

Week

Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Review Bill of Materials

Assess Test/Assembly Plan

Order Parts

Software Development

Discuss possible design modifications

Generate testing procedures

Receive first tier of parts

Documentation

Format testing datasheets

Talk to machine shop

Draft insulation testing block

Machine specimens

Machine insulation

Receive heater and thermocouples

Construct presentation

Test thermocouples

Assemble insulation

Test heat source

Test cold side

Failure analysis on insulation

Test specimens w/o insulation

Test specimens in insulation w/ cold side

Test specimens in insulation w/o cold side

Failure analysis on housing material

Construct cold side housing modification

Form housing structure

Assemble final apparatus

Final testing

Functional and Performance Review

Format Lab Procedure

Final Project Review

Final Project Management Review

Upload all documentation

Future Projections

Future Work

� Further testing can be done to better understand the instrumental error

� Downsizing the design would allow for faster testing

� An additional cooling jacket and/or quick release tubing would make it easier to handle specimens

� An appropriate container to dispose of hot specimens, make exchanges easier and safer

� Modify certain components to allow more flexibility

Questions?