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Members: Ryan Foringer
John Miller Curtis Williamson Stephen Heisler
Emulsion Polymerization Reactor Group (13622)
Agenda LabVIEW analysis Updated Customer needs/P&ID/PFD Test Plan System Architecture Updated Engineering Specifications BOM and Gant Chart Risk Assessment
Changes To Customer Needs
Changed Two Inlets no longer required Control of the inlet flow rates is only open close Automated process no longer required Automated overflow protection no longer required
New Tank must feed downstream coater at 200 g/min 60 min batch time with 5 min CIP Cost per batch is less than $10 Particle Size must be visible via optical microscope for product
evaluation
Updated Block Diagram
Updated PFD
P&IDs
Test Plan
Test Plan Example Format
Test Plan Example Testing Steps
Feasibility Analysis - Vessel
Glass Vs Stainless Steel • Cost • Heat Loss • Durability • Reaction Visibility • Use in Lab setting
Feasibility Analysis – Mixing Blade Cowles Mixer vs Propeller Blade type mixers
Emulsification ability Propeller blade testing Expert Opinion
Availability
Feasibility Analysis- Particle Size
S
O
SO
t
t
MMRatiio
RV
V
RRP
xnVn
=
=
−+=
+=
+=−
30
33max
3max
34
)(34
10)9.264.27(
)1265.154(.
π
π
CMC Calculations and Equations
Symbol Value Units n 12 atoms R 25000 nm Lmax 1.672 nm Vt 0.3502 nm3 P 3.75E+10 Par@cles Mols (SDS) 6.23E-‐14 mol Mass (SDS) 1.8E-‐11 g Volume (Oil) 6.54E-‐08 cm3 Mass (Oil) 6.02E-‐08 g Ra@o (O/S) 3353.089
R
Feasibility Analysis- Particle Size Inputs
Par@cle Diameter 50 microns Volume of DI Water 18 L
Outputs Volume of Canola Oil 2 L
Mass Ra@o of Oil to SDS 3353.089 O/S Mass of SDS 0.548748 g Batch Cost 4.688747 $
Inputs Par@cle Diameter 50 microns
Volume of DI Water 10 L Outputs
Volume of Canola Oil 10 L Mass Ra@o of Oil to SDS 3353.089 O/S
Mass of SDS 2.743739 g Batch Cost 23.44373 $
Condition 90% DI-Water 10% Oil
Condition 50% DI-Water 50% Oil
Inputs Par@cle Diameter 50 microns
Volume of DI Water 15.73447 L Outputs
Volume of Canola Oil 4.265533 L Mass Ra@o of Oil to SDS 3353.089 O/S
Mass of SDS 1.170351 g Batch Cost 10 $
Condition Converged Volume to meet Customer Need 11
Inputs Par@cle Diameter 5 microns
Volume of DI Water 16 L Outputs
Volume of Canola Oil 4 L Mass Ra@o of Oil to SDS 335.1071 O/S
Mass of SDS 10.98156 g Batch Cost 20.74417 $
Condition 90% DI-Water 10% Oil
Inputs Par@cle Diameter 5 microns
Volume of DI Water 10 L Outputs
Volume of Canola Oil 10 L Mass Ra@o of Oil to SDS 335.1071 O/S
Mass of SDS 27.45391 g Batch Cost 51.86043 $
Condition 50% DI-Water 50% Oil
Inputs Par@cle Diameter 5 microns
Volume of DI Water 18.07175 L Outputs
Volume of Canola Oil 1.928252 L Mass Ra@o of Oil to SDS 335.1071 O/S
Mass of SDS 5.293806 g Batch Cost 9.999999 $
Condition Converged Volume to meet Customer Need 11
Feasibility Analysis- Particle Size Assumptions
The cost of DI Water is negligible The CMC theory equations are applied
Desired Parameters Batch Cost is $10.00 Oil to DI Water ratio varies from 10% to 50% Vessel Size needs to meet a 200g/min continuous flow rate to the
coater
All Three conditions cannot be simultaneously met Optimum parameter to be changed: Coater Flow Rate
All three parameters could be achieved simultaneously Overall cost of reactor will decrease
Feasibility Analysis- Sub-Feed Flow Calculations
h0 h2
h3
h1
P2
Tank 1
P1
Tank 2
P1 =!oilgh1
P2 =!oilg h2 " h0( )+!h2ogh0
#V2#t
= A2#h2#t
=m
#V1#t
= A1#h1#t
= "m
m =$D4!128µL
P1!oil
+gh3%
&''
(
)**"
P2!oil
+
,--
.
/00
Feasibility Analysis- Sub-Feed Flow Calculations
Flow Rate Analysis Assumptions Incompressible liquid Fully developed flow Laminar flow Discharge is to bottom of tank (h=0)
Optimized Dimensions Oil vessel height above reactor vessel Pipe Diameter Oil Vessel Diameter
Feasibility Analysis- Sub-Feed Flow Calculations
Oil vessel height above reactor vessel Higher h3, more constant flow rate
Slight decrease in discharge time
h3>1m is unrealistic for apparatus dimensions
Diameter of pipe
Pipe Dia Approx. Flow rate Tank 1 emp6es?
in ml/s Worst Case (50% oil)
0.25 6.08 N
0.5 97.29 Y
0.75 492.5 Y
Feasibility Analysis- Sub-Feed Flow Calculations
Percentage Oil to Aqueous Analysis
Oil % Discharge Time Start Flow Rate Final Flow Rate
s m3/s m3/s
10 181 0.0126 0.0081
20 302 0.0172 0.0082
30 392 0.0219 0.0084
40 464 0.0264 0.0085
50 523 0.0311 0.0087
Feasibility Analysis- Sub-Feed Flow Calculations
0
20
40
60
80
100
120
140
160
180
0 10 20 30 40 50 60
Flow
Rat
e (m
l/s)
Percentage Oil
Discharge Time vs. Oil Percentages
Feasibility Analysis- Sub-Feed Flow Calculations
0
20
40
60
80
100
120
0 10 20 30 40 50 60
Flow
Rat
e (m
l/s)
Percentage Oil
Flow Rates vs Oil Percentage
Starting Flow Rate
Final Flow Rate
Feasibility Analysis- Sub-Feed Flow Calculations
10% Oil, 2in Dia
-0.01
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0 10 20 30 40 50 60 70 H
eigh
t In
Tank
1 (m
)
Time (s)
Height In Tank 1 vs Time
0.00003
0.000032
0.000034
0.000036
0.000038
0.00004
0.000042
0.000044
0.000046
0 10 20 30 40 50 60 70
Volu
met
ric
Flow
Rat
e (m
3/s)
Time (s)
Volumetric Flow Rate vs Time
Feasibility Analysis- Sub-Feed Flow Calculations
50% Oil, ½ in Dia
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 50 100 150 200 250
Hei
ght I
n Ta
nk 1
(m)
Time (s)
Height In Tank 1 vs Time
0
0.00002
0.00004
0.00006
0.00008
0.0001
0.00012
0 50 100 150 200 250
Volu
met
ric
Flow
Rat
e (m
3/s)
Time (s)
Volumetric Flow Rate vs Time
Engineering Specifications Specifica6on Number Importance Customer
Needs Descrip6on 1 Emulsion Characteris6cs 1.1 1 2 The emulsion shall have a 10% standard devia@on par@cle size distribu@on. 1.2 1 The emulsion shall have a par@cle growth no more than 5% the original size per hour. 1.3 2 2,7 The emulsion shall have a transmission above .8. 1.4 1 The emulsion must have par@cle sizes that are easily observale by means of op@cal imaging. 2 Emulsion Process 2.1 1 10 The emulsion batch dura@on shall be within 60 minutes to perform desired specifica@ons. 2.2 1 11 The emulsion process shall have a chemical cost under 10$ per batch. 2.3 2 10 The emsulsion process shall end with a 5 minute CIP as part of the process dura@on. 2.4 1 9 The emulsion batch size shall be large enough to compensate for a coater feed rate of 200g/min 3 Motor Proper6es 3.1 2 6 The motor shall have a rmp ramp rate of 100rpm/s. 3.2 3 5,6 The motor shall have max rmp of 6000rpm. 3.3 1 7 The motor shall have a rpm that corresponds to a shear rate. 4 Flowing Fluids 4.1 2 2 The solvent/surfactant flow rate shall be 500mL/s into the vessel. 4.2 2 The emulsion fluid shall drain out of the vessel at a rate of 250mL/s. 4.3 2 The oil feed shall be sub-‐fed at a rate of 25mL/s
Bill of Materials
Risk Assessment ID Risk Item Effect Cause Likelihood Severity Importance Ac6on to Minimize Risk Owner
Describe the risk briefly
What is the effect on any or all of the project deliverables if the cause actually happens
What are the possible causes of this risk L*S
What ac=on(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring
Who is responsible for following through on mi=ga=on?
1 Customer Needs Requires For Expensive Vessel
Budget Surpassed, Customer Need 1 not met
Ideal reactor vessel material is Stainless Steel and calls for jacked vessel both of which are expensive.
3 3 9
Sacrifice energy savings, and use less conduc@ve glass vessel. If jacket is too expensive to implement, disregard need *approved by customer*
Ryan
2 Subfeeding doesn’t complete emptying of the oil vessel
Process fails, Emulsion not created. Customer Need 2 not met.
Assump@ons on flow rate feasability analysis were too lenient. 3 3 9
If subfeeding fails and cannot be fixed, we will revert to a top feeding system.
Ryan
3 Flow from Oil Tank exceeds Predic@ons
Unrealis@c flow rate, improper emulsifica@on Flow Calula@ons inaccurate 3 2 6
If flow rate is too high, poten@al correc@on with valve opening, change of pipe size possible
John
4 Par@cle is not visible by op@cal means
Customer Need 12 is not met and analysis of par@cle cannot be determined
Mixng @me and rate may not be at op@mum values 2 3 6
If aher chemical tes@ng op@miza@on, desired par@cles are not achieved, poten@ally a new surfactant or oil could be used.
Cur@s
5 Unable to achieve stable, repeatable par@cle size.
Customer Need 2 not met Theore@cal CMC calcula@ons were inacurate. 2 3 6
If aher chemical tes@ng op@miza@on, desired par@cles are not achieved, poten@ally we could add thickening agent or mixed surfactants.
Cur@s
6 Tes@ng Facili@es Not available
Cannot test chemical combina@ons, process configura@ons
closed, booked 2 2 4 Prevent; schedule tes@ng ahead of @me to ensure availability Cur@s
7 Chemicals Not Available Tes@ng is delayed Backordered, delayed in shipment 1 3 3 Prevent: Order chemicals in advance,
check availibility John
8 Defec@ve Equipment Delayed project comple@on, budget exceeded
improper construc@on, structural integrity comprimised 1 3 3 Purchase equipment in advance. Stephen
9 Insufficient mixing of the oil water solu@on
Target par@cles not achieved/ batched lost. Motor failure 1 3 3
Ensure motor is func@onal prior to batch run, and ensure motor is in spec.
John
10 Blade doesn’t provide proper shear mixing
Target par@cles not achieved within max batch @me
Current blade is not appropriate dispite expert guidance. 1 3 3 Back up informa@on from experts
with blade company website info. Stephen
11 Valve Fails Loss of batch Poor Manufacture 1 1 1 Inspect valve before purchase, if fails, purchase new valve. John
Satisfaction of Customer Needs Customer Need # Process used to sa@sfy specific customer need
1 The vessel that will be purchased for this emulsion will be a jacketed glass wall vessel with an inlet and outlet port for temperature controlling flow.
2 This need will be sa@sfied through the par@cle size tes@ng plan.
3 The vessel that will be purchased for this emulsion will be a glass walled vessel, so every part of the emulsion will be visible to the viewer.
4 The exit of the vessel will be made of glass, so the outlet port will have a visible fluid flow.
5 The motor that will be used to make the emulsion and do par@cle tes@ng will have a variable RPM control.
6 The motor that will be used to make the emulsion and do par@cle tes@ng will have a variable RPM control.
7 This need will be sa@sfied through the par@cle size tes@ng plan and the motor tes@ng plan.
8 The vessel that will be purchased for this emulsion will be a jacketed glass wall vessel with an inlet and outlet port for temperature controlling flow.
9 The size of the vessel will be large enoguh to compensate a con@nuous flow rate of 200g/min.
10 This need will be sa@sfied through the par@cle size tes@ng plan.
11 This need has been sa@sfied by use of the CMC calcula@ons.
12 This need will be sa@sfied through the par@cle size tes@ng plan.
QUESTIONS & IDEAS