Improvements to CarBETe Dry Powder Injector Systemedge.rit.edu/content/P05104/public/CDR presentation_05104...Project 05104 Improvements to CarBETe Dry Powder Injector System Multidisciplinary

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


Outline

Project OverviewDesign ProcessFinal Design


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


… 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


Design Process

Needs AssessmentConceptsFeasibility


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


Concepts

‘Venturi’ Principle

Auger Feed

“Snow Blower” PrincipleAuger x 2 w/ shaft in middle

Powder

Air pipe


… 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


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%


Weighted Method


Relative Weight


Planned Schedule


… Planned Schedule


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


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


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


… Major Design Challenges

Bleeder hole positioning

15 20

20


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"


… 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 ∆=


… 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


… 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


Final DesignContainer• 4” I.D. PVC pipe with a funnel inserted

• PVC cap – 4 holes


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


… 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


… Final DesignAir supply

• Electrically activated solenoid valve

Bleeder• 3 holes (1/8”) in feeding tube• 3/4” bushing


… 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)


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


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


Questions ?


Documents

Improvements to CarBETe Dry Powder Injector Systemedge.rit.edu/content/P05104/public/CDR presentation_05104...Project 05104 Improvements to CarBETe Dry Powder Injector System Multidisciplinary