Bill Dullea, Garry Clarke, Jae Ho, Kelly McNabb, Mary Medino

Process Flow Diagram

Process & Instrumentation Diagram

Current Specifications: Chiller

Labview Interface Design

Current Specifications: Beaker

Heat Transfer Equations Table 1: Data Sample Set Data SampleCurrent (mA) Sample #PeakS.S A125A A127A A129A A131A A135A A139A Ave Ave of P & SS Illustrates the sample set taken from previous tests to provide a peak current and a steady- state current

Heat Transfer Equations Table 2.1: Beaker Dimensions D6.8072cm thickness1mm Table 2.2: Beaker Dimensions dependent on volume of solution in a 250ml Beaker Volume (ml)height (cm)A (m2) Illustrates the dimensions of the Polypropylene Beaker The area of heat transfer is dependent on the amount of solution that is within the beaker There are three different volumes of solution provided to give a range of results

Heat Transfer Equations Table 4: Overall Heat Transfer Overall Heat Transfer U (W/m 2 K) Table 3: Properties of Elements Ethylene Glycol Polyproplylene (Beaker) Water k h500 Utilizing the elemental properties values, the Overall Heat Transfer Coefficient. [Reference] Forced Convection of water Thermal Conductivity

Heat Transfer Feasibility Table 5: Heat Generated due to average current V (volt)I (current)P or Q (heat)ΔT (K) Table 5 illustrates the Heat Generated from the electrodes Applied an average of peak and steady state current use Ultimately calculate the temperature difference from Solution to coolant, to see how effective the water bath system is at cooling.

Heat Transfer Feasibility Table 7: Heat Generated with peak current Calc at Peak Initial T ( o C) (Solution) 65 V (volt)I (current)P or Q (heat) T ( o peak Table 6: Heat Generated with Steady State current Calc at S.S Initial T ( o C) (Solution) 65 V (volt)I (current)P or Q (heat)T ( o S.S Table 6 Heat Generated from the electrodes Average steady state current Calculated the T of the coolant Initial Temperature of solution was 65 Deg C Temperature was calculated with the Heat Transfer Equation (Previous Slide) Table 7 Heat Generated from the electrodes average peak current; calculated the T of the coolant

Heat Transfer Feasibility Table 9: Time needed for chiller to change temperature from Peak to Steady State Calc Time need for chiller V (volt)ΔTTime (s)Time (min) Table 8: Time for Chiller to change by 1 o C Chiller Transient Time time o C/s Table 9 illustrates the time required for the chiller to translate from the peak heat generated to the steady state heat generated. These results provide vital information on what needs to be done with labview. Table 8 illustrates the time required for the chiller to change the coolant temperature by 1 degree.

Test Plans SpecificationRangeTests Controlling temperature of solution within 1°0-70°C 1)Cool solution to 0°C 2)Measure temperature every couple of minutes until solution reaches 0°C 3)Once at 0°C measure temperature every 5 minutes for an hour 4)Heat up to 20°C 5)Repeat the same tests 6)Heat up to 50°C 7)Repeat the same tests 8)Heat up to 70°C 9)Repeat the same tests Control and monitor voltage0-100V 1)Set voltage to 1V 2)Check multimeter every 5 minutes for an hour 3)Set voltage to 25V 4)Check multimeter every 5 minutes for an hour 5)Set voltage to 50V 6)Check multimeter every 5 minutes for an hour 7)Set voltage to 75V 8)Check multimeter every 5 minutes for an hour 9)Set voltage to 100V 10)Check multimeter every 5 minutes for an hour Control and monitor current100μA-5A 1)Set multimeter to 100μA 2) Check multimeter every 5 minutes for an hour 3)Set multimeter to 1μA 4) Check multimeter every 5 minutes for an hour 5)Set multimeter to 1mA 6) Check multimeter every 5 minutes for an hour 7)Set multimeter to 1A 8) Check multimeter every 5 minutes for an hour 9)Set multimeter to 5A 10) Check multimeter every 5 minutes for an hour Control humidity<15% 1)Purge system with N 2 2)With a data logger measure humidity every 5 minutes for an hour Easy use for loading and unloading electrodes 1)Record how long it takes to load electrodes 2)Record how long it takes to unload electrodes 3)Repeat both steps 5 times

Risk Assessment Risk ItemEffectCause Likelihood Severity Importance Action to Minimize RiskOwnerComment Labview Coding of transient chiller Wrong temperature range Transient code's cooling rate 3391)Code at steady state conditions; 2)Code transient chiller rate to start before reaction Kelly User Interface with Labview Acquiring poor data analysis Programming Error236 Integrate unit tests 1 at a time by weeks; specification TBD Chief Programmer Transient Cooling Time Rapid cooling of solution Chiller temperature change time is too long 326Coding labview with timed equations for constant heat transfer Garry/Bill Controlling excess Humidity not purged by nitrogen Changes concentration which ultimately changes the end product result Undesired Reactions224 Utilized CaCl as a hydrophilic material to control excess/ produced water (drierite) Team Leader Run away reactionMaterials become scrap Temperature becomes too high/current get high 224 Program Emergency Shutdown, increase cooling Chief Design Engineer Building Technique/ Machine Work Lose of building integrity Implementing wrong Technique point check technique, basically double check work with two different perspective Chief Design Engineer material/equipment budget Can't buy needed equipment Trying to fufill client's neededs 122 talk to clientProcument material/equipment wait time can't start building design on time Shipping time restrained by costs 212 work on other aspects as parts arriveProcument Controlling Temperature with set specification Becomes run away reaction Chiller/ Heater339 Once we get specs 10/2/12; test the machine for data by 10/9/12 or 10/11/12 Team Leader Decided not a risk after calculations of water bath concept. 10/23 Heat Transfer (Overall) at electrodes Doesn't cool the soln effectively the material used is not thermally conductive 339increase the diameter of the tube to increase the surface area, while trying to decrease the plastic tubing; change the coolant Chief Programmer Decided not a risk after calculations of water bath concept. 10/23

Bill of Materials ProductDescriptionDimension Catalog QuantiyCostVendorPurposeNotes PFA Coated Thermocouple Probes with Standard Connectors PFA Coated Probes are the perfect solution when there is a need to measure the temperature of caustic or corrosive chemical solutions in industrial and laboratory environments. The superior corrosion resistance of PFA allows you to measure the temperature of sulfuric, hydrochloric, nitric and chromic acids, as well as caustic compounds. 1 /16 " or 1 /8 " Diameter 12" Probe Standard † ICSS-116G-12-PFA1$52.00omega Temperature Monitoring TriCorner Beaker Plastic beaker with three dripless pouring spouts. Polypropylene (PP). 250 mL 76mm x 88mm (wxh) $31.10 globe scientific Reaction Vessel Scratch-Resistant Cast Acrylic Color: Clear, Temperature Range: 0° to 150° F, Tensile Strength: Good Impact Strength: Poor 5" D 1' Length8528K491$307.06McMasterMain Chamber VWR® Advanced Digital Controller Refrigerated/Heated Circulating Baths 120V 60Hz Temp Rang: -40 to 200 C Overall dimensions 54.1L x 22.1W x 61.7H cm W orking Access 15.7L x 14.2W x 12.7D cm $3,903.59VWRChiller/Heating Polycarbonate (1 Chambers) Color: Clear Temperature Range: -40° to 180° F Tensile Strength: Good Impact Strength: Excellent 1' x 3' (3/16" Thickness)8574K2732$26.49McMasterReactor May Change due to size VWR® Dylastir® Magnetic Stirrer Cast Aluminum Top Plate Large 16.5 cm (61/2") Diameter VWRMixer TDK-Lambda ZUP /U Current Out:3.6A, Voltage out:120VDC , Allied Electronics Power Supply Agilent Technologies Test Equipment 34405A Allied Electronics Multimeter Half-Mortise/Half- Surface Mount Template Hinges 1498A McMasterHinges for Door Exposed Latches 13435A McMasterDoor Latch Metric O-Rings 4 mm wide9262K McMaster O Ring for cooling Chamber Hex NutZinc-Plated Grade 2 Steel 99961A McMasterHinges Flat Head screws 91253A McMaster Barbed Tube Fittings 5463K McMasterNitrogen fitting Compression Tube Fitting 5533K McMasterCooling fittings Steel Support Rectangular Bases VWRStand

Questions, Comments, Concerns?? Why are we doing this? What problem are we solving? Is this actually useful? Is there an easier way? What’s the opportunity cost? Are we on our critical path? Is it really worth it?