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

2. Process Flow Diagram

3. Process & Instrumentation Diagram

8. Current Specifications: Chiller

9. Labview Interface Design

10. Current Specifications: Beaker

11. Heat Transfer Equations Table 1: Data Sample Set Data SampleCurrent (mA) Sample #PeakS.S A125A12680.611.1 A127A128100.724 A129A13074.52 A131A1329325.6 A135A136101.723.7 A139A14091.324.1 Ave90.3 18.416667 Ave of P & SS54.35833 Illustrates the sample set taken from previous tests to provide a peak current and a steady- state current

12. 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) 11805.870.012553 21906.190.013238 32106.820.014585 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

13. Heat Transfer Equations Table 4: Overall Heat Transfer Overall Heat Transfer U (W/m 2 K)90.16393443 Table 3: Properties of Elements Ethylene Glycol Polyproplylene (Beaker) Water k.2580.11.609 h500 Utilizing the elemental properties values, the Overall Heat Transfer Coefficient. [Reference] Forced Convection of water http://www.engineeringtoolbox.com/convective-heat-transfer-d_430.html Thermal Conductivity http://www.engineeringtoolbox.com/thermal-conductivity-liquids-d_1260.html

14. Heat Transfer Feasibility Table 5: Heat Generated due to average current V (volt)I (current)P or Q (heat)ΔT (K) 1000.05445.43584.8026 800.05444.34873.6435 600.05443.26152.4802 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.

15. 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 C) @ peak 1000.09039.030057.02192 800.09037.224058.94749 600.09035.418060.87994 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 C) @ S.S 1000.01841.841763.37287 800.01841.473363.76559 600.01841.105064.15971 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

16. 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) 1006.351134.1018.90 804.82860.3814.34 603.28585.679.76 Table 8: Time for Chiller to change by 1 o C Chiller Transient Time time0.0056 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.

17. 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

18. 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 133 3 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

19. 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) 3642100$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 89202-9781$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 12620-9741255.83VWRMixer TDK-Lambda ZUP 1203.6/U Current Out:3.6A, Voltage out:120VDC 7017688811,450.00 Allied Electronics Power Supply Agilent Technologies Test Equipment 34405A 701801169 765.00 Allied Electronics Multimeter Half-Mortise/Half- Surface Mount Template Hinges 1498A1229.52McMasterHinges for Door Exposed Latches 13435A6326.22McMasterDoor Latch Metric O-Rings 4 mm wide9262K37117.70McMaster O Ring for cooling Chamber Hex NutZinc-Plated Grade 2 Steel 99961A450110.90McMasterHinges Flat Head screws 91253A425114.02McMaster Barbed Tube Fittings 5463K12815.26McMasterNitrogen fitting Compression Tube Fitting 5533K49926.54McMasterCooling fittings Steel Support Rectangular Bases 60110-222140.87VWRStand

20. 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?