CONDUCTIVE HEAT TRANSFER APPARATUS P13624

Transcription

1 CONDUCTIVE HEAT TRANSFER APPARATUS P13624

2 Group Members John Durfee, Ryan Murphy, Fielding Confer Dan Unger, Katie Higgins, Robin Basalla

3 Roles Fielding Confer Dan Unger Robin Basalla John Durfee Katie Higgins Ryan Murphy Dr. Michael Antoniades Project Manager Lead Engineer Secretary Mechanical Engineer Chemical Engineer Chemical Engineer Team Guide

4 Customers and Sponsor Karuna Koppula and Paul Gregorius RIT Chemical Engineering

5 Agenda Project Description 10:15 Concept Summary Design Summary 10:20 System Architecture System Testing Results 10:25 Project Evaluation Future Projections 10:35 Questions

6 Project Description

7 Top Level Function Uninformed Student Partial Assembly Energy Unknown k Demonstrate Principle of Thermal Conductivity Informed Student Hands-on Experience Thermal Energy Known k

8 Functional Decomposition Demonstrate Thermal Conductivity Creates 1-Dimensional Heat Transfer Generates Measurable Data Enhance Student Lab Skills Minimal heat loss from boundaries Generates heat flux Provides proper temperature variation Accepts multiple geometries Accepts multiple materials/phases Minimizes resistance at heat exchanges Accurate Precise Manual collection Digital collection (Labview) Displays rate of heat flux Displays temperature distribution Requires manual assembly and disassembly Can be used within given time periods Fits on the chemical engineering carts Has replaceable components Low maintenance Durable

9 Project Plan II Week Task 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 Software Development Document Templates Construction and Testing Final Assembly and Testing Documentation and Presentation

10 Concept Summary

11 Subsystems and Ideas Subsystems Hot Liquid flow jacket Steam flow jacket Steam flow jacket Electric heater Cold Liquid flow jacket Cold air gun (vortex tube) Liquid N2 Thermoelectric Device Specimen Rectangular prism (bar) Cylinder (rod) Temp. Trans. Thermocouples Resistance Thermometer Thermistors Color-changing Material Insulation Form-fitted Solid Form-fitting malleable Wrapped Packed

12 Combined Concept

13 Design Summary

14 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

15 Cross Sections Hot Side Cold Side

16 Bill of Materials Project Conductive Heat Transfer Demonstration Apparatus Part Name Material Manufacturer Distributor Part # k value Dimensions Quantity Needed Unit Price Shipping Total Price Rigid Calcium Calcium Silicate McMaster-Carr 9353k W/mK 24 x 48 1 $ $8.75 $ Silicate Insulation Kiln-Dried Hem-Fir S4S Dimensional Lumber Hemlock Wood Lowe's Item # Model # - N/A.89 BTU/in 2 x 8 x 8 4 $7.35 N/A $29.40 Ready Made Insulated Thermocouples Multi-Purpose Aluminum 6061 Multi-Purpose Copper Alloy 110 Nickel- Chromium/Nick el-alumel with Glass Braid Insulation Omega Omega 5TC-gg-k N/A Package of 5 2 $41.00 $5.00 $87.00 Aluminum 6061 McMaster-Carr 8974k W/mK 1 in diamter by 3 feet Copper 110 McMaster-Carr 8966k W/mK 1 in diamter by 3 feet 1 $19.34 $8.75 $ $ $8.75 $ Ultra Machineable Brass Alloy 360 Brass 360 McMaster-Carr 8953k W/mK 1 in diamter by 3 feet 1 $83.51 $8.75 $ A Variac Variable AC Power Transformer N/A PHC Enterprises Parts- Express.com N/A N/A 1 $ $3.99 $128.49

17 Bill of Materials (continued) Cabot Australian Timber Oil Transparent Exterior Stain The Hillman Group 50-Count #8 x 2-1/2 High Watt Density Cartridge Heater with Incoloy Sheath Epoxy Adhesive E-40Ht Reducing coupling (10pk) Zinc Plated Wood Screws Cabot The Hillman Group Lowe's Lowe's Item # Model # Item # Model # Incoloy Sheath Omega Omega CIR N/A Hysol E-40 Epoxy N/A 1-Quart Transparent Exterior Stain 1 $16.48 $0.00 $16.48 N/A 50-Count 1 $5.58 $0.00 $ /4 in long by 3/8 in around 2 $42.00 $5.00 $89.00 Loctite McMaster-Carr 7555A41 N/A 1.69 oz (50 ml) 2 $15.80 $8.75 $40.35 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 Tubing Water-Resistant Clear Tubing Water-Resistant Clear Tubing Polyurethane McMaster-Carr 5195T84 N/A 1" ID (1 ft piece) 2 $4.05 $5.00 $13.10 Polyurethane McMaster-Carr 5195T78 N/A Polyurethane McMaster-Carr 5195T73 N/A 1/2" ID (1 ft piece) 3/8" ID (1 ft piece) 2 $3.05 $5.00 $ $1.34 $5.00 $38.50 Union Tee Brass Swagelok B N/A 1" OD 1 $50.61 $8.00 $58.61 Totals $947.69

18 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

19 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

20 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

21 System Architecture

22 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

23 Current Revision

24 Financial Status Current Expenditures: $ Projected Expense: $ Savings: $42.16 Below ideal budget: $1000

25 LabView Interface

26 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

27 System Testing Results

28 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 Thermocouple Average Temperature ( C) Standard Deviation

29 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, Q in. 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 Power (W) Power Curve Voltage (Dial) =

30 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

31 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

32 Final Test Values Material Emperical Value (W/m.K) Std Deviation (W/m.K) McMaster- Carr Value (W/m.K) % error Steady State Time (min) Aluminum Copper Brass 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

33 Project Evaluation

34 Success Safe Robust Simple Precise Reliable components High temperature gradients

35 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

36 Project Plan Reassessment Week Task 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

37 Future Projections

38 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

39 Questions?