Emulsion Polymerization Reactor Group (13622)

Transcription

1 Emulsion Polymerization Reactor Group (13622) Members: Ryan Foringer : Team Leader & Process Design John Miller : Procurement Specialist & Process Design Curtis Williamson : Engineering Manager & Process Design Stephen Heisler : Process Automation & Programming Specialist Sponsor: RIT Department of Chemical and Biomedical Engineering

2 Project Description Concept Summary System Architecture Design Summary Complications in Design System Testing and Results Project Evaluation Suggestions for Future Work Acknowledgements Agenda

3 Project Description Customer Need # Priority CN1 1 Description A mixing vessel with ability to perform temperature control of contents (i.e. jacket for steam flow, or, jacket for hot water flow, or, electrical heater. CN2 1 One outlet of mixed, homogenous, emulsion. CN3 1 Port, window or lid that allows visual inspection of the mixing vessel (higher surface area such as the visualization of the top of the entire vessel might enable better visual assessment). CN4 1 The ability to see the outlet flow, i.e. the stream lines if dye is added visible through transparent tubing. CN5 1 A mechanical mixer/stirrer, designed for emulsion preparation, or other mixing solution the rate of which can be adjusted. CN6 1 The ability to control mixer stir rate CN7 1 CN8 1 Characterization of the emulsion homogeneity in time by taking sequential samples of the effluent and measuring their viscosity. Design must include the capacity for temperature control or includes a strategy by which the temperature control capability could be added in future projects without the significant alteration of the existing apparatus. CN g/min coater rate CN minute batch time with 5 minute CIP CN11 1 Cost per batch less than $10 CN12 1 Particle size must be visible by optical microscope for product evaluation. Assumption Assumption Room temperature operation Viscometers will be provided

4 Project Description Specification Number Importance Customer Needs Description 1 Emulsion Characteristics The emulsion shall have a 10micon range particle size distribution The emulsion shall have a particle growth no more than 5% the original size after 1 hour ,7 The emulsion shall have a transmission above The emulsion must have particle sizes between 500 to 5microns. 2 Emulsion Process The entire emulsion batch process shall be 60 minutes with a 5 minute CIP included The emulsion process shall have a chemical cost under 10$ for each batch tested The emulsion batch size shall deviate no larger than 5% of a 10L batch. 3 Reproducibility The emulsion shall have a batch to batch particle sizes with no more 5micron deviation. 4 Flowing Fluids The oil feed shall be sub-fed at a rate of 146mL/s to 66mL/s.

5 Concept Summary Lab application for future chemical engineering students Visual insight into emulsion creation Designed for process parameter variability Low budget batch runs Future project expansion

6 System Architecture 500 ml/s 3 hp ml/s 200 ml/s

7 Design Summary Vessel jacketed glass reactor High shear Cowles mixing blade 3 Hp VSD electrical motor Water, canola oil and sodium dodecyl sulfate system Subsurface oil feeding

8 Complications in Design Weight of the motor - 61 lbs Shaft Stability (Chuck Design) - above 1500 RPM Motor Power Supply - 240V Subsurface Flow Rate Assumptions 2 minor losses in elbow 1 minor loss from valve Longer than anticipated discharge

9 System Testing and Results Compilation of Results Sample Oil (%) SDS (wt%) Avg. Size (um) Concentrati on RPM Shakes Time (min) E E E E E E E E

10 System Testing and Results

11 System Testing and Results

12 System Testing and Results Spec Number Importance CN # Description Target Goal Pass/ Fail 1 Emulsion Characteristics The emulsion shall have a 10micon range particle size distribution. +/- 10microns from average Pass 10 The emulsion shall have a particle growth no more than 5% the original size after 1 hour. Under 5% growth Fail ,7 The emulsion shall have a transmission above.8. Transmission Value >.8 Fail - Particle Diameter between The emulsion must have particle sizes between 500 to 5microns. 500microns Pass 4,5,6,9,10 2 Emulsion Process The entire emulsion batch process shall be 60 minutes with a 5 minute CIP included 60min run time Pass 12, The emulsion process shall have a chemical cost under 10$ for each batch tested. $10 batch Pass 7,8,9, The emulsion batch size shall deviate no larger than 5% of a 10L batch. 5% volume fluctuation Fail All Tests 3 Reproducibility The emulsion shall have a batch to batch particle sizes with no more 5micron deviation. 4 Flowing Fluids +/- 5microns from average Test # Pass/ Fail The oil feed shall be sub-fed at a rate of 146mL/s to 66mL/s. Flow rates between mL/s Fail 13 CN # Physical Characteristics Equipment Acquired Pass/ Fail 1 A mixing vessel with the ability to control temperature Glass Jacketed Mixing Vessel Pass 3 Reactor allows for visual inspection of the mixing process Glass Jacketed Mixing Vessel Pass 4 Ability to see the outlet flow Glass Jacketed Mixing Vessel Pass Mechanical mixer designed for preparation of emulsions and variable 3hp VSD motor, high shear 5,6 control. Cowles blade Pass Heat compatability and ability to add heating element without significant 8 changes Glass Jacketed Mixing Vessel Pass

13 Successes Project Evaluation Exceeded expectations for particle size Successful gravity subsurface oil feed Vessel design exceed expectations Successful management of obstacles Failures Max 1500 RPM Subsurface feeding flow rate Particle stabilization Volume change not taken into consideration

14 Suggestions for Future Work Addition of a salt into the process Particle stability Chuck Redesign Shaft stability In-line measurements Accuracy Ensure closed volume system Fixed Volume More accurate form of measurement Precision Pump installation Flow rate dependence Automation Valves Pump Motor Labview Temperature control

15 Acknowledgements We would like to thank the Rochester Institute of Technology Department of Chemical and Biomedical Engineering in funding the Emulsion Reactor. A thank you to Christiaan Richter for the opportunity to develop the Emulsion Reactor. A special thanks to Neal Eckhaus and Steve Possanza for their guidance in project management and expert advice in engineering design. We would also like to thank Kevin Penfield from Croda Inc, whom had helped us narrow down our range of variables and provided insight into stable emulsions. Many thanks to Gabriel Zajia and Mike Sanchez for lending their expertise on emulsion generation techniques. Thank you Karuna Koppula for your assistance with the flow systems design. Thank you Ken Ruschak and Evident Technologies for the donation of chemicals for our tesing.

16 QUESTIONS