Conductive Heat Transfer Apparatus Final Rev2 -...
Transcript of Conductive Heat Transfer Apparatus Final Rev2 -...
CONDUCTIVE HEAT TRANSFER APPARATUS
P13624
John Durfee, Ryan Murphy, Fielding Confer
Dan Unger, Katie Higgins, Robin Basalla
Group Members
Roles
• Project ManagerFielding Confer
• Lead EngineerDan Unger
• SecretaryRobin Basalla
• Mechanical EngineerJohn Durfee
• Chemical EngineerKatie Higgins
• Chemical EngineerRyan Murphy
• Team GuideDr. Michael Antoniades
Karuna Koppula and Paul Gregorius
RIT Chemical Engineering
Customers and Sponsor
Agenda
• 10:15Project Description
Concept Summary
• 10:20Design Summary
System Architecture
• 10:25System Testing Results
Project Evaluation
• 10:35Future Projections
Questions
Project Description
Top Level Function
Uninformed Student
Partial Assembly
Energy
Unknown k
Informed Student
Hands-on Experience
Thermal Energy
Known k
Demonstrate Principle of Thermal
Conductivity
Functional Decomposition
Demonstrate
Thermal
Conductivity
Creates
1-Dimensional
Heat Transfer
Minimal heat loss from boundaries
Generates heat flux
Provides proper temperature variation
Accepts multiple geometries
Accepts multiple materials/phases
Minimizes resistance at heat exchanges
Generates
Measurable
Data
Accurate
Precise
Manual collection
Digital collection (Labview)
Displays rate of heat flux
Displays temperature distribution
Enhance
Student
Lab Skills
Requires manual assembly and disassembly
Can be used within given time periods
Fits on the chemical engineering carts
Has replaceable components
Low maintenance
Durable
Project Plan II
Week
Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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
Construction and Testing
Final Assembly and Testing
Documentation and Presentation
Software Development
Document Templates
Concept Summary
Subsystems and Ideas
Subsystems
Hot
Cold
Specimen
Temp. Trans.
Insulation
Liquid flow jacket
Liquid flow jacket
Rectangular prism (bar)
Thermocouples
Form-fitted Solid
Steam flow jacket
Cold air gun (vortex tube)
Cylinder (rod)
Resistance Thermometer
Form-fitting malleable
Steam flow jacket
Liquid N2
Thermistors
Wrapped
Electric heater
Thermoelectric Device
Color-changing Material
Packed
Combined Concept
Design Summary
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
Cross Sections
Hot Side Cold Side
Bill of Materials
Project 13624 - Conductive Heat Transfer Demonstration Apparatus
Part Name Material Manufacturer Distributor Part # k value DimensionsQuantity Needed
Unit Price ShippingTotal Price
Rigid Calcium Silicate Insulation
Calcium Silicate McMaster-Carr 9353k43 .073 W/mK 24 x 48 1 $126.93 $8.75 $135.68
Kiln-Dried Hem-Fir S4S Dimensional
LumberHemlock Wood Lowe's
Item # - 4545Model # - N/A
.89 BTU/in 2 x 8 x 8 4 $7.35 N/A $29.40
Ready Made Insulated
Thermocouples
Nickel-Chromium/Nickel-Alumel with Glass Braid Insulation
Omega Omega 5TC-gg-k-20-36 N/A Package of 5 2 $41.00 $5.00 $87.00
Multi-Purpose Aluminum 6061
Aluminum 6061 McMaster-Carr 8974k133 167 W/mK1 in diamter by 3
feet1 $19.34 $8.75 $28.09
Multi-Purpose Copper Alloy 110
Copper 110 McMaster-Carr 8966k23 388 W/mK1 in diamter by 3
feet1 $126.22 $8.75 $134.97
Ultra Machineable Brass Alloy 360
Brass 360 McMaster-Carr 8953k983 115 W/mK1 in diamter by 3
feet1 $83.51 $8.75 $92.26
5A Variac Variable AC Power
TransformerN/A
PHC Enterprises
Parts-Express.com
120-842 N/A N/A 1 $124.50 $3.99 $128.49
Bill of Materials (continued)
Cabot Australian Timber Oil
Transparent Exterior Stain
Cabot Lowe'sItem # - 220549
Model # -140.0019400.005
N/A1-Quart
Transparent Exterior Stain
1 $16.48 $0.00 $16.48
The Hillman Group 50-Count
#8 x 2-1/2
Zinc Plated Wood Screws
The Hillman Group
Lowe'sItem # - 68356
Model # - 35058N/A 50-Count 1 $5.58 $0.00 $5.58
High Watt Density Cartridge Heater
with Incoloy Sheath
Incoloy Sheath Omega Omega CIR-2012-120 N/A1 1/4 in long by 3/8 in around
2 $42.00 $5.00 $89.00
Epoxy Adhesive E-40Ht
Hysol E-40 Epoxy
Loctite McMaster-Carr 7555A41 N/A 1.69 oz (50 mL) 2 $15.80 $8.75 $40.35
Reducing coupling
(10pk)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 TubingPolyurethane McMaster-Carr 5195T84 N/A 1" ID (1 ft piece) 2 $4.05 $5.00 $13.10
Water-Resistant
Clear TubingPolyurethane McMaster-Carr 5195T78 N/A
1/2" ID (1 ft piece)
2 $3.05 $5.00 $11.10
Water-Resistant
Clear TubingPolyurethane McMaster-Carr 5195T73 N/A
3/8" ID (1 ft piece)
25 $1.34 $5.00 $38.50
Union Tee Brass Swagelok B-1610-3 N/A 1" OD 1 $50.61 $8.00 $58.61
Totals $947.69
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
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
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
System Architecture
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
Current Revision
Financial Status
� Current Expenditures: $905.53
� Projected Expense: $947.69
� Savings: $42.16
� Below ideal budget: $1000
LabView Interface
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
System Testing Results
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
ThermocoupleAverage
Temperature (°C)
Standard Deviation
1 99.46 0.0516
2 98.64 0.0516
3 98.63 0.0675
4 98.27 0.1059
5 98.33 0.0675
6 99.25 0.0527
7 98.52 0.0422
8 98.45 0.0527
9 98.35 0.0972
10 98.62 0.0789
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, Qin.
� 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
0
20
40
60
80
100
120
140
160
0 20 40 60 80 100 120
Power (W)
Voltage (Dial)
Power Curve
� = � ∗ ��
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
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
Final Test Values
� 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
Material
Emperical
Value
(W/m.K)
Std
Deviation
(W/m.K)
McMaster-
Carr Value
(W/m.K)
% error
Steady
State Time
(min)
Aluminum 275 6 167 64.4 ̴60
Copper 470 6 388 21.1 ̴50
Brass 184 7 115 59.8 ̴150
Project Evaluation
Success
� Safe
� Robust
� Simple
� Precise
� Reliable components
� High temperature gradients
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
Project Plan Reassessment
Week
Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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
Future Projections
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
Questions?