ENGR 435 Lab Manual - chem.engr.utc.educhem.engr.utc.edu/engr435/Lab-manual/435manual-Fal… · Web...

Manual for

ENGR 435PROCESS SYSTEMS LABORATORY

Web site http://chem.engr.utc.edu/435

Dr. Jim Henry425-4398

[email protected]

Dr. Jim Cunningham755-4361

[email protected]

College of Engineering and Computer Science

University of Tennessee at Chattanooga

Fall, 1999

Contents

1: Schedule 22: Grading 33: Objectives & Guidelines 44: Project Information 55: Assignments 16

Appendices

1: SCHEDULE

Week 1 Introduction

Week 2

Week 3

Week 4

Performance measurements, Statistics,Data acquisition software, Cleaning upGetting familiar with your systemMaking measurements, Analysing dataReviewing operating instructionsGiving presentations, Writing reports

Week 5

Week 6

Week 7

Getting familiar with your systemMaking measurements, Analysing dataReviewing operating instructionsGiving presentations, Writing reports

Week 8

Week 9

Week 10

Getting familiar with your systemMaking measurements, Analysing dataReviewing and revising operating instructionsGiving presentations, Writing reports

Week 11

Week 12

Week 13

Getting familiar with your systemMaking measurements, Analysing dataReviewing and revising operating instructionsGiving presentations, Writing reports

Week 14 Giving presentations, Turning in reports, Cleaning up

If I treat you as you are, I will make you worse.If I treat you as though you are what you are capable of becoming, I help you become that.

--Goethe

2: Grading

2: GRADING

The grading in ENGR 435 will reflect what is observed of your understanding of process systems operation. Evidence of this understanding can be observed in your

• ability to apply the principles to a physical system (performance in the laboratory and quality of results)

• ability to interpret, describe and explain experimental and modeling work (reports and presentations)

The weights given will be40 points Physical laboratory

(attendance, performance)30 points Reports30 points Presentations

Lab work will be graded on this scalepoints for Leadership Contributions

Participation CreativityCooperation Teamwork

0 points Absent

The semester grade will be determined by your point total90-up A80-89 B70-79 C65-69 D0-64 F

The following must be completed to receive a passing grade in the lab:2 reports, 3 presentations, performance descriptions and a submitted report notebook.

All work done will receive credit if it is submitted before the last scheduled lab meeting of the semester.

3: OBJECTIVES & GUIDELINES

ObjectivesThe main objectives of the laboratory experiences are to help you sharpen your skill in observing what happens to an engineering system and to accurately and completely describe what you observe.

Guidelines on Safety, Cleanliness, Conservation, Citizenship

We have had over three years of experience with no lost-time injuries in this lab. Let's all do our part to make this year another one. In the event that someone is injured in the lab and is bleeding, before you help them, put on latex gloves that are available in the lab. Have someone show you where they are.

These labs are not routinely cleaned by the custodial workers. We have to keep them clean ourselves. Always leave the lab cleaner when you leave than when you arrived. If the trash cans are full, set them in the hall to be emptied. If an empty trash can is outside the door, bring it into the lab.

Around computer workstations, do not have food or drink. If you have food or drink elsewhere, please clean up your stuff. Recycle aluminum cans and Styrofoam containers. Rinse them first if there's grunge in them.

Conserve resources and money by printing only what is necessary for effective learning. If you print something that you don't need, place the paper in the "one-side-good" recycle stack to be reused. (Put the good side up.) If you are printing a draft, please use paper from the "one-side-good" stack.

Printers are not instantaneous. This lab has one printer and many users. During heavy use times, plan twice and print once. This will reduce frustrations. In the event you don't get a printout instantly, re-read this paragraph.

If you have any suggestions to improve this lab, pass it on to an instructor or assistant.

4: PROJECT INFORMATION

Room 303, Administration Building

Absorption column

(significant, but not all, data acquisition with computer)

∆p vs air flow & water flowMaterial balanceFlooding behaviorSO2 absorptionFlow meter installationDesign of experiments

Material balance-Complete a PIT for the column

Gas outLiquid in

Gas inLiquid out

Drying furnace

Drying rate for wet materialsDesign of experimentsMaterial balance-Complete a PIT for the furnaceEnergy balance-Show a calculation of the heat -Estimate the heat losses-Complete a transient energy balanceAdding data acquisitionDrying history curveDrying Rate curveMatch experiments with theory in McCabe, Smith

& HarriotExpress drying rates in g/min or lh/hr, flux in

g/min/cm2 or lb/hr/ft2

Moist air out

Dry air in

Heat in

4. Project Information

Particulate studies

Sieve analysis equipment

Ahlstrom Filtration participation (?)

Design of experiments

Filter Press

Set-up & operationMaterial balance-Complete a PIT for the unit

Water-only operationSlurry operationFlow meter installationDesign of experimentsAdding data acquisition

Filtrate out

Slurry in Filter cake

out


Flow through Packed Beds

Flow rate vs. pressure dropDispersion of concentration functionsDesign of experimentsAdding data acquisitionMaterial balance-Complete a PIT for the beds

Liquid in

Liquid out

²P

Ground-water pollution modelling (physical, scaled models)

To be designed

Stream modelGround transport model

LUST simulatorSpill simulatorElution



Domestic dehumidifier

Performance testMaterial balanceEnergy balanceInstrumentationAnalysis of performance,

transient & steady-stateDesign of experimentsAdding data acquisitionMeasure air velocities over the exit. Make a map of

the velocity distributiion. Calculate the air volumetric flow rate

Measure heat transfer area for the Freon evaporator coil

Measure heat transfer area for the Freon condenser coil

Calculate heat flux & heat transfer coefficientsReport air velocities in ft/min, ft3/minReport water rates in lb/hrReport energy flows in Btu/hrReport areas in ft2

Dry air out

Moist air in

Work in

Water out

Gas-Fired water heater

Installation & instrumentationPerformance test

Steady-state operationsTransient operations

Emissions testingMaterial balance-Complete a PIT for the combustionEnergy balance-Show a calculation of the heat of reaction and heat in

the flue gases-Estimate the heat losses-Complete a transient energy balanceAnalysis of performancePlot the time-response of the temperatures and gas

analyses

Flue gases out

Air in

Fuel in

HW out

CW in


Design of experimentsAdding data acquisitionReport heat rates in Btu/hrReport flows in lb/hr

Room 115, Grote Hall

Distillation column


Material balance-Complete a PIT for the unitEnergy balance-Show a calculation of the heat -Estimate the heat losses-Complete a transient energy balance

Steady state operation, ~18% MeOH feedTransient operation, ~18% MeOH feedT-x-y plotsMcCabe-Thiele plotsFlooding behaviorFeedback controlled operationHeat transfer theory & operation of condenserHigh purity product operationMedium purity product operationDesign of experiments

Tops out

Condeser heat

Feed

Bottoms

Reboiler heat

Cooling towers

Laboratory, 3-ton unit(significant, but not all, data

acquisition with computer)Hot, dry day operation

Cool, wet day operationMaterial balance-Air balance-Water balanceEnergy balance-Air side energy balance (heat gained)-Water side energy balance (heat lost)

-Estimate the heat losses-Complete a transient energy balance

Steady state operation

Hot water in

Cooled water out

Ambient air in

Moist air out


Transient operationDesign of experimentsReport heat flow in Btu/hr and tons of coolingReport flows in lb/hrReport air velocities in ft/minShow air velocity distributions & averagesShow impact of ambient conditions

Demonstrate on a psychro-chart the calculation procedure

Administration Building cooling tower

Energy balanceMaterial balanceSteady state operationDesign of experimentsAdding data acquisition

(More as above under Lab Cooling Tower)

Central Energy Plant cooling tower

Energy balanceMaterial balanceSteady state operationDesign of experimentsAdding data acquisition

(More as above under Lab Cooling Tower)

Coffee maker

Energy Balance

Material Balance

Transient operation

Fluid flow theory & operation

Heat transfer theory & operation


Product concentration

Grinding impact


Adding data acquisition

Room 213, Grote Hall

Chemical reactor w/ spectrophotometer


Batch reactor

CSTR reactor

Tubular ("plug flow") reactor

Seady-state and transient operation


Reactant NaOH

Reactor outlet

Reactant CV


Plant visit

BASF/Amnicola

Velsicol

W.R. Grace

Alco Chemicals

Bowater Paper

Moccasin Bend Waste Water Treatment Plant

Tennessee-American Water Treatment Plant

DuPont Plant

Bunge Foods


Various Locations

Emissions inventory

ENGR 435 "Chemical Release Inventory"

Distillation columnMethanol

Grote Hall "Chemical Release Inventory"

UTC "Chemical Release Inventory"

Central energy plantNatural gasOilFreonBlowdowns from cooling towers &

boiler water

Chattanooga motor vehicle fueling operations

Equipment performance testing

Boilers in Central Energy PlantO2 analyzerStack gas monitor

Cooling towersPitot tubes

Refrigeration chillers in Central Energy Plant

Energy audit of Challenger Center


Computer Simulations

Chemical plant simulator (ProII)

Flash tank

Distillation, 18% MeOH in water

Design of simulation runs

Air pollution monitoring & modelling

Air Pollution Control Board participation (?)

ALOHA & CAMEO dispersion modelling

Simulated Methanol spill

Design of simulation runs

5: ASSIGNMENTS

WEEK 1 BACKGROUND

Spend a few hours researching the information in the Library and on the Web for one of these subjects:

Industrial DistillationIndustrial DryingPlate and frame filtrationCombustion heatersDehumidificationPacked column absorbersChemical reactorsCooling towersAbsorption chillers

Look for methods of operation and analysis of performance of the units.

Write a report to your directors that summarizes what you find.

WEEK 2 INTRODUCTION

Describe how to determine the fuel usage (miles per gallon) of your car or truck.

5. Assignments

Here are some data for gasoline purchases. Calculate the miles per gallon for these. List the things that might need to be considered in describing why the results are not all the same.

5. Assignments

EACH WEEK WORK STATEMENT

Each week that the lab meets, you are to submit a weekly Work Statement by noon on Friday. If you submit the statement on paper, you are to submit two copies of the statement; one each to Dr. Cunningham and to Dr, Henry. You may submit the statement electronically from the 435 Web Site (http://chem.engr.utc.edu/435) and no need to duplicate it.

The Work Statement is to describe your activities in the lab and following the lab. It is to include the data you collected. The data must be presented clearly so that another engineer can understand it. It is to include any calculations and/or graphs that you have completed. Again, these must be presented clearly.

5. Assignments

THE UNIVERSITY OF TENNESSEEAT CHATTANOOGA

Chemical and Environmental EngineeringCollege of Engineering and Computer Science

615 McCallie AvenueChattanooga, TN 37403-2598

MEMORANDUM

To: ENGR 435From: J. R. Cunningham & J. M. HenrySubject: Performance Documentation

Please prepare a memo addressed to us that describes your semester in ENGR 435. The nature of this memo is similar to documentation that bosses commonly request from employees for annual performance reviews or in the process of granting them promotions or awards. Give a copy of the memo to each of us by 3:00 pm on 2 October 1999.

In your memo, please address as many of the following as appropriate:what your participation was in the various projectswhat your activities were in the various weekswhat contributions you made in the laboratory

(background work, operating help, reporting or presentation)

how you displayed leadershiphow you exhibited creativitywhen, where and how you were cooperative and worked as a member of a team

Make the last paragraph a summary of the earlier parts of the memo.

Your memo should deal almost exclusively with specifics. In the last paragraph, and only in the last paragraph, you may make general statements about your part in ENGR 435.

Here are suggested first sentences:

This memo is in response to your request. In here is a description and documentation of my part in ENGR 435 so far this semester. For each project I was involved with, I describe my participation, leadership, contributions, creativity and team work.

THE UNIVERSITY OF TENNESSEEAT CHATTANOOGA

Chemical and Environmental EngineeringCollege of Engineering and Computer Science

615 McCallie AvenueChattanooga, TN 37403-2598

MEMORANDUM

To: ENGR 435From: J. R. Cunningham & J. M. HenrySubject: Performance Documentation

Please prepare a memo addressed to us that describes your semester in ENGR 435. The nature of this memo is similar to documentation that bosses commonly request from employees for annual performance reviews or in the process of granting them promotions or awards. Give a copy of the memo to each of us by 3:00 pm on 4 December 1999.

In your memo, please address as many of the following as appropriate:what your participation was in the various projectswhat your activities were in the various weekswhat contributions you made in the laboratory

(background work, operating help, reporting or presentation)

how you displayed leadershiphow you exhibited creativitywhen, where and how you were cooperative and worked as a member of a team

Make the last paragraph a summary of the earlier parts of the memo.

Your memo should deal almost exclusively with specifics. In the last paragraph, and only in the last paragraph, you may make general statements about your part in ENGR 435.

Here are suggested first sentences:

This memo is in response to your request. In here is a description and documentation of my part in ENGR 435 this semester. For each project I was involved with, I describe my participation, leadership, contributions, creativity and team work.

APPENDICES

1 References

2 Statistics

3 SSOC

4 Information

5 Hints on Lab Reports

6 Oral presentation format, hints and grading

APPENDIX A1 REFERENCES

McCabe, Smith & Harriott, Unit operations of chemical engineering CALL NO: TP155.7 M3 1976

Perry's Chemical Engineer's Handbook, 6th ed. / prepared by a staff of specialists CALL NO: TP151 P45 1984 PUBLISHER: New York : McGraw-Hill, 1984.

APPENDIX A2 STATISTICS

Variations in Measured Quantities(ENGR 322)

Every time an experimental measurement is taken, there is some error associated with the measurement. Today you are to determine the error in measurements in your system. Do this by taking steady-state measurements of the output function, C(t), for a number of data points. Find the mean and standard deviation of the measurements you make. Report your results as mean±2x(standard deviation). This range will include the true value of the function at a confidence level of 95%. Be aware that the standard deviation may be different at different operating points. Software packages like Excel or Kaleidagraph can help a lot with the statistics.

The following graph shows how this statistical analysis could look. This graph is the measured output for a steady input.

15

16

17

18

100 105 110 115 120

Out

put

Time

Output = 16.08 ± 0.27

Variation in Output Data

Output data varying with time

APPENDIX A3 SSOC

System Operating Curve

For each value of a constant value of the input function, there will be a value of the output function; this is called the steady-state value of the output for that value of the input. A graph of the output function (on the ordinate) versus the input function (on the abscissa) is called a steady-state operating curve.

An example of what steady-state operating curves look like is below.

0

5

10

15

20

0 20 40 60 80 100

Outp

ut

Input

Example of Steady-State Operating Curve

APPENDIX A4 INFORMATION

Information Flow

In the Figure below is a diagram that depicts the flow of information is the LabVIEW environment. The computer operator and the equipment transmitters provide inputs into the program. The program provides outputs to the pieces of equipment, the computer monitor and to data files on computer disks.

After using LabVIEW, the controller program, the data can be read by other programs, such as spread sheet programs (Excel or Lotus, for examples) or graphing programs (KaleidaGraph or DeltaGraph, for examples). Excel is available on the computers at UTC.

LabVIEW Controller Program

Operator Inputs

Outputs to Equipment

Outputs to Data Files

Data PlotsSpread Sheet or Graphing programs

Equipment inputs

Information paths in laboratory experiments

APPENDIX A5 HINTS ON LAB REPORT

Diagrams, Graphs, & Tables:The reason for putting diagrams, graphs and tables in a report is to organize information so that

it can be easily understood. However, the point that you want to convey in a diagram, graph or table may not be obvious to the reader or grader. You have to tell the reader or the grader what point you want him or her to see in the diagram, graph or table so that he or she doesn't miss that point. A good rule of thumb is to write 2 or 3 sentences for each diagram, graph or table to explain or describe the diagram, graph or table.

Figures:Try to size figures so they fit upright on the page. If you have to turn them sideways, remember

that the top of the figure goes to the left of the page.

See the examples below.Top

BEST

axis

O.K . BAD

Binder:The reports submitted are to have all your group's reports included in a binder. Put the newest in the front. Include the grading sheet with each report. Separate the reports with tabbed separators that are labeled to identify the reports.

"TJe":This is known as the "Thomas Jefferson Error." This is marked when you

write it's when you mean its. Both words are legitimate words, but they mean different things. It's is the contraction of the two words it is; its is a possessive pronoun that refers to an object.

Contents of "Theory & Background"(by Jay Ware)

Brief review of systemThis should include a schematic diagram of your system with control elements labeled using the standard symbols in the appendix of S&C. The schematic diagram does not have to be pictorial, but is to show the functional relationships among the various components of the system. The block diagram should be included. The input and output functions should be clearly defined.

Discussion of Principles behind experiment

This should include the theoretical output for a given input.

Discussion of theory as applied to system

All variables for your system should be defined. Where you know the values of parameters (from previous measurements or reports) these are to be described in this section.

Brief summary of theoretical responseThis should consist of an explanation of how the system should respond based on theory. In the "Discussion" section, this theoretical response should be compared with experimental and/or approximate modeling response.

Informal Report

REPORT CONTENTS

Title PageIncludes "UTC," "Engineering 435," Title, Your Name, Your partners' names, Date

Introduction In the first paragraph, it tells briefly what was done and for what purpose. In the second paragraph, it tells how the report is organized.

Background and Theory Describes the engineering background of the lab, including equations and schematic diagrams

ProcedureDescribes what was done in the physical lab

ResultsDescribes what you observed, the data. Includes tables and graphs. Each table and graph must be explained.It builds on the "Procedure;" the "Procedure" section must describe how all the results in this section were obtained.It includes results of experiments: estimates of errors of the results, SSOC

Discussion Tells the significance of the experiment and the results. It builds on the "Results;" the "Results" section must include all the results that are discussed in this section. "No surprises"

Conclusions and RecommendationsDescribes what principles were demonstrated by the experimental results. It builds on the "Discussion;" the "Discussion" section must prepare the reader for all conclusions that are mentioned in this section. "No surprises"

AppendicesIncludes raw data, references & other things that interrupt the "flow" of the report. Anything that is in an appendix (except "references") must be mentioned someplace in the report.

AttachmentsInclude a sheet for each team member that describes the contribution to the work in the laboratory.

Formal ReportA draft of Formal Report is due the second school day before the scheduled lab meeting.

FORMAL REPORT CONTENTS

Introduction

Theory & BackgroundDescription & explanation of system components & connectionsSchematic diagramInput function(s) and output functionTheory & governing equations for components and systemBlock diagram

ModelingEquations & methods used in modeling

Procedure

ResultsExperimental results. Estimates of errors in results.Experimental and modeling results

DiscussionComparison among theory, experiment & modeling

Conclusions

Recommendation

AppendicesPhysical propertiesModeling diagram, equationsData curves & calculations

AttachmentsInclude a sheet for each team member that describes the contribution to the work in the laboratory since last reported.

ENGINEERING LAB REPORT COMMENTS & GRADING

NAME:___________________________REPORT DATE:

GROUP:___________________________TITLE:

CONTENT (50%)Title Page -- Name and name of team members? Introduction -- Clear reason for report?

Background-enough to follow report? Introduces report?

Theory (diagrams, equations, calculations) Modeling (diagrams, equations) Results (tables, graphs, calculations) Discussion (follow from Results?) Conclusions (follow from Discussion?) Recommendations Appendices Evaluator's recommendations

Total points (out of 50)

FORM (50%)Appearance (margins, page #s) Type (size, quality, consistency) Graphs (clear, consistent) Tables (clear, consistent) Diagrams (clear, consistent) Language (word choice, significant figures)

Total points (out of 50) OVERALL COMMENTS

EVALUATOR_____________________________ OVERALL GRADE

APPENDIX A6

ORAL PRESENTATIONS

ORGANIZATIONEstablish Purpose: What is your objective in making presentation?Assume your audience does not know anything about your subject.Write Conclusion FirstOutline:

IntroductionName and name of team members State reason for presentationBackground-provide enough to follow talk

BodyPresent ideas Include strengths and weaknesses

SummarySummarize briefly State conclusion

Questions-be preparedSelect Information Based on Support of Conclusion-KISS

PREPARATIONVisual aids

Overhead, charts etc. - approximately 1/minute of talkone idea/slide

Include -title slide outline of talk conclusionDo not have complete sentences on your slidesMake your letters on the overheads at least 1/4 inch high.

If you can't get a printer to do that for you, do it by handor use the copy machine to enlarge your copy.

Everything on your slide must be important enough to be there.If it's not important, leave it off. If it's important, makeit clear and tell your audience about it.

Have a balance among the number of slides with words only, those with diagrams or graphs and those with tables

Practice--to have confidenceMemorize introduction and conclusions Make them strongPractice out loud to an empty roomPresent to other group members for critique and potential questions.

DELIVERYCommunicate Stay within time limitConfidence Be in controlMaintain eye contact-maintain eye contact-maintain eye contact

FORMAL ORAL PRESENTATION CONTENTS

Brief system description, including input & output functionsReview of performance curves (SSOC)Sample time response graph: Transients, steady operationModeling approachComparison of results of experiment & modelComparisons of experimental results and modeling resultsConclusion(s) about systemConclusion(s) about approximate model

ORAL PRESENTATION GRADE

NAME: DATE GROUP: SUBJECT:

CONTENT (50%)Introduction

Name and name of team members?_______State reason for presentation?______Background-enough to follow talk?_______

Body Summary

Summarize briefly?

State conclusion? Questions?

VISUAL AIDS (20%)Overhead?

Include -title slide? outline of talk? conclusion? # Text slides # Graphic slides # Tabular slides

DELIVERY (30%)Confidence Stay within time limit? start________end______time_____ Delivery In control/evidence of practice? Maintain eye contact?

OVERALL COMMENTS

EVALUATOR OVERALL GRADE

GRADE RECORD STUDENT

PHONE

WEEK TOPIC GRADE DATE INITIALS

1 INTRO /52 /53 /5

FIRST REPORT /1045 /56 /5

MID-TERM TOTAL POINTS /35

GRADE A | B | C | D | F31 28 24 23

7 /58 PLANT VISIT

9 /510 /511 /512 /513 /5

SECOND REPORT /10ORAL REPORT #1 /10ORAL REPORT #2 /10

PRE-LAB /5SEMESTER TOTAL POINTS

GRADE A | B | C | D | F90 80 70 65

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