John Zink Burn Process Simulator

Team Leader: Kyle Davis

Johnny Benson

Michael Cap

Kyle Davis

Van Mai

Dr. Wilson Merchan-Merchan

(Advisor)

Sponsor: John Zink Institute

Objective

The purpose of this capstone project was to produce a portable burner process simulator that allows the user to manipulate the combustion process by altering multiple variables in the system. Portability is a main concern due to John Zink Institute using the unit as a teaching aide in various locations in the country.

Desired to demonstrate with apparatus

• Burners• Varying firing rates of burners• 1 burner out of service• Varying burner spacing• Varying amount of premixing

• Heater• Varying draft levels

• Varying excess O2 levels

• Varying heater length• Tramp air leakage

• Emissions (NOx, CO)

Desired design from John Zink

Capstone group’s Design

Budget

Item Description Qty Unit Price Sub-Total Total InvoiceBurner for LPG 3 $22.09 $66.27 $69.02 Flow meter 1 $139 $139 $147.68 Parts for burners testing $21.26 Adjustable propane regulator 1 $18 $18 $21 Disposable cylinder adapter 1 $9.84 $9.84 $12.83 Snap well thermometer 2 $13.95 $27.90 $37.55 Water pump 1 $59.99 $59.99 $67.98 Fume Hood 1 $50.00 $50.00 $50.00Motor (DC, gear, 12V, 60RPM) 3 $19.95 $59.85 $66.75 Flow meter 3 $160.00 $480.00 $490.94 6 Amp Linear Power Supply 1 $39.95 $39.95 $52.34 Water Tank 1 $46.95 $46.95 $60.45 Unislide 3 $273.00 $819.00 $833.69 Acquaric chamber 1 $95.45 $95.45 $99.20 Acquaric tray 1 $37.49 $37.49 $41.24 Aluminum sheet 1 $97.30 $97.30 $97.30 Cabinet 1 $471.76 $471.76 $471.76 Flexible hose 4 $150.00 $600.00 $617.26 Motor (DC, gear, 12V, 110RPM) 3 $18.95 $56.85 $63.75 Powder coating 7 $10.00 $70.00 $70.00 Camera 2 $60.00 $120.00 $135.00 Glass tubes 1 $400.00 $400.00 $400.00

Total $3927.00

Cabinet SystemCabinet System

System Highlights

•Made from 1” x 1” aluminum profile order through Bosch Rexroth Corporation

•Easy to assemble and disassemble

•This design allows to set the piece in parts and easy transportation as JZ needs to transport the system from one state to another in a limited volume.

•Rolling bottom shelf for easy access to the water tank and fuel supply

System Highlights

•Made from 1” x 1” aluminum profile order through Bosch Rexroth Corporation

•Easy to assemble and disassemble

•This design allows to set the piece in parts and easy transportation as JZ needs to transport the system from one state to another in a limited volume.

•Rolling bottom shelf for easy access to the water tank and fuel supply

Cost: $471.76

Necessary Items to Constrict the Cabinet

Qty Length Description Total

2 n/a3 x 3 T-junction joining plate $18.72

13 21 Profile 1"x1", - / - $134.89

4 18 Profile 1"x1", - / - $38.43

50 n/a #8 T-Nut, 1/4-20 UNC $39.50

4 n/a 3 x 3 base plate $48.32

34 n/a1"x1" Gusset with fasteners $80.58

4 n/a Cap, 1 x 1, black $4.20

30 n/a#8, 1/4-20 square nut, one $11.10

2 21 Profile 1"x2", - / - $31.50

3 20 Profile 1"x1", - / - $30.36

14 n/a8mm-to-8mm slide bearing B $34.16

$471.76

Powder CoatingAdvantages of powder coating over

conventional liquid coating• Used to create a hard finish that is tougher

than conventional paint• Powder coatings emit zero or near zero

volatile organic compounds (VOC). • Powder coatings can produce much thicker

coatings than conventional liquid coatings without running or sagging.

• Powder coating overspray can be recycled and thus it is possible to achieve nearly 100% use of the coating.

• Powder coating production lines produce less hazardous waste than conventional liquid coatings.

• Powder coated items generally have fewer appearance differences between horizontally coated surfaces and vertically coated surfaces than liquid coated items.

• A wide range of specialty effects is easily accomplished which would be impossible to achieve with other coating processes.

Combustion chamber & fume hood

System Highlights

•Visibility

•Able to handle high temperatures

•Easily replaceable

System Highlights

•Visibility

•Able to handle high temperatures

•Easily replaceable

Estimated Cost: $150.00

Heat Exchanger System

System Highlights

•8-Pass glass heat exchanger

•Water as working fluid

•Fluid changes color with temperature change

System Highlights

•8-Pass glass heat exchanger

•Water as working fluid

•Fluid changes color with temperature change

Cost: $759.00

Heat exchanger system

Danner Mag-Drive• Flow Rate: 350 GPH maximum

flow with a 10.5` shut-off

3 Gallon Maximum Tank

Leuco dye• A 5 degree change in the

temperature of the water will cause the dye to change colors.

System Highlights

•Water Pump

•Water Reservoir

•Water Dye

Heat Exchanger System (PUMP)

System Properties

• System equation•hp =8.9X10-3(Q²)

Q (gal/hr)

hp ( in )

•Pump curve•Given in pump specifications

• System Pump can will operate in the 90 gallon per hour area.

System Properties

• System equation•hp =8.9X10-3(Q²)

Q (gal/hr)

hp ( in )

•Pump curve•Given in pump specifications

• System Pump can will operate in the 90 gallon per hour area.

0 50 100 150 200 250 300 350 4000

100

200

300

400

500

600

700

800

900

system curvepump curve

Q, Flow rate (gal/hr)

Pum

p H

ead,

hp (

in)

Glass Tubing

•½” Glass Tubing

•Can be disassembled

•Threaded connection

•½” Glass Tubing

•Can be disassembled

•Threaded connection

Heat Exchanger System Part Description QTY

Unit Price

Sub-Total

8-pass glass tube system 1 $500.00 $500.00

3 gallon water tank 1 $42.56 $42.56

Danner mag-drive supreme 3 water pump

1 $53.99 $53.99

1/4" barb x 1/2" MIPS 1 $3.14 $3.14

1/4" barb x 1/2" FIPS 1 $3.40 $3.40

1/4" barb x 3/8" MIPS 2 $1.65 $3.30

Clear Vinyl Tubing 3/8"id 10 $0.31 $3.10

Stainless Steel Hose Clamp - 3/8"-7/8" 6 $0.92 $5.52

Water Additive 1 $150 $150.00

Temperature Gages 2 $30 $60.00

Estimated parts and price list for the heat exchanger system

Estimated parts and price list for the heat exchanger system

Positioning System

System Highlights

•Simultaneous movement

•Single switch control

•Precise motion

•Forward and reverse motion

Positioning System

Part Description QTY Unit Price Sub-Total

Velmex, manual sliding system, 3.5” 3 $273.00 $819.00

12V DC electric motors 3 $20.00 $60.00

Control switch 1 $6.00 $6.00

Push button Switch 1 $6.00 $6.00

6 amp ac/dc linear power supply 1 $40.00 $40.00

Miscellaneous wiring 1 $10.00 $10.00

Mounting hardware 1 $10.00 $10.00

System total $951.00

Estimated parts and price list for positioning system

Estimated parts and price list for positioning system

Fuel Supply System

System Highlights

• Propane fuel supply

•¾” burner flame diameter

•Up to 12” flame height

•Flexible stainless steel hose design

•Variable rate flow meters

•System is pressure regulated

System Highlights

• Propane fuel supply

•¾” burner flame diameter

•Up to 12” flame height

•Flexible stainless steel hose design

•Variable rate flow meters

•System is pressure regulated

Approx. Cost: $1500.00

Fuel Supply System

Part Description QTY Unit Price Sub-Total

P series graduated flow meter w/valve 3 $139.00 $417.00

1/4" x 12" Flexible supply hose 5 $130.00 $650.00

1/4" x 18" Flexible supply hose 1 $140.00 $140.00

1/4" x 24" Flexible supply hose 1 $150.00 $150.00

1/4 x 48" Flexible supply hose 1 $180.00 $180.00

Adjustable propane regulator 0-15 psi 1 $18.00 $18.00

Female cylinder adapter x 1/4" male 1 $9.84 $9.84

Propane cylinder 14.1 oz 1 $2.85 $2.85

1/4" standard pressure gauge 1 $7.97 $7.97

.75" Bunsen burner 3 $24.87 $74.61

¼” female brass cross 1 $12.00 $12.00

Miscellaneous brass fittings 1 $20.00 $20.00

System Total $1632.53

Estimated materials and price list for fuel supply system

Estimated materials and price list for fuel supply system

Construction

• Took approximately 3 weeks

• No major set-backs

• Heat exchanger is the only remaining system to be built

Up-To-Date Project Scheduling

Task 1/18 1/25 2/1 2/8 2/15 2/22 3/1 3/8 3/15 3/22 3/29 4/5 4/12 4/19 4/26 5/3 5/10

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Concepts  

Initial Design

Drawings

Order Parts

Mid-Term Presentation

Production

Final Revisions

Final Report

Poster Fair

Special Thanks

• John Zink Institute• Dr. Charles Baukal

• AME Machine Shop• Billy Mays• Greg Williams

• Local Part Suppliers• Jennings Powder Coating• Regal Plastics• Bosch Rexroth

Questions?