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 GregoriusRIT Chemical Engineering

Customers and Sponsor

Agenda • 10:15Project

DescriptionConcept

Summary• 10:20Design Summary

System Architecture

• 10:25System Testing ResultsProject

Evaluation• 10:35Future

ProjectionsQuestions

Project Description

Top Level Function

Uninformed Student

Partial Assembly

Energy

Unknown k

Informed StudentHands-on

ExperienceThermal Energy

Known k

Demonstrate Principle of

Thermal Conductivity

Functional DecompositionDemonstrateThermalConductivity

Creates1-DimensionalHeat Transfer

Minimal heat loss from boundariesGenerates heat fluxProvides proper temperature variationAccepts multiple geometriesAccepts multiple materials/phasesMinimizes resistance at heat exchanges

GeneratesMeasurableData

AccuratePreciseManual collectionDigital collection (Labview)Displays rate of heat fluxDisplays temperature distribution

EnhanceStudent Lab Skills

Requires manual assembly and disassemblyCan be used within given time periodsFits on the chemical engineering cartsHas replaceable components Low maintenanceDurable

Project Plan II  Week                              Task 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Review 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 Thermomet

erForm-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 SectionsHot Side Cold Side

Bill of MaterialsProject 13624 - Conductive Heat Transfer Demonstration Apparatus

 

Part Name Material Manufacturer Distributor Part # k value Dimensions Quantity Needed Unit Price Shipping Total

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 Lumber

Hemlock 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/mK 1 in diamter by 3

feet 1 $19.34 $8.75 $28.09

Multi-Purpose Copper Alloy 110 Copper 110   McMaster-Carr 8966k23 388 W/mK 1 in diamter by 3

feet 1 $126.22 $8.75 $134.97

Ultra Machineable Brass Alloy 360 Brass 360   McMaster-Carr 8953k983 115 W/mK 1 in diamter by 3

feet 1 $83.51 $8.75 $92.26

5A Variac Variable AC Power

TransformerN/A PHC

EnterprisesParts-

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's Item # - 68356

Model # - 35058 N/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/A 1 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 Tubing Polyurethane   McMaster-Carr 5195T84 N/A 1" ID (1 ft piece) 2 $4.05 $5.00 $13.10

Water-Resistant Clear Tubing Polyurethane   McMaster-Carr 5195T78 N/A 1/2" ID (1 ft

piece) 2 $3.05 $5.00 $11.10

Water-Resistant Clear Tubing Polyurethane   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 IIThe 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

Thermocouple

Average Temperature

(°C)Standard Deviation

1 99.46 0.05162 98.64 0.05163 98.63 0.06754 98.27 0.10595 98.33 0.06756 99.25 0.05277 98.52 0.04228 98.45 0.05279 98.35 0.097210 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 1200

20406080

100120140160

Power Curve

Voltage (Dial)

Pow

er (

W)

𝑃=𝑎∗𝑉 𝑏

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)

% errorSteady

State Time (min)

Aluminum 275 6 167 64.4 ̴)60Copper 470 6 388 21.1 ̴)50Brass 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 16Review 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?