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Air Products Reactor Catalyst Changeout

Air Products Reactor Catalyst Changeout. Daniel Brisach, Nick Dobies, Laura Elliott, Chris Reed, Janessa Smith. Presentation Agenda. Project Objectives and Scope Background Concept Solution Cost Analysis Summary Questions and Discussion. Project Objective.

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Air Products Reactor Catalyst Changeout

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  1. Air ProductsReactor Catalyst Changeout Daniel Brisach, Nick Dobies, Laura Elliott, Chris Reed, Janessa Smith

  2. Presentation Agenda • Project Objectives and Scope • Background • Concept Solution • Cost Analysis • Summary • Questions and Discussion

  3. Project Objective The objective of this project is to develop a more effective way for operators to load the catalyst used for the production of TEDA into the main reactor.

  4. Project Scope • Design a system to load 18 drums of catalyst into the TEDA reactor • Revise the Safe Work Practice of the reactor catalyst changeout process

  5. Current Process • Hoist with carriage

  6. Current Process • Manual dumping with a mopping bucket

  7. Customer Wants

  8. Metrics & Target Values

  9. The Design Drum is loaded and secured to cart. Cart is winched up the track. Barrel empties via linkage engagement using pistons. Cart stops once in pouring position.

  10. Components • Track (rail) • C3x6 Steel C-Channel • Can be cycled indefinitely under normal operating conditions • Custom fabricated

  11. Components • Track Support • 2” x 2” square tube • Can be cycled indefinitely under normal operating conditions • Custom fabricated • Accommodates pulley system

  12. Components • Pulley System • Guides and powers the cart throughout its path of motion • Custom pulley and winch, some stock components

  13. Components • Cart • Can cycle indefinitely under normal operating conditions • Custom fabricated • Facilitates dumping motion

  14. Validation • Fabricated components were designed for infinite fatigue life. • All stock parts have a high factor of safety. • Favored safety when assumptions were required.

  15. Prototype • Tested pouring trajectory with respect to the manhole

  16. Results • Successfully emptied catalyst into model manhole with zero waste • Determined optimum positioning between rail and manhole • Determined that 90° of tilt would be necessary to empty entire drum • Drum cone did not require a valve

  17. Results • Prototype Test

  18. Benefit to the Sponsor • A safer and more ergonomic process • Reduction of reactor downtime by approximately 24 hours • Reduction of man-hours from 36 to 9 • Labor savings of about 100 hours/year

  19. Cost Analysis • Total: $14,483 • Rail and support: $1787 • Cart: $2401 • Winch, pulleys, pneumatic supply: $6395 • Drum cone and collar: $1400 • Safety fence: $500 • Labor: $2000 • Total without cone: $13,083

  20. Current Status • Successfully designed and validated our best concept. • Analyzed budget and installation costs and sources. • Closed the loop through sponsor feedback. • Ready to Celebrate.

  21. Going Forward • Deliver design to Air Products so the implementation path may chosen.

  22. Acknowledgements • Our sponsor – Air Products • Our advisor – Dr. Wilkins • Dr. Glancey • Steve Beard • Jeff Bupp – Metal contracting • Motor Pool personnel

  23. Questions ?

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