Combustion Air Pre-heater Design Review Presentation

1. Combustion Air Pre-heater Design Review Presentation ME 486 3/13/03 Carl Vance

2. Purina Boiler Efficiency Team Members and Roles Ryan Cook • Documenter and Secretary Kofi Cobbinah • Team Leader and Website Manager Carl Vance • Communicator and Historian Matt Bishop • Financial Officer and Mediator Carl Vance

3. Summary • Client Introduction • Project Description • Our Design • Mathematical Model • Schedule • Budget • Conclusion Carl Vance

4. Our Client – Nestlé Purina • Client contact is John Cain Manager of Engineering at the Flagstaff Plant. Purina as a company: • Flagstaff Plant opened in 1975 • Employs 180 people • Purina is now a division of Nestlé Foods Carl Vance

5. Purina Steam System • The boiler produces approximately 500,000 lbm of steam per day. • 40%: cooking products. • 50%: drying products. • 10%: miscellaneous areas: air and water heating systems. • Steam production is 2/3 of the plant's total energy use. Carl Vance

6. Project Description • Problem Definition • Nestlé Purina has requested a proposal for a combustion air pre-heater. The goal of the project is to provide savings for the plant by reducing energy costs and improving efficiency in the steam system. • Justification for the project is cost reduction and fuel conservation through higher efficiency. Carl Vance

7. Project Description Client’s Needs Statement: • Design of a combustion air preheater must be: • Efficient • Economically Feasible • Minimize Modifications to Existing Systems Carl Vance

8. Our Design Philosophy • Finish Design and Construction Under Budget. • Satisfy the Client’s Requirements. • Design for Safety. • Act with Integrity. Carl Vance

9. What is a Combustion Air Preheater • Device or system that heats the boiler intake air. • Uses recaptured waste heat to that would normally leave the boiler to the atmosphere. Carl Vance

10. Design Choice • Final Design Choice: • Concentric Duct Design • Air enters into a duct that surrounds the stack. • The stack transfers heat to the air by convection and radiation. • The air enters into the boiler at a higher temperature. Ryan Cook

11. Preheater Design Basics Ryan Cook

12. Design Benefits • Concentric Duct Design Will Provide: • Relatively Low Installation Cost • Low Material Costs • Low Impact on Existing Systems • High Payback on Investment • Low Maintenance Costs Ryan Cook

13. Specifications to date • The stack height is 4.3 meters, which fixes our duct height and will provide our surface area for heat transfer. • Duct diameter will be 1.15 meters to optimize forced convection. Ryan Cook

14. Proposed Design Ryan Cook

15. Forced Convection Model

16. Heat Exchanger Model

17. Radiation Model

18. Project Monetary Savings Convection Savings Forced Convection Radiation

19. Accomplishments to Date • Proposal Document has been accepted by client • Mathematical Analysis of the design has been accepted by the client. Kofi Cobbinah

20. Problems Encountered • CAD model is taking more time than estimated. Kofi Cobbinah

21. Future Design Tasks • Final Design will include: • Finalizing Mathematical Models • Finishing CAD Models • Design Results • Bill of Materials • Construction Methods Kofi Cobbinah

22. Project Schedule CAD Models ------------- March 24, 2003Final Design-------------- April 20, 2003Capstone Presentation- April 25, 2003Final Report ------------- May 2, 2003 Kofi Cobbinah

23. Budget • Printing Cost • Proposal Document ----------------- $15 • Mathematical Models Document - $15 • Total--------------------------------------- $30 Kofi Cobbinah

24. Team Time Log Kofi Cobbinah

25. Conclusion • We are on schedule to finish all deliverables and have a completed design as planned. • We will provide the client with a design that is both efficient and feasible to implement. Kofi Cobbinah

26. Questions? Kofi Cobbinah