ME 462 Capstone Design

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ME 462 Capstone Design Pressurized Chemical
Reactor Presented by Brandon Meyer Jason
Moore Alemayehu Mulat Jane Simpson December 15,
2004
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Chemical Reactor

• Creates a temperature and pressure controlled
  environment for parallel synthesis reactions.
• Can be used to run anywhere from 1 to 96
  different chemical reactions in test tubes at
  once.
• Speeds up the formulation of new prescription
  drugs.

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Previous Reactor Design

• Original closing mechanism failed
• Required four bolts and one tool to seal
• Extremely heavy - 40 lbs

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Key Customer Requirements

• Easy and Safe to operate
• Fits in vacuum lock chamber
• Can be lifted with one hand
• Does not interfere with magnetic stirrer
• Provides sufficient gas exchange area
• Pressure control
• Temperature control

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Engineering Specifications Targets

• Specification
  Target
• Easy and Safe to operate
• Quick setup time
  10 min
• Number of tools required
  0 tools
• Can be lifted with one hand
• Lightweight
  20-30 lbs
• Small exterior dimensions 9w x
  10d x 8h
• Pressure control
• Maximum sustainable pressure
  100 psi
• Associated leakdown rate
  0 psi / hr

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Concept Development

• Functional Decomposition
• Isolating the environment
• Box vs. Cylinder

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Conceptual Development

• Functional Decomposition
• Isolating the environment
• Flat vs. Domed Lid

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Final Concept

• Consists of
• Vertical Cylinder with a Domed top
• Allows for thinner walls
• Light weight
• Reduced stresses

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Final Concept

• Consists of
• Flat Base
• Allows for installation of the reaction block and
  heating cartridges
• Light weight geometry
• Fillet to reduced stresses

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Final Concept

• Consists of
• Toggle Clamps
• Provide sufficient sealing
• Easy operation
• Light weight

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Final Concept

• Consists of
• Off-the-Shelf Parts
• Thermocouple
• Heating Cartridges
• O-Ring

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Final Concept

• Handle welded to the lid provides access to
  thermocouple
• Clamps welded to the cylinder create seal with
  the base
• Heating cartridges are inserted in the base

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Final Concept

• Locator pins ensure alignment of reaction block
• Flange design facilitates alignment of
  thermocouple with reaction block
• Fillet design reduces stress

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Product Evaluation

• Stresses in Vessel
• Maximum von Mises stress 14.518 ksi
• Maximum yield strength of 304 SS 29.1 ksi
• Factor of Safety 2.004

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Product Evaluation

• Deflection in Vessel
• Maximum deflection of flange 0.0014 in

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Product Evaluation

• Deflection in Clamp
• Maximum deflection of clamp 0.0031 in
• Force/Clamp 1283 lbf

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Product Evaluation

• Total Deflection in Vessel and Clamp 0.0045 in
• Compression Distance of the O-Ring 0.032 in
• The total deflection in the vessel and clamp is
  seven times smaller than the compression of the
  O-ring.
• This ensures a zero leakdown rate

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Product Evaluation

• Time required for reaction block to reach 150 C
• Heating cartridges operating at full capacity
• (126 W/in2) 9 Minutes

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Product Evaluation

• Time required for reaction block to reach 150 C
• Heating cartridges operating at low capacity
• (38 W/in2) 15.5 Minutes
• The maximum temperature can be lowered, but will
  increase heat up time

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Product Specs vs. Engineering Targets

• Specification Target
  Achieved
• Quick setup time 10 min 10 min
• of tools required 0 tools
  0 tools
• Lightweight 20-30 lbs
  21.96 lbs
• Small ext dims 9 x 10 x 8
  9 x 9 x 10
• Max pressure 100 psi
  100 psi
• Leakdown rate 0 psi / hr
  0 psi / hr
• Heating Time 30-45 min 15.5 min

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Conclusion

• Design successfully meets customer requirements
• Engineering targets were either met or exceeded
• Prototype completion and laboratory testing
  recommended
• Vast improvements made over benchmark design

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Acknowledgements

• Dr. Chen, Advisor
• Mr. David Bradley, Chemist Eli Lilly and Co.
• Mr. Charles Alt, Chemist Eli Lilly and Co.
• Mr. Dennis Walsh, Manufacturing Consultant
• Mr. Rudy Earlson, Manufacturing Consultant
• Mr. Rusty Scutt, Scutt Tool Die