Combustion Air Pre-heater Design Review Presentation

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Combustion Air Pre-heater Design Review
Presentation

• ME 486
• 3/13/03

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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

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Summary

• Client Introduction
• Project Description
• Our Design
• Mathematical Model
• Schedule
• Budget
• Conclusion

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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

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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.

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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.

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Project Description

• Clients Needs Statement
• Design of a combustion air preheater must be
• Efficient
• Economically Feasible
• Minimize Modifications to Existing Systems

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Our Design Philosophy

• Finish Design and Construction Under Budget.
• Satisfy the Clients Requirements.
• Design for Safety.
• Act with Integrity.

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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.

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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.

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Preheater Design Basics
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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

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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.

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Proposed Design
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Forced Convection Model
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Heat Exchanger Model
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Radiation Model
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Project Monetary Savings
Convection Savings
Forced Convection
Radiation
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Accomplishments to Date

• Proposal Document has been accepted by client
• Mathematical Analysis of the design has been
  accepted by the client.

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Problems Encountered

• CAD model is taking more time than estimated.

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Future Design Tasks

• Final Design will include
• Finalizing Mathematical Models
• Finishing CAD Models
• Design Results
• Bill of Materials
• Construction Methods

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Project Schedule

• CAD Models ------------- March 24,
  2003Final Design-------------- April 20,
  2003Capstone Presentation- April 25, 2003Final
  Report ------------- May 2, 2003

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Budget

• Printing Cost
• Proposal Document ----------------- 15
• Mathematical Models Document - 15
• Total--------------------------------------- 30

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Team Time Log
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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.

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Questions?