Air Products Reactor Catalyst Changeout Daniel Brisach, Nick Dobies, Laura Elliott, Chris Reed, Janessa Smith.

Air ProductsAir ProductsReactor Catalyst ChangeoutReactor Catalyst Changeout

Daniel Brisach, Nick Dobies, Laura Elliott, Daniel Brisach, Nick Dobies, Laura Elliott, Chris Reed, Janessa SmithChris Reed, Janessa Smith

Presentation AgendaPresentation Agenda

Project Objectives and ScopeProject Objectives and Scope BackgroundBackground Concept SolutionConcept Solution Cost AnalysisCost Analysis SummarySummary Questions and DiscussionQuestions and Discussion

Project Objective Project Objective

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

Project ScopeProject Scope

Design a system to load 18 drums of Design a system to load 18 drums of catalyst into the TEDA reactor catalyst into the TEDA reactor

Revise the Safe Work Practice of the Revise the Safe Work Practice of the reactor catalyst changeout processreactor catalyst changeout process

Current ProcessCurrent Process

Hoist with carriageHoist with carriage

Current ProcessCurrent Process

Manual dumping with a mopping bucketManual dumping with a mopping bucket

Customer WantsCustomer Wants

1.1. ErgonomicErgonomic

2.2. Fast ChangeoverFast Changeover

3.3. One Man OperationOne Man Operation

4.4. Low ComplexityLow Complexity

5.5. Ease of RepairEase of Repair

Metrics & Target ValuesMetrics & Target ValuesMetricsMetrics Target ValuesTarget ValuesSpeed of ProcessSpeed of Process 12 man hours12 man hours

Cost of ImplementationCost of Implementation Less than $15,000Less than $15,000

Footprint sizeFootprint size Less than 8’ x 8’Less than 8’ x 8’

Ease of OperationEase of Operation Physically & Mentally SimplePhysically & Mentally Simple

Resistance to Ambient Resistance to Ambient ConditionsConditions

YesYes

Resistance to CatalystResistance to Catalyst YesYes

Electrical RatingElectrical Rating Class 1, Div 2 approvedClass 1, Div 2 approved

Number of Required OperatorsNumber of Required Operators 11

Special ToolsSpecial Tools NoNo

Special Training to OperateSpecial Training to Operate NoNo

Special Training to RepairSpecial Training to Repair NoNo

Number of Pinch PointsNumber of Pinch Points 00

The DesignThe Design

Drum is loadedand secured tocart.

Cart is winchedup the track.

Cart stops oncein pouring position.

Barrel emptiesvia linkageengagement using pistons.

ComponentsComponents

Track (rail)Track (rail) C3x6 Steel C-ChannelC3x6 Steel C-Channel Can be cycled Can be cycled

indefinitely under indefinitely under normal operating normal operating conditionsconditions

Custom fabricatedCustom fabricated

ComponentsComponents

Track SupportTrack Support 2” x 2” square tube2” x 2” square tube Can be cycled Can be cycled

indefinitely under indefinitely under normal operating normal operating conditionsconditions

Custom fabricatedCustom fabricated Accommodates pulley Accommodates pulley

systemsystem

ComponentsComponents

Pulley SystemPulley System Guides and powers Guides and powers

the cart throughout the cart throughout its path of motionits path of motion

Custom pulley and Custom pulley and winch, some stock winch, some stock componentscomponents

ComponentsComponents

CartCart Can cycle indefinitely Can cycle indefinitely

under normal operating under normal operating conditionsconditions

Custom fabricatedCustom fabricated Facilitates dumping Facilitates dumping

motionmotion

ValidationValidation

Fabricated components were designed Fabricated components were designed for infinite fatigue life.for infinite fatigue life.

All stock parts have a high factor of All stock parts have a high factor of safety.safety.

Favored safety when assumptions were Favored safety when assumptions were required.required.

PrototypePrototype

Tested pouring trajectory with respect to Tested pouring trajectory with respect to the manholethe manhole

ResultsResults

Successfully emptied catalyst into model manhole Successfully emptied catalyst into model manhole with zero wastewith zero waste

Determined optimum positioning between rail and Determined optimum positioning between rail and manholemanhole

Determined that 90Determined that 90°° of tilt of tilt would be necessary to empty would be necessary to empty entire drumentire drum

Drum cone did not require a Drum cone did not require a valvevalve

ResultsResults

Prototype TestPrototype Test

Benefit to the SponsorBenefit to the Sponsor

A safer and more ergonomic processA safer and more ergonomic process Reduction of reactor downtime by Reduction of reactor downtime by

approximately 24 hoursapproximately 24 hours Reduction of man-hours from 36 to 9Reduction of man-hours from 36 to 9

Labor savings of about 100 hours/yearLabor savings of about 100 hours/year

Cost AnalysisCost Analysis

Total: $14,483Total: $14,483 Rail and support: $1787Rail and support: $1787 Cart: $2401Cart: $2401 Winch, pulleys, pneumatic supply: $6395Winch, pulleys, pneumatic supply: $6395 Drum cone and collar: $1400Drum cone and collar: $1400 Safety fence: $500Safety fence: $500 Labor: $2000Labor: $2000

Total without cone: $13,083Total without cone: $13,083

Current StatusCurrent Status

Successfully designed and validated our Successfully designed and validated our best concept.best concept.

Analyzed budget and installation costs Analyzed budget and installation costs and sources.and sources.

Closed the loop through sponsor Closed the loop through sponsor feedback.feedback.

Ready to Celebrate.Ready to Celebrate.

Going ForwardGoing Forward

Deliver design to Air Products so the Deliver design to Air Products so the implementation path may chosen.implementation path may chosen.

AcknowledgementsAcknowledgements

Our sponsor – Air ProductsOur sponsor – Air Products Our advisor – Dr. WilkinsOur advisor – Dr. Wilkins Dr. GlanceyDr. Glancey Steve BeardSteve Beard Jeff Bupp – Metal contractingJeff Bupp – Metal contracting Motor Pool personnelMotor Pool personnel

Questions ?Questions ?