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Final Presentation


Stephen Kunkel

on 28 April 2010

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Transcript of Final Presentation

Sponsored by:
Mr. Robert Pearsall, Research Engineer Scientist
Center for Electromechanics
Austin, TX Design of an
Algae Photobioreactor Team: CEM-Reactor - Stephen Kunkel, Daniel Schmid, David Townsend Prototype Design Main Body Geometry Selection Flat Panel Cylindrical Multi-tube Pros Cons high light exposure area
lacks expensive tube numerous joints
airlift adverse
unfamiliar operation
settling in corners Cons familiar operation
small number of joints
"off the shelf" part Cone Dome Parabolic Flat Reverse Engineering

conducted mind mapping, 6-3-5, and brain writing

decided we needed to select main body geometry first

consulted with CEM
mind map Accomodate two instruments
Support upriser
Prevent contamination decomposed product design problem into simpler subproblems

allows product architecture decisions to be made earlier in the development process

provides a method of comparing current vs. new design

Activity Diagram Black Box Model Functional Model Brainstorming low surface area to volume ratio Pros large surface area to volume ratio
"off the shelf" parts
air lift friendly large number of joints
difficult to clean
unfamiliar operation Cons Pros Bottom Cons simple
easily replaced may promote settling
hard to drain
Pros Cons simple
easily replaced
may promote settling
Pros Cons prevents setting
hard to drain
long lead time
complicates airlift Pros Cons prevents settling
improved draining expensive
difficult to mfg
long lead time
Pros Experimentation Top Sampling Mechanism "Keg Tap" siphon "Shepherd's Crook" hand pump syringe QUESTIONS ? Senior Design Project Spring '10 CEM-REACTOR http://upload.wikimedia.org/wikipedia/commons/0/0d/Siphon_%28PSF%29.png www.cheapbikeparts360.com http://img.tradeindia.com/fp/1/151/545.jpg Requirements Cleaning Procedure http://www.clamlynch.com/blog/brainstorm.jpg Future Work Approximate Material Cost Assembly Drawings Our remaining work:

optimize top plate

completed design drawings

optimize spacing between cone bottom and upriser

Proposed work for CEM:

further growth studies

source unibody construction

adapt sampling mechanism to large volume transfer

outfit the PBR with instrumentation

stand design

lighting scheme Design Sizing The PBR size was determined by main tube

EnviroKing ThinWall is available in 2,3,4,6,10 and 12 inch IPS

CEM desired a 100L total volume, multiple small PBRs were an option

A single 12" diameter design of was chosen due to ease of operation & cost effectivenss Constructed a 1:2 scale prototype due to budgetary constraint

All features of the prototype are scalable and the prototype is fully functional

Nominally 20L total volume Background Research www.jmu.edu/.../wm_library/Bioreactor-286.jpg graemefielder.wordpress.com/2008/04/16/algae-based-biofuel-vertigro-bioreactor/ sustainabledesignupdate.com Patents Personal Contacts Literature www.utexas.edu/research/cem www.massey.ac.nz/~ychisti/FileB1.html www.sbs.utexas.edu/utex/default.aspx Current Projects at CEM:
Vehicle Program
Materials Program
ONR Electric Ship
Oil Exploration
Rail Pulsed Power

Biofuels Sponsor Background Agar slant Erlenmeyer flasks bioreactor covered raceway pond greenhouse pond CEM's Algae Process The Center For Electromechanics (CEM) is a research center affiliated with UT Austin

CEM is located in North Austin on the J.J. Pickle Research Campus

Conduct research in a wide variety of areas, both publicly & privately funded
www.utexas.edu/research/cem/vision www.utexas.edu/research/cem Algae's Promise absorbs atmospheric carbon dioxide
no competition with arable land
can be grown in salt/wastewater
high oil yield per land area
can be produced domestically saferenvironment.wordpress.com
Project Background www.utexas.edu/research/cem/projects.htm Project Purpose To improve the operational ease and effectiveness of CEM's current photobioreactor design by seeking innovative solutions to known design flaws. Current Design Flaws to Be Adressed

Build up of algae in joints

Lack of consistent sampling method

Uneven distribution of bubbles

Growth conditions not optimized

Increased cleaning time

Inaccurate test results

Uneven mixing of contents

Decreased algae concentration
Criteria to be met Main Demand Specifications Utilize an airlift circulation

Minimize settling of algae

Uniform sampling mechanism

Sufficient growth conditions

Minimize cleaning time

Simplistic design Design Flaw Effect CEM's Current PBR Key Improvements Based on material cost, the design will fall well under the max cost constraint of $5,000 UV resistant clear PVC pipe Harvel EnviroKing www.harvel.com Material Selection Main Tube Flanges Top and Bottom
Plates Sampling Mechanism pressure vessel
UV resistant Material selected: PVC

Deciding factors:
bonding to main body
Material selected: UHMW-PE Pros:
self lubricating
increased durability
chemically inert
machinability Concerns with Prototype
Top plate removal for algae transfer

Possible corrosion of metal components

PVC solvent welded joint durability

Growth restriction due to decreased light penetration

Adequate venting
Easily removable Upriser Support Latch Mechanism Selection requirements: All things being equal, cost was also considered designed for algae applications
"off the shelf" part Other deciding factors: PVC can be solvently welded & is available in both clear and gray sheeting Material selected:
fitting: stainless steel
tube: clear PVC
Deciding factors:
reactivity with medium

Background Methodology Selection Sizing Prototype Conclusions
Recommendations Deliverables Drawings for a newly designed PBR of ~100 liters

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