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final Stephen


Stephen Kunkel

on 19 April 2010

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Transcript of final Stephen

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 Protype 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 2 instruments -adequate venting
-support upriser -air tight
-prevent contamination -easily removable 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
cleaning time 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 UV resistant clear PVC pipe Harvel EnviroKing Main tube - Harvel EnviroKing ThinWall
12" dia x 5' long
Upriser - Harvel EnviroKing ThinWall
3" dia x 6' long
Main tube flanges - PVC

Cone - 12" dia x 8" tall x 4" dia

Cone flanges - same material as cone

Cone blind flange - no material selected www.harvel.com 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 Material Selection Main Tube Flanges Top and Bottom
Plates Sampling Mechanism Remaining Work Material Cost Assembly Drawings converting sampling mechanism to volume transfer
stand design
lighting scheme
light penetration selected on a cost basis
pressure vessel
UV resistant Selected PVC to use
solvent welding techniques

PVC is also cost effective Selected 316 Stainless
Steel for its corrosion
resistant properties in
an aerated saltwater
enviroment Concerns with Prototype Design Sizing The PBR size was driven by main tube size

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

A single large design was chosen due to its superior cost effectivenss & ease of operation Due to the budget limit of $1000 we designed and constructed a 1:2 scale prototype
All features of the prototype are scalable and the prototype is fully functional Background Research www.jmu.edu/.../wm_library/Bioreactor-286.jpg graemefielder.wordpress.com/2008/04/16/algae-based-biofuel-vertigro-bioreactor/ sustainabledesignupdate.com Patent number: 6509188 Patent number: 4649117 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/2008/10/03/algae-tremendous-potential-for-next-generation-green-energy
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 Selected UHMW PE Pros:
self lubricating
increased durability
chemically inert Cons: increased machining Top Assembly Bottom Assembly
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