John Zink Burn Process Simulator

1. John Zink Burn Process Simulator Team Leader: Kyle Davis Johnny Benson Michael Cap Kyle Davis Van Mai Dr. Wilson Merchan-Merchan (Advisor) Sponsor: John Zink Institute

2. Objective The purpose of this capstone project was to produce a portable burner process simulator that allows the user to manipulate the combustion process by altering multiple variables in the system. Portability is a main concern due to John Zink Institute using the unit as a teaching aide in various locations in the country.

3. Desired to demonstrate with apparatus • Burners • Varying firing rates of burners • 1 burner out of service • Varying burner spacing • Varying amount of premixing • Heater • Varying draft levels • Varying excess O2 levels • Varying heater length • Tramp air leakage • Emissions (NOx, CO)

4. Desired design from John Zink

5. Capstone group’s Design

6. Budget

7. System Highlights • Made from 1” x 1” aluminum profile order through Bosch Rexroth Corporation • Easy to assemble and disassemble • This design allows to set the piece in parts and easy transportation as JZ needs to transport the system from one state to another in a limited volume. • Rolling bottom shelf for easy access to the water tank and fuel supply Cabinet System Cost: $471.76

8. Necessary Items to Constrict the Cabinet

9. Powder Coating Advantages of powder coating over conventional liquid coating • Used to create a hard finish that is tougher than conventional paint • Powder coatings emit zero or near zero volatile organic compounds (VOC). • Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging. • Powder coating overspray can be recycled and thus it is possible to achieve nearly 100% use of the coating. • Powder coating production lines produce less hazardous waste than conventional liquid coatings. • Powder coated items generally have fewer appearance differences between horizontally coated surfaces and vertically coated surfaces than liquid coated items. • A wide range of specialty effects is easily accomplished which would be impossible to achieve with other coating processes.

10. Combustion chamber & fume hood System Highlights Visibility Able to handle high temperatures Easily replaceable Estimated Cost: $150.00

11. Heat Exchanger System System Highlights 8-Pass glass heat exchanger Water as working fluid Fluid changes color with temperature change Cost: $759.00

12. Heat exchanger system Danner Mag-Drive • Flow Rate: 350 GPH maximum flow with a 10.5` shut-off 3 Gallon Maximum Tank Leuco dye • A 5 degree change in the temperature of the water will cause the dye to change colors. System Highlights Water Pump Water Reservoir Water Dye

13. Heat Exchanger System (PUMP) System Properties System equation hp =8.9X10-3(Q²) Q (gal/hr) hp ( in ) Pump curve Given in pump specifications System Pump can will operate in the 90 gallon per hour area.

14. Glass Tubing ½” Glass Tubing Can be disassembled Threaded connection

15. Heat Exchanger System Estimated parts and price list for the heat exchanger system

16. Positioning System System Highlights Simultaneous movement Single switch control Precise motion Forward and reverse motion

17. Positioning System Estimated parts and price list for positioning system

18. Fuel Supply System System Highlights Propane fuel supply ¾” burner flame diameter Up to 12” flame height Flexible stainless steel hose design Variable rate flow meters System is pressure regulated • Approx. Cost: $1500.00

19. Fuel Supply System Estimated materials and price list for fuel supply system

20. Construction • Took approximately 3 weeks • No major set-backs • Heat exchanger is the only remaining system to be built

21. Up-To-Date Project Scheduling

22. Special Thanks • John Zink Institute • Dr. Charles Baukal • AME Machine Shop • Billy Mays • Greg Williams • Local Part Suppliers • Jennings Powder Coating • Regal Plastics • Bosch Rexroth

23. Questions?