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Design and Financial Analysis of a Redesigned Titanium Degreaser Basket . Stanley T. Anderson II, Nicolette Grannum , Kenneth Manley, Mingze Niu. Project Scope. Concept Generation. Design Validation. Basket Design Process. Background. Testing Plan.

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Design and Financial Analysis of a Redesigned Titanium Degreaser Basket

Stanley T. Anderson II, Nicolette Grannum, Kenneth Manley, MingzeNiu

Project Scope

Concept Generation

Design Validation

Basket Design Process

Background

Testing Plan

  • Primary goal is to test the structural stability of the basket
  • Due to high cost of basket, only the metrics below were tested
  • Analyze the new basket and check that basket meets each target value
  • Superior Tube, located in Collegeville, Pennsylvania, produces high quality tubes for various industries
  • Tubes produced through cold drawing and annealing process and requires a large amount of lubricant
  • Existing process: completed parts are loaded into the steel basket and lowered into a giant solvent full of the hazardous solvent, n-Propyl Bromide (nPB)
  • During the exit, the heated basket breaks the cold boundary layer by heat transfer (shown left) and releases nPB vapors into the environment

Concept Evaluation and Comparison

  • FEA validated structure, but cold barrier information is limited
  • Scale test using hot plate, water and metal samples to show effectiveness of material change and insulation
  • These samples were cross referenced and a general assumption that less heat released in the cold barrier would lead to decreased nPB loss

Scope

  • Design a basket that will reduce solvent loss throughout the degreasing process when compared to the current basket

Specifications and Metrics

Financial Analysis

Final Titanium Design: Titanium Concept 9

  • Finances are an essential component to the analysis post design.
  • What is the profitability of the new basket in terms of throughput and solvent savings?
  • Titanium reduces weight has longer life through continues chemical use
  • The final design was the most innovative and accomplished all of the project goals at the lowest weight, and highest values for safety
  • Final design is fabricated with commercially pure, Grade 2 titanium and will need to be welded at several strategic points to come together in one assembly

Path Forward

  • Need for insulation validated, increasing costs and overall savings
  • Combined with financial data, shows that the two baskets are profitable, through solvent and operational savings
  • Fabrication and delivery are the next steps to the redesigned degreaser basket from being used
  • The estimated for implementation is over the next two years, with the current basket being scrapped in 2015.

Acknowledgements

Superior Tube Representatives:

James Brooks, Chris Nagele, Jeff Mlynarski

Advisor:

Dr. James Glancey