1SEMINAR PRESENTATION

ON“ 3-D MODELS IN CHEMICAL ENGINEERING ”

Name : Pandya Shreyas K.B.E.-IV , Roll No.- 806Chemical EngineeringGuide : Dr. N.V. Bhate

Faculty Of Technology and EngineeringThe Maharaja Sayajirao University Of Baroda

Acknowledgements

Prof. S. M. Mahajani, Dr. Suhas Zamre and Mr. Yatin PatilTata Centre for Technology and Design, IIT Bombay for their encouragement and support in 3-D printing

2Outline

Introduction

Concept of 3-D Models

Commercially Available 3-D Plant Models & Alternatives

Process Flow-diagram of Sulfuric Acid by DCDA Process

Layout for Sulfuric acid Manufacturing Plant

Hardware for 3-D Model of Sulfuric Acid Plant

3-D Model of Sulfuric acid Plant

Conclusions

3Introduction

Chemical processes – Integral part of Chemical Engineering.

Sequential arrangement of process equipment with respect to flow and utilities.

Seeing is believing – A 3-D plant model helps understand the process much better than a flow-sheet.

Also gives information about the plant layout

Makes the understanding of piping, piping layout and instrumentation much simpler

Very few commercial versions available - Expensive

Typically used by industries to train their personals

Student’s version to the best of our knowledge does not exist

Simple, in-expensive version of 3-D model can make teaching-learning process simple and interesting

Present work – Build a 3-D model for one of the most important chemical processes – Sulfuric acid

• Anil Kumar S., Suresh N. Production and Operation Management (with skill development, caselets and cases ) – 2nd Edition. New Delhi. New age international (P) ltd. 2008.• Abha Kumar. Plant Location and Layout. https://archive.org/stream/PlantLocationAndLayuot/PlantLocationAndLayout_djvu.txt

4Concept of 3-D Models

Easily dismantle the parts of the model and again can make a model of a new plant such as nitric acid.

Would not require additional parts in making a model if there is parity in the two.

Cheaper and one can easily make these models without expensive resources.

Aid to solve the ambiguity and make the understanding of the plant more lucid.

Optimize the layout of a plant which can improve productivity, safety and quality of products.

• Klaus D. Timmerhaus, Max S. Peters. Plant Design and Economics For Chemical Engineers- 4th Edition. McGraw-Hill. Singapore. 1991.• Daniel Back, Peter Johansson. A model for effective development of plant layouts and material handling systems. 2006• Abha Kumar. Plant Location and Layout. https://archive.org/stream/PlantLocationAndLayuot/PlantLocationAndLayout_djvu.txt

Salient Features

Proper plant model or layout will include such factors as :

• Type of process and product control

• Operational convenience and accessibility

• Type of buildings, reactors, columns, structures,

supports

• Auxiliary equipment

• Space available and space required

• Possible future expansion and Roads

Examination is carried out periodically

to ascertain the need for modifications

and revisions.

About 6 months after implementation

and then annually should be designed.

5 Miracle Models leading model manufacturers based at Bangalore, India.

Specialized in providing Engineering Models, Plant Models, Product

Models, Project Models, Miniature Models, Defense Models.

Several free-lancers make it from extruded tubes/pipes. This makes the

prototype very expensive.

Apart from these there is no source available for these models

• LiDAR Magazine. Vol. 3 No. 3. Copyright 2013 Spatial Media. www.lidarnews.com• http://www.miraclemodels.in/

Commercially available 3-D Models

Alternatives 3-D printing technology provides a new dimension for 3-D models

A combination of tailor-made extruded tubes or different

dimensions along with 3-D printing can may become a cost

effective option for designing and making 3-D models

The prototypes may be modular – the plants can be

assembled/dismantled like a lego/mechano set.3D Printer

6Process Flow-diagram for Sulfuric Acid by DCDA Process

7Layout for Sulfuric acid manufacturing Plant

8Hardware for 3-D Model for Sulfuric Acid Plant

All columns are made from PVC pipes as shown in Fig-1, Fig.3.

Pipe ends are connected with heads which are made by 3D

Printing at I.I.T. Mumbai as shown in Fig-2.

All pipelines are made from refiles covered with straws as shown

in Fig-4.

Fig-1 PVC Pipe

Fig-3Vertical column

Fig-2Reactor Caps

Fig-4 Pipeline made from refile & straw

9 Converter is 4 stage fixed bed type and is made from acrylic material as shown in

Fig-5.

All beds are made of thermocol sheets.

Packings are made of thermocol balls.

Converter ends are connected with heads which are made from PVC Caps.

All vertical columns are supported with skirt supports which are made by 3D

printing at I.I.T. Mumbai as shown in Fig-6

All storage tanks are made from Caps of PVC as shown in Fig-7.

All horizontal columns/tanks are supported with Saddle Supports as shown in

Fig-8 & 9, which are made from Acrylic Sheet.

Fig-5 Converter

Fig-7 Skirt support

Fig-6 Storage tank

Fig-8 Saddle support

Fig-9 Horizontal tanks supported with Saddle support

10 Chimney is also made from long PVC pipe.

Also supported with Skirt Support are shown in Fig-10.

Final complete vertical columns are shown in Fig-11.

Final complete horizontal columns are shown in Fig-12.

Fig-10 Chimney

Fig-11 Vertical column

Fig-12 Horizontal ColumnCost

Acrylic Sheet 220

Pipes & Caps 100

Paper & Other 45

3D Printing 175

Total Cost Rs. 540/-

11Conclusion

The visualization of the any chemical processes can become much easier and much better with the help of these

models. These models are help better visualization thereby helping academia as well as industries Low cost models made from available resources can increase their popularity This initiative can help built a modular kit comprising of several columns, reactors, pumps and other equipment

which can be connected to build different plants. These modular plants can be of great use to fresh graduates in industries Pipe tracing and layout can become much simpler and easy to understand in a 3-D model as compared to

orthographic and isometric views. While assembling the plant the students can develop a sound understanding of the connectivity and the

significance of not only process units but also the utilities.

12

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