ONLINE TEMPARATURE MONITORING OF

ELECTROWINNING PROCESS USING

MICROCONTROLLER

STUDENT : SHALET K S, REG NO:13MMT1045

PROJECT GUIDE : DR. V G SRIDHAR , SMBS

OBJECTIVE

2

The objective of this project is to develop an on-line temperature

monitoring and control system for bipolar electro-winning processes done

for zinc extraction using LM35.

SCOPE OF WORK

3

Scope of this project is to develop a prototype of online temperature

monitoring and control system of an electro-winning process in laboratory

conditions by using electronics components in order to make it cost

effective.

LITERATURE SURVEY

4

1. A good comparison between uni-polar and bipolar electro-winning cell modeling is made

in[1]. Serially connected bipolar electrodes are not wire connected, just immersed in electrolyte

hence uses much lower DC current comparatively.

2. Advances and trends in primary and small secondary batteries with Zinc anodes and

manganese dioxide or air cathodes[2]. T he study tells Zinc cells can produce more service than

lithium cells.

3. A remote monitoring system for temperature, voltage, current and power

measurements[3]uses three sensors. Voltage sensor, Current sensor and temperature sensor.

LM35 is the temperature sensor used here because of the advantage of delivering tension as

linear function of the temperature input.

54. Heat exchange due to air flow is measured by a thermocouple and an LM35. Hence

constant temperature shows a variation and respective voltage can be measured.

Thermocouple has high response time than LM35. Due to inherent character of ADC

thermocouple output cannot be digitized[4].

5. Energy Saving by Automatic Control of Power in Simple Home Appliances[5] uses

different sensors and the sensor used for temperature measurement is LM35.

6. The application of soil temperature measurement by LM35 temperature sensors[6]. Here

the theoretical equation between sensor output voltage and Celsius temperature also carried

out.

7. Research on the elevator door control system based on the image processing

technology[7]. Here image acquisition chip of elevator used is 0V7620 and the image is

transmitted to the main controller ATmega32 and the control action is done.

8. Fabrication of MEMS based temperature sensor, controlling and monitoring is done by

Lab-VIEW. From sensor to ADC and then to PC via wireless data acquisition device[8].

6METHODOLOGY

Step by step method of

measuring monitoring and

controlling the temperature

of the process

ATMEGA 16

LM35 (sensor)

ADCLCD DISPLAY

PC

TEC

(actuator)

POWER SUPPLY

7805

DRIVER

PROCESS

USB

PO

RT

PORT

KEYPAD

Block diagram representation of control and monitoring

system for temperature 7

DESIGN

8

9TRIAL APPARATUS

TRIAL APPARATUS

10

REQUIRED PROCESS COMPONENTS

Process Tank Graphite electrodes Zinc electrodes

11LM35

TEC

Electrode holder

12Big heat sink

Small heat sink

Billet

Fan

13SL. NO COMPONENTS DIAMENTION (cm) NO

1 Basement 47 X 30 X 4.6 1

2 Glass beaker 14.3 X 14.3 X 16 4

3 Heat sink (big) 10 X 6.5 X 1.8 4

4 Heat sink (small) 6.5 X 4.5 X 1.8 4

5 TEC hole 4.4 X 4.9 4

6 Zinc electrode 16 X 1 (dia) 4

7 Graphite electrode 15 X 2 ( dia) 4

8 Electrode holder 33 X 3.7 X 1.1 2

9 Fan 8 X 8 X 2.5 4

10 Billet 4 X 4 X 1.1 4

DESIGN SPECIFICATIONS

Table 1. Specification of process components

14SL. NO COMPONENTS SPECIFICATION No

1 Dotted PCB board 140 X 90 (mm) 1

2 ATMega 16 (base) 40 Pin - DIP 2

3 LCD 16 X 4 (mm) 1

4 ULN 2003 (base) 5X5X5 (cm) 2

5 USB module TTL 4 pin connector 1

6 Keypad 70 X 77 X 1 (mm) 1

7 TEC 40 X 40 X 3.8 (mm) 4

8 LM35 10mv/ °C 4

9 Mosfet IRFZ533 (heat sink) 4

10 Resistors 15, 5.2, 8.2(k), 68, 47(ohm) 11, 5, 1, 5, 5

11 Berg strips - M - 3, F - 1

12 Pot 10k 1

13 2 pin connectors - 18

14 Relay 12v 8

15 SMBS power supply 450 watt, 24 pin 1

Table 2. Specification of electronic components

15

MCU 1 MCU 2

PORT A

PA0 - TT1 PA0 - ELV1

PA1 - TT2 PA1 - ELV2

PA2 - TT3 PA2 - ELV3

PA3 - TT4 PA3 - ELV4

PA4 - TV1 PA4 - 12VM

PA5 - TV2 PA5 - 3.3VM

PA6 - TV3 PA6 - 5VM

PA7 - TV4 PA7 - LL

PORT B

PB0 - RS PB0 - S1

PB1 - RW PB1 - S2

PB2 - EN PB2 - S3

PB3 - EL1 PB3 - EL2

PB4 - BZ PB4 - SS

PB5 - MOST PB5 - MOSI

PB6 - MISO PB6 - MISO

PB7 - SCK PB7 - SCK

PORT C

PC0 - LD0 PC0 - KP1

PC1 - LD1 PC1 - KP2

PC2 - LD2 PC2 - KP3

PC3 - LD3 PC3 - KP4

PC4 - LD4 PC4 - KP5

PC5 - LD5 PC5 - KP6

PC6 - LD6 PC6 - KP7

PC7 - LD7 PC7 - KP8

PORT D

PD0 - COM PD0 - F1, F2

PD1 - COM PD1 - F3, F4

PD2 - TEC1M PD2 - TEC3M

PD3 - TEC2M PD3 - TEC4M

PD4 - TEC1V PD4 - TEC3V

PD5 - TEC2V PD5 - TEC4V

PD6 - S4 PD6 - PS ON

PD7 - EL3 PD7 - EL4

MCU DESIGNIn the control unit two ATMega 16 are used. The table reveals each pin connections of

both controllers

16CIRCUIT DIAGRAM

17CONTROLLER MODULE PART 1

18CONTROLLER MODULE PART 2

19CONTROL UNIT

20EXPERIMENTAL SETUP

21EXTRACTED ZINC

• 2.8g of ZnSO4 in 100ml of distilled

water.

• 1.2g of Zinc extracted after

Electro winning process in

Chemistry lab.

ZINC

22VOLTAGE (volt)

TEMPERATURE (degree Celsius )

TIME (cumulative sec)

0 29 0

3 29 6

3 30 4

3 31 2

3 32 1

3 33 1

3 34 1

3 35 1

3 36 1

3 37 1

3 38 1

3 39 1

3 40 1

3 41 1

3 42 1

3 43 1

40

Temperature

verses time at

constant

voltage forzinc deposition

Complete extraction

23TEMPERATURE

(degree Celsius)TIME

(minute)DEPOSITION

(gram)

27 60 5.2

30 60 6.4

35 45 8.2

40 20 9.3

45 20 9.3

50 20 9.2

55 20 9

60 20 8.1

65 20 7.5

70 20 6.4

Readings During Electro - winning Process at Different Temperature

20 g of Zn SO4 in 750 ml of

distilled water. After processing

9.3g of Zn is extracted.

Required amount is 9.6g.

24

Temperature verses time graph

2730

35

40

45

50

55

60

65

70

5.2 6.48.2 9.3 9.3 9.2 9 8.1 7.5 6.4

1 2 3 4 5 6 7 8 9 10

Temperature v/s deposition

Temperature (°C) Deposition (gm)

Temperature verses deposition graph

2730

35

40

45

50

55

60

65

70

60 60

45

20 20 20 20 20 20 20

1 2 3 4 5 6 7 8 9 10

Temp v/s Time

Temperature (°C) Time (min)

CONCLUSION AND FUTURE WORK25

Successfully done with the control unit of online temperature control and monitoring of

electro winning process. By automatic monitoring and control of tank temperature it is

possible to reduce the time lag and inaccuracies of monitoring of temperature, reduce the

power consumption by making temperature at optimum value. Integrated the mechanical,

electronics and software sections and processing will be doing in future.

REFERENCE

26

[1] Ralph Bittner, Antonio Pagliero, Lautaro Sal, Mauricio Valemuel, Electric Field and Potential

Determination for Electro-winning Cells with Bipolar Electrodes Finite Difference Models, IEEE,

1998.

[2] Brooke Schumm, Advances and Trends in primary and Small Secondary Batteries with Zinc

Anodes and/or Air Cathodes, IEEE, 2000.

[3] E. Barakat, N. Sinno, C. Keyrouz, A remote monitoring system for voltage, current, power and

temperature measurements, Physics Procedia 2014.

[4] Beatriz Ariadna Jacome Hernandez1, Esperanza Medina Hernandez2, Jesus Yalja Montiel

Perez3, Arrangement Of Temperature Sensors As A Wind Sensor, IEEE Associate.

27

[5] Kazi Mahtab Kadir, Md. Saleh Forhad, Mahran Muhammad Fadlullah, Niamul Quader, Md. Masudur

Rahman AI-Arif, Maruf Ahmed Dhali, Energy Saving by Automatic Control of Power in Simple Home

Appliances, IEEE, 2011.

[6] Cuihong Liu, Wentao Ren, Benhua Zhang,Changyi Lv, The application of soil temperature

measurement by LM35 temperature sensors, International Conference on Electronic & Mechanical

Engineering and Information Technology, 2011.

[7] Xi Zeng, Guo-jun Zhao, Yuan-ping Wang, Chao-rong Wang, jun-hui Wang, Research on the elevator

door control system based on the image processing technology, International Conference on Electrical and

Control Engineering, 2010.

[8] Abhishek Mallik and Sauvik Das Gupta MODELLING OF MEMS BASED TEMPERATURE

SENSOR AND TEMPERATURE CONTROL IN A PETROCHEMICAL INDUSTRY USING LabVIEW.

International Conference on Computer and Automation Engineering, 2009.

THANK YOU…..