Implementing a New Drying Oven at Pacific Can A Major Qualifying Project Submitted to the Faculty of WORCESTER POLYTECHNIC INSTITUTE In Partial Fulfillment of the Requirements for the Degree of Bachelor of Science By: Joseph Atchue______________________________ Kyle Chang________________________________ Gilberto Hernandez__________________________ Khoa Tan_________________________________ Project Advisors: Professor Jianyu Liang______________________ Professor Amy Zeng________________________ Contents Table of Figures ............................................................................................................................................ 5 Table of Tables.............................................................................................................................................. 8 Abstract ......................................................................................................................................................... 9 Acknowledgements .................................................................................................................................... 10 Authorship .................................................................................................................................................. 11 Executive Summary ..................................................................................................................................... 14 Problem Statement ................................................................................................................................. 14 Goal and Objectives ................................................................................................................................ 15 Methodology ........................................................................................................................................... 15 Results & Analysis ................................................................................................................................... 16 Conclusions & Recommendations .......................................................................................................... 18 1 Introduction ........................................................................................................................................ 20 2 Background ......................................................................................................................................... 22 2.1 Innovation & Entrepreneurial Practices .................................................................................... 22 2.2 Manufacturing & Drying Processes of Other Industries ........................................................... 23 2.3 Engineering Concepts ................................................................................................................. 24 2.3.1 Engineering Design Process................................................................................................ 24 2.3.2 Systems Thinking ................................................................................................................ 25 2.3.3 Design of Experiments........................................................................................................ 25 2.3.4 Cost-Benefit Analysis .......................................................................................................... 27 2.3.5 Sustainability ...................................................................................................................... 28 2.4 Infrared Energy ........................................................................................................................... 29 2.4.1 Infrared Applications .......................................................................................................... 29 2.4.2 Infrared Heating ................................................................................................................. 30 2.4.3 Radiation Heat Transfer ..................................................................................................... 31 2.4.4 Infrared as a Viable Drying Process ................................................................................... 32 2.5 Heat Exchangers ......................................................................................................................... 33 2.5.1 Heat Exchanger Applications ............................................................................................. 33 2.5.2 Heat Exchangers in Industrial Drying Processes ................................................................ 35 2.5.3 Convection Heat Transfer .................................................................................................. 37 2.5.4 Heat Exchangers as a Viable Drying Option ...................................................................... 38 2.6 Ceramics ..................................................................................................................................... 39 2 2.6.1 Ceramic Ovens .................................................................................................................... 40 3 Methodology ...................................................................................................................................... 41 3.1 Analysis of Pacific Can’s Current Drying Process ....................................................................... 41 3.2 Analysis of Previous MQP’s Results & Recommendations ....................................................... 42 3.3 Design & Prototype .................................................................................................................... 42 3.4 Experimentation with Cans ........................................................................................................ 43 3.4.1 Experiment Procedure ....................................................................................................... 43 3.4.2 Explanation of Trials ........................................................................................................... 44 3.5 Scaling up to the Industrial Level ................................................................................................ 45 3.5.1 Energy Calculation............................................................................................................... 45 3.5.2 Material Analysis ................................................................................................................. 46 3.5.3 Cost-Effectiveness in our Design ......................................................................................... 46 3.6 Sustainability in our Design ....................................................................................................... 46 3.7 Research Methods Overview ..................................................................................................... 47 3.8 Project Timeline.......................................................................................................................... 48 4 Results & Analysis .............................................................................................................................. 50 4.1 Pacific Can’s Current Drying Process ......................................................................................... 50 4.2 Experimental Design & Prototype ............................................................................................. 51 4.2.1 New Concept ...................................................................................................................... 52 4.2.2 New Design ......................................................................................................................... 53 4.3 Experimental Data ...................................................................................................................... 57 4.4 Scaling up to the Industrial Level ............................................................................................... 59 4.4.1 Energy Calculation .............................................................................................................. 59 4.4.2 Material Analysis ................................................................................................................ 59 4.4.3 Cost-Effectiveness in our Design ........................................................................................ 60 4.5 Sustainability Assessment .......................................................................................................... 60 5 Conclusions & Recommendations ...................................................................................................... 62 5.1 Innovation & Entrepreneurship Revisited .................................................................................. 62 5.2 Interpreting the Results .............................................................................................................. 62 5.3 Drying Processes ......................................................................................................................... 63 5.3.1 Heat Exchanger ................................................................................................................... 63 5.3.2 Ceramic Infrared Tubes ....................................................................................................... 64 5.3.3 Infrared Tubes ....................................................................................................................