Engineering Commons^™

Conversion Of Biomass To Bio-Fuel Using Fast Pyrolysis With Companion Coal Gasification, Nicholas Hayes

Honors Theses

The objective for this design is to determine the economic benefits of using soybeans to combine biomass pyrolysis with coal pyrolysis processes to reduce the complexity and cost of producing bio-oils. Biomass is produced in multiple industries and is converted to a usable fuel substitute for petroleum. There will be many methods to analyse the pros and cons which will be used for comparison of biomass to bio-oils reactors system which in this case would be soybeans vs coal gasification.

After thorough research, the team selected a fluidized bed reactor as the main equipment for the fast pyrolysis. The reactor …

Api Drying And Packaging Technology Upgrades, Destiny Washington

Honors Theses

Certain classes of active pharmaceutical ingredients (APIs) require higher levels of containment during handling. This project explores upgrades and new technology to improve currently used systems. The upgrades will include containment during drying and packaging while maintaining required ergonomic, industrial health, and GMP requirements. Design of this system and a full economic analysis have been performed for these upgrades.

This project details the profits and costs that are associated with the conversion of the API drying process from a batch process to a semi continuous process using an agitated thin film evaporator. The implementation of the new equipment is expected …

Air Pre-Heat System Optimization For Flash Dryers, Sophia Louden

Honors Theses

Primient, a leading producer of food and industrial ingredients made from plant-based, renewable sources is the industrial sponsor for this project. The company is currently using Plate & Frame Heat exchangers to heat up a 40% by-weight glycol and water solution that is then used to preheat the incoming ambient air. Glycol is being added to reduce the risks of freezing in the system during the winter season. It is important to highlight that this fact affects the heat transfer properties of the liquid overall. Since air heating is a highly energy-demanding process, an outlet stream of hot water produced …

Comparison Of Bio-Mass To Bio-Oil Reactor Systems: Direct Conversion Vs. Companion Coal Gasification, Luci Evans

Honors Theses

The purpose of this project was to define, design, and optimize the economic feasibility of the production of bio-oil from a direct conversion of biomass to bio-oil using fast pyrolysis and a secondary side reaction of the production of a syngas from coal gasification. In the end, a combined process of these two was created to show the new strengths and more efficient options to produce a desired product within a budget. The main objectives of this project were to research the economic feasibility of the biomass and bio-oil industry, obtain a market survey, design two process flow diagrams showing …

Investigation On The Effect Of Binders On The Performance Of Si-Based Anodes Of Lithium-Ion Batteries, Christopher Rohen

Honors Theses

For the production of lithium-ion batteries with the different binders, a few things must be considered. The process of production has several steps. First is the preparation of the slurry with the composition of 70/10/20, 70% active material, 10% carbon black and 20% selected binder. Then, the bar coating of the slurry into a copper sheet is required. After drying in the oven, the sample in the cooper sheet, a few holes on the sample are made and the half-cell assembly. Lastly, the cell is assembled and its subject of rigorous testing to determine performance and stability; A few of …

Design Of A Full-Scale Plant For Plastic Pyrolysis, Hannah Sargent

Honors Theses

With over thirty million tons of plastic accumulating in the United States every year, the need for an environmentally safe means of disposal is increasing. Only ten percent of this plastic is recycled while the majority is disposed of via landfill. With recent advances in pyrolysis research, a permanent solution is presented. By creating a pyrolysis plant, not only could billions of pounds of plastic be prevented from contributing to landfills, but also be converted to oil resulting in an environmentally beneficial and lucrative solution to plastic waste.

Paper Recycling Fiber Recapture, Abigail Cortright

Honors Theses

The goal of the Yoda Chemical Company Paper Recycling Fiber Recapture project and subsequent report was to identify and recommend plant optimization opportunities associated with the potential recovery of five waste streams. Additionally, an analysis of the upgrade’s design was completed in order to determine the economic viability of fiber recapture. Beginning the analysis, the five waste streams were identified and analyzed. The waste streams include the top liner, back liner, and filler liner primary cleaner rejects on the K1 machine, the common rejects from under the K3 paper machine, and the tertiary cleaner rejects from stock preparation.

Two different …

Comparison Of Pretreatment Methods For The Production Of Ethanol, Emily Schulte

Honors Theses

Bioethanol provides a great alternative to regular ethanol sources because it uses secondary substrates that are byproducts of other industries, rather than substrates that compete with food products. The technology is available for industrial bioethanol production, but the production costs just aren’t competitive enough with traditional ethanol production. The goal of this project was not to prepare a proposal for a bio-ethanol plant with all of the associated costs and financial calculations, but rather to provide a direct comparison of two pretreatment methods to highlight which factors could make one method less costly than the other. Pretreatment is a critical …

Bio-Mass To Bio-Oil: Direct Conversion Vs Companion Coal Gasification, Gabriel Hayes

Honors Theses

Biomass is produced in agriculture and forestry, and can be converted to use as a fuel substitute for petroleum. Direct conversion of biomass to bio-oil is conventionally accomplished with a process called fast pyrolysis, in which the biomass is heated to promote the chemical breakdown of its components. This produces some condensable vapors which, when condensed, yield bio-oil. Such a process was compared to a process that gains heat from companion coal gasification instead of traditional heating media such as heated sand. The conversions were then compared to determine the more cost-effective method for producing bio-oil. Additional parameters investigated include …

Development Of A Flexible Printed Paper-Based Battery, Justone Crosby

Honors Theses

Market demand for flexible electronics continues to grow, which, in turn, increases the demand for flexible energy storage devices. There are several types of energy storage devices available, including the alkaline (Zn-MnO₂) battery, which is the subject of this project. This project's objective was to develop a flexible, printed paper-based battery, which may be a sustainable solution to the increasing market demand. This device is low-cost and can be manufactured commercially using a scalable process.

The proposed device is an alkaline flexible cell, whose components can be printed onto paper. This alkaline system includes a zinc-based negative electrode …

Steam Valve Thermo-Performance Analysis, Turner Slaughter

Honors Theses

Steam leaks occur in aging power systems due to heat energy loss in the valves of that system. A model was developed and programmed using Excel to determine the amount of heat energy lost in an aging power plant steam pipe valve system. This model was tested using data from an existing model called PEPSE. The PEPSE model determined the estimated energy that was lost due to seal leakage and general valve degradation. The energy from the steam was quantified using downstream temperature measurement data that was processed with multiple calculation methods to ensure accuracy in the model. The excel …

Steam Valve Thermo-Performance Analysis, Benjamin Evans

Honors Theses

Steam leaks occur in aging power systems due to heat energy loss in the valves of that system. A model was developed to determine the amount of heat energy lost in Donald C. Cook Nuclear Power Plant’s steam pipe valve system. Several methods were used to determine the mass flow rate and used to model the system in PEPSE. The PEPSE model determined the estimated energy that was lost due to seal leakage and general valve degradation. A program was created for use of plant employees to easily calculate the lost generation in MWe due to these leaks using the …

Syrup Process Optimization, Anelis Susana Chiluisa Calvache

Honors Theses

The purpose of this project involves the optimization of a marshmallow syrup process, sponsored by the owners of the line, the Kellogg Company was the sponsor. This report shows the work that was done for the period of three months, and covers the objective of the project, as well as the problem statement. The Kellogg Company currently produces a Syrup as an ingredient in the production of several cereal bars. The process is divided in four sections: Gelling Mix Tank, Syrup Mix Tank, Syrup Cool Tank and Syrup Use Tank. The entire process itself takes around 80 to 120 minutes …

Replacement Of A Liquid Filling System For Corrosive Materials, William Breining

Honors Theses

An aging liquid filling system in contact with highly corrosive materials required replacement to protect personnel and surrounding equipment. The current system was investigated to identify areas where efficiency, safety, and productivity could be improved. Several competing solutions, including fillers and bulk chemical storage, were determined along with the corresponding economic and safety studies. The completed study provides information for filler and storage options and provides the necessary legwork for purchase of a replacement system.

Distillation Optimization In The Pharmaceutical Industry, Daniel Vanzweden

Honors Theses

Distillations are commonly used throughout industry to perform separations by phase change, producing a liquid phase and vapor distillate. However, the process of distilling can be slow and energy intensive, providing a limitation in the production process. Possible improvements to current distillation systems were considered on the basis of thermal efficiency, material throughput (cycle time), and material tolerance. Consideration was given to ensure maintenance is straightforward and relatively quick, as fouling, contamination and tank utilization were concerns. Economic viability of the improvements was completed to determine the project benefit. The optimized design offers increased efficiency for production lines.

Distillation Optimization In The Pharmaceutical Industry, Clayton Carter

Honors Theses

Distillations are commonly used throughout industry to perform separations by phase change. producing a liquid phase and vapor distillate. However. the process of distilling can be slow and energy intensive, providing a limitation in the production process. Possible improvements to current distillation systems were considered on the basis of thermal efficiency, material throughput (cycle time), and material tolerance. Consideration was given to ensure maintenance is straightforward and relatively quick, as fouling, contamination and tank utilization were concerns. Economic viability of the improvements was completed to determine the project benefit. The optimized design offers increased efficiency for production lines.

Optimizing Frosted Mini-Wheats' Finished Food Cooling Process, Jessica Graves

Honors Theses

Analyzing energy intensive processes in industry is crucial for improving sustainability, lowering costs, and increasing profit margins on products. Material and energy balances were performed to identify process losses in the cooling of Frosted Mini-Wheats. Existing cooling technology was compared to alternate technology available on the market, and a cost analysis was performed to compare all options explored. Recommendations were made to the system to potentially reduce the line's energy usage and downtime, with the objective of creating a more sustainable and efficient process.

Optimization Of Toaster Pastry Icing Preparation And Application, Rebecca Martus

Honors Theses

The Kellogg Company is interested in optimizing the way the icing for a baked good is prepared and applied during production. The current method has not been significantly changed since the item was first introduced over 50 years ago. A new process was developed to make a more efficient preparation and application of the icing operation. New equipment was identified based on established methods in the food industry. The new equipment and process was verified after the mass and energy balances were calculated. A capital and operating cost analysis was performed to determine if the introduction of the new process …

Natural Polymer Barrier Coatings For Oil And Grease Resistance, Andrew Kathan

Honors Theses

Many barrier coating formulations currently used for oil and grease resistance development in the paper industry have issues with sustainability, biodegradation, or have health concerns associated with them. This thesis tests two starches as barrier coatings to develop oil and grease resistance for food grade packaging sheets. Starch is compatible with almost all papermaking chemicals, is biodegradable, and is easily treated in wastewater systems making it a great candidate to create a more sustainable barrier coating. Cooked hydrophobic starch esters have a unique shear-thinning rheology that allow for high solid starch coatings to be applied with a reduced risk of …

New Work Center Optimization, Clarissa Stanton

Honors Theses

No abstract available.

Modeling Product Cooling For Baked And Snack Crackers, Jenna Hagenloch

Honors Theses

The cooling of snack crackers, after the baking process is an important step prior to packaging. A model was developed for cooling the crackers. The model allows for the adjustment of multiple operating conditions, such as temperature, depth of the crackers, and the speed of the line. The completed model provides the user with the ability to predict cooling requirements and to validate pre-existing equipment operating conditions. The model will aid in the design of new equipment as well as modifications to improve existing installations to operate within the desired specifications for each process.

The Effects Of Colorimetry And Spectroscopy Using The Iso M0, M1 And M2 Modes, Kaylee Flannery

Honors Theses

The use of Optical Brightening Agents (OBA’s) in printing and proofing papers has drastically increased and, while the use of OBA’s has improved the appearance for end-use consumers, it represents great challenges to those attempting to successfully color manage the print. Therefore, standards have been created in order to assist in the measurement of these papers, and can be found within ISO 13655-2009: Spectral Measurement and Colorimetric Computation for Graphic Arts Images. This newly defined measurement standard is referred to as the “M” series. While this new standard has its advantages, it also poses some disadvantages. This report will …

Substantiate Percent Yield Within Aerosol Personal Care Plant, Gregory Maxwell

Honors Theses

The project identified losses of bulk product throughout the mix and packaging process substantiating percent yield. Support data for yield calculations was found by mapping multiple equipment trains, collecting and weighing samples, tracking waste streams, and executing engineering studies. The completed studies identified and verified product loss ensuring the accuracy of yield calculations. This project identified potential cost savings to the facilities.

Replacement Options For The Ap1-Lew System, Tiffany M. Sherburn

Honors Theses

This report details the upgrade of Pfizer’s Active Pharmaceutical Ingredient-Low Endotoxin Water (API-LEW) distribution system. The current system is suffering from chloride induced stress corrosion which has caused pitting and cracking throughout the exterior portions of the loop. The system will eventually fail catastrophically if an update is not undertaken. Many variables and system constraints are considered to maintain the API-LEW grade water.

The system operates at 65 ^○C and maintains turbulence to prevent any microbial growth. The distribution loop spans 8,500 feet of 4 inch diameter stainless steel pipe which is carried on trestles that are exterior to …

Cooling Tunnel Optimization, Trisha Janicki, Jason Thomas

Honors Theses

The goal of this senior design project was to design an Excel spreadsheet which would model a cooling tunnel at the production facility for Kellogg. This model takes the inputs from the operator, the ambient conditions, and the product going through the model and shows exactly what is happening within the tunnel. Once the model was built, an economic analysis was done based on the normal operations versus the increased efficiency of the cooling tunnel. This economic comparison showed that if the throughput of the cooling tunnel was increased by 17.6%, the cost of running the chiller, which is the …