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\author 270189200 "owner" 
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\begin_layout Title
Demonstration Plant Team Final Report
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\begin_layout Date
Fall 2012
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\begin_layout Author
Owen Guldner and Diana Kelterborn
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\begin_layout Abstract
The Demonstration Plant (Demo Plant) is an important educational tool to
 explain and publicize AguaClara technologies.
 In the Spring of 2012, a new Demo Plant was constructed, tested, and documented
 which included the two lastest AguaClara technologies, a chemical doser
 and a stacked rapid sand filter (SRSF), as well as the older flocculator
 and sedimentation tank.
 In the summer of 2012 the demo plant structure and system was completely
 revised; the SRSF was fixed so that it can completely backwash all four
 layers, the chemical doser was labeled to include coagulant concentrations,
 and the overall plant was streamlined for transport and assembly.
 This semester we finalized construction materials and methods and built
 four more demo plants to be used at Cornell and abroad.
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\begin_layout Subsection*
Project Objectives 
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\begin_layout Standard
The goal of the Demo Plant team is to create a demo-scale version of the
 technologies used in full-scale AguaClara plants in several rural communities
 in Honduras.
 The Demo Plant is an important tool used to promote AguaClara in the Cornell
 community, at national conferences such as the EPA P3, and for community
 workshops in Honduras.
 It is also used to train plant operators.
 This semester we built several more plants that can be sent to other countries
 where AguaClara is hoping to grow.
 We also improved the current design so Monroe could take the Demo Plant
 to Nepal over Fall Break in just a carry-on suitcase.
 
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Background
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	filename Final Plant Picture.JPG
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	scale 20

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\begin_inset Caption

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Demo Plant from Summer 2012
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name "fig:Demo-PlantSummer 12"

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\begin_layout Standard
The Demo Plant from the summer of 2012 is shown in figure 
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reference "fig:Demo-PlantSummer 12"

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.
 The plant frame is made of extruded aluminum (80/20).
 This modular material is extremely strong, relatively light, and allows
 for easy adjustments.
 There are hinges added that allow for the entire frame to be folded into
 four large pieces.
 The plant contains a chemical dose controller, a flocculator, a sedimentation
 tank, and a stacked rapid sand filter all of which have been updated to
 reflect current AguaClara technologies.
 The entire plant fits into a small rolling suitcase and lacrosse bag.
 
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\begin_layout Subsection*
Construction Materials
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\begin_layout Standard
After consulting with Monroe and Paul Charles, we decided on making the
 plant frame out of PVC pipe instead of extruded aluminum (80/20).
 This is because the aluminum is much stronger than necessary, heavier,
 and more costly.
 We purchased materials and constructed a basic frame.
 It was very easy to construct because the PVC can be cut with a handheld
 pipe cutter instead of the bandsaw in the machine shop.
 It also is still structurally stable and is able to support the weight
 of all of the tanks.
 The finished plant can be seen in figure 
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reference "fig:New-PVC-Frame"

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.
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New PVC Frame
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name "fig:New-PVC-Frame"

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\begin_layout Subsection*
Trip to Nepal
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New Stacked Rapid Sand Filter
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name "fig:New-Stacked-Rapid"

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\begin_layout Standard
In order for Monroe to take the Demo Plant to Nepal over Fall Break, we
 needed to fit the entire plant in the given Eddie Bauer suitcase.
 For this to work all parts of the plant needed to be 20'' or less.
 The longest pieces of the frame were 38-1/2'' so they were cut in half;
 this was easy to do with the new PVC frame.
 The SRSF was 30'' so we shortened it by switching to the old sand filter
 column used in the Spring of 2012.
 We attached a 1/2'' ID flexible rubber tube to the top of the column using
 a zip tie.
 This extends for about 8'' and then there is a connection to 1/4'' tubing
 which leads to the backwash valve.
 After experimenting with the filter we found the flexible tubing also acts
 as a diaphragm that can be pumped to remove air bubbles from the sand or
 jump start sand fluidization.
 The new filter in shown in figure 
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reference "fig:New-Stacked-Rapid"

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.
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\begin_layout Standard
Another way to ensure that everything fit in the suitcase was to shrink
 the coagulant stock tank because it was much bigger than necessary.
 We used a column 6'' long and 2'' in diameter and constructed a new tank
 similar to the other tanks with a clear acrylic cylinder glued to the bottom.
 This tank can be seen in figure 
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reference "fig:New-Coagulant-Stock"

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.
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New Coagulant Stock Tank
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name "fig:New-Coagulant-Stock"

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\begin_layout Standard
In the aftermath of the Nepal trip various parts of the plant were broken
 due to the rough handling of checked items.
 The main broken parts were the flocculator, PACl container, and SRSF.
 For the PACl container, we replaced it with a sturdier container with a
 screw on lid (rather than a snap on).
 Solutions for the other items are discussed below in each corresponding
 section.
 Other than reinforcing the parts of the plant, we also looked into specific
 packing methods in order to ensure that the plant reaches its destination
 in one piece.
\end_layout

\begin_layout Subsection*
Finalizing Flow Rates and Doses
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\begin_layout Standard
While preparing for Monroe's Nepal trip, we finalized the flow rates and
 coagulant doses.
 The plant flow rate is now 75 mL/min, the coagulant stock concentration
 is now .8 g/L (6 scoops), and the coagulant flow rate at the maximum dose
 is now 2.34 mL/min instead of 9.9 mL/min.
 The flow rate was changed by lengthening the tube from the coagulant constant
 head tank to the drop tube by four times the previous length.
 
\end_layout

\begin_layout Subsection*
Flocculator
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\begin_layout Standard
Monroe recently acquired more polycarbonate siding, from which the current
 flocculator is constructed.
 With this in hand we have started to build more flocculators, including
 replacing the current one that was broken on the trip.
 Our new design involves replacing the 1
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 diameter rod base with a 1
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 square rod because the clamps for the current flocculator are expensive
 and not necessary in this new configuration.
 This is important because one of the possible reasons for the current flocculat
or breaking is because the feet previously stuck out, allowing for stresses
 to be applied to them.
 
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\begin_layout Standard
Although we previously were leaning towards finding a new construction method
 that will allow us to make the bottom of the flocculator curve around the
 baffles, we decided that it is much easier and cheaper to just mount in
 it a channel cut into the base, as before.
 Although it does not solve the problem, the problem is usually not evident
 if the proper dosage is used and the plant runs for less than half an hour
 (which is usually the case).
 Furthermore, the distance between the bottom of each baffle and the bottom
 of the flocculator is currently larger than the space between the individual
 baffles.
 This might be part of the problem, so we will cut the new baffles so that
 the mentioned distances are the same.
 
\end_layout

\begin_layout Subsection*
Stacked Rapid Sand Filter
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\begin_layout Standard
With the old SRSF breaking in the trip to Nepal, we switched the material
 we used for the column.
 Previously it was acrylic, which was brittle and fractured easily, so we
 switched to clear PVC, which although is not as transparent, is more sturdy.
 In order to make sure that the new one would still work, we kept the same
 inner diameter though increased the wall thickness (schedule 80) just to
 make sure that the new filter holds up.
 We have constructed the new one and tested it and it works just as well
 and is still clear enough to see the individual sand particles.
 This has been decided as the final design and will be replicated as such.
 
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\begin_layout Subsection*
Cost Analysis
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Cost per Plant
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Old Version (80/20)
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$512.62 
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New Version (PVC)
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$276.43 
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Cost Comparison
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name "tab:Cost-Comparison"

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In table 
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reference "tab:Cost-Comparison"

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 above a comparison between the costs of the old (80/20) and new (PVC) versions
 of the plant can be seen.

\change_deleted 270189200 1354828800
 
\change_unchanged
 The new version is considerably less expensive than the previous version.
 This is mostly due to the difference in price between 80/20 and PVC.
 
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\begin_layout Subsection*
Machined Parts
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Several key components of the Demo Plant need to be machined.
 For the past month or so, the machine shop has been backed up, so it is
 taking a lot longer to complete parts than we expected.
 We are trying to find ways to make the parts ourselves, and are now focusing
 on just finishing two more plants instead of four more.
 
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\begin_layout Subsection*
Future Work
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\begin_layout Standard
As of right now there is a definite possibility that not all the parts will
 be ready by the end of the semester.
 We were trying to make four more plants, so we would have a total of five.
 However, as mentioned above, it is taking a lot longer than we expected
 to get the machined parts finished.
 Because we know three plants will be needed over break, we are going to
 focus on finishing at least two more.
 Future work will include finishing the other two plants.
 
\end_layout

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