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SEMINAR PRESENTATION
ON
3-D MODELS IN CHEMICAL ENGINEERING
Name : Pandya Shreyas K.
B.E.-IV , Roll No.- 806
Chemical Engineering
Guide : Dr. N.V. Bhate
Faculty Of Technology and Engineering
The Maharaja Sayajirao University Of Baroda

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

Outline
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

Introduction

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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
Students 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

Concept 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.

Salient Features
Proper plant model or layout will include such factors as :

Examination is carried out periodically

Type of process and product control

to ascertain the need for modifications

Operational convenience and accessibility

and revisions.

Type of buildings, reactors, columns, structures,

About 6 months after implementation

supports

and then annually should be designed.

Auxiliary equipment
Space available and space required
Possible
future expansion
and
Roads
Klaus D. Timmerhaus,
Max S. Peters.
Plant
Design and Economics For Chemical Engineers- 4

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
th

Commercially available 3-D Models

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

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

LiDAR Magazine. Vol. 3 No. 3. Copyright 2013 Spatial Media. www.lidarnews.com

http://www.miraclemodels.in/

Process Flow-diagram for Sulfuric Acid by DCDA Process

Layout for Sulfuric acid manufacturing Plant

Hardware 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-2
Reactor Caps

Fig-4 Pipeline made from refile & straw

Fig-1 PVC
Pipe

Fig-3
Vertical column

 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.

Fig-7
Skirt support

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

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

Fig-8
Saddle support

Fig-9 Horizontal tanks supported with Saddle support

Fig-5
Converter

Fig-6
Storage tank

 Chimney is also made from long PVC pipe.

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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-12 Horizontal Column

Cost
Acrylic Sheet

220

Pipes & Caps

100

Paper & Other

45

3D Printing

175

Total Cost

Rs. 540/-

Fig-10
Chimney

Fig-11
Vertical column

Conclusion

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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.

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THANK YOU