Delta-V - Modular Explosives Manufacturing Plant: Optimization & Design
Team: Jadon Bucklin, Zack Christensen, Aaron Groethe, Jacob Hansen, Joseph Millett, Kyle Nalder and Jeremy Prinster
Project Description
Design and optimization of a compact, modular explosives manufacturing plant with emphasis on automation, remote operation, and safety. Focus areas include equipment selection, process flow efficiency, and reliable control strategies for continuous operation.
Performance Review
| Type | Requirement, Constraint, or Goal | Target | Threshold | Predicted |
|---|---|---|---|---|
| Constraints | Total Design Cost | N/A | $500,000 | $409,109 |
| Constraints | Total Production Volume | 38 ft x 4.5 ft x 7.9 ft | 38 ft x 6 ft x 7.9 ft | 24 ft x 4.5 ft x 7.9 ft |
| Requirement | Reaction Vessel Temperature | 25°C | 30°C (Maximum) | 24.5°C |
- The “Total Design Cost” constraint is self explanatory in that a budget analysis was performed to see if all the components with their quote prices combined could pass under the $500,000 limit. It was found that only $409,109 was needed.
- For the “Total Production Volume” constraint, a spacial analysis was performed in solidworks given the approximate dimensions and piping requirements for each component. The total space required was 24 ft x 4.5 ft x 7.9 ft, almost half of the threshold.
- For the “Reaction Vessel Temperature” requirement, the custom reaction vessel was built in Solidworks and simulated in Solidworks Flow Simulation. The vessel maintained a 24.5±0.25°C average equilibrium, a temperature both under the Threshold and Target.
Design Description
The modular plant layout emphasizes compact integration, automation, and safety. The design utilizes gravity to eliminate pumps and minimize critical joints.
The plant contains key equipment; reaction vessel, chiller, scrubber, quench tank, and filter. The plant also receives input material, coolant, water, and gas streams.
The manufacturing process includes two stages: a continuous flow process through the reaction and a batch process to quench and filter the product.
Conclusions
The modular plant design successfully addresses all of the essential requirements and constraints.
- The total cost is $90,891 below the budget.
- The plant layout is compact enough to fit multiple plants within the required volume.
- The reaction vessel theoretically keeps the reaction 5.5°C below the maximum permissible temperature and 0.5°C below the target value.
Lessons Learned:
- Consult with industry experts early in the design process.
- Clearly define requirements and constraints at the beginning of the project.
- Be adaptable as requirement evolve and new information arises.
Recommended Future Work:
- Maximize profits by including distillation of nitric acid and post-manufacturing processing of the explosive product.
- Increase the scale of the modular plant.
- Recycle the diluted nitric acid.
Special thanks to Delta-V Energetics for the opportunity to work on this project and for the resources and support provided throughout.