1
CHAPTER I
This chapter defines and elaborates simply to what the study is all about, the
background of the study where the researcher identifies the extent of the problem,
and the profile of the company to where the study was conducted. The objectives and
scope and limitation of the study was also emphasized in this chapter.
INTRODUCTION
The competitiveness of automation in industrial systems able to increase in
production, processing and income as envisioned by the organization. The provision of
conducive environment to the local manufacturers strengthen quality processes. The
City Agricultural Services Department of Calamba City gives enforces and gives priority
its constituents to established appropriate transfer of technologies for the upliftment
of economic management.
Mixing was a local activity performs by Mayo Holdings Inc. According to
(Jakobsen, 2008) the term “mixing” is an excellent and key process for homogeneity of
liquids used for dilution of immiscible liquids or the formation of mixture. It is usually
equipped in a container with a medium such as paddle, impeller, and propeller. The
specially formulated chemicals that were manufactured by the company contains an
active ingredient used for complete mechanical and chemical de-clogging of kitchen
and sewer lines by dissolving heavy and hardened deposits of fats, oil, and grease
inside drain pipes in the prevention of clogging and maintenance of free-flowing
kitchen lines in commercial malls and restaurants.
2
To develop these complexities in production, manual addition of raw materials,
excessive mixing time, risk of operators, and production inefficiency, and the
researchers designed a mechanized mixer which also enables the company to meet
the demand of clients.
Background of the Study
Mayo Holdings Inc. is a company engaged in mechanical works, particularly in
kitchen exhaust system and air handling units of certain fast food chains or food eatouts as well as some specific malls in the country, respectively. Moreover, the company
is engaged in supplying hazardous chemicals (declogger and degreaser) to certain
clients. For them to produce those, manpower becomes an asset on the production.
In manual operation, it was reported that the company must produce a certain target
quantity per month of containers, with a 20 kg capacity for each of those chemical
solutions (degreaser and declogger). Mixture of chemicals are dissolved per drum
using a wooden paddle as a medium for a 10-minute duration of continuous mixing.
After being transferred from drum to 20 kg container, there is a potential of losses
from unwanted dispense of the chemicals with water and mixing one part of chemical,
they are subjected to idle for 24 hours before transferring the solution manually from
the drum to a container with a 20 kg capacity to avoid extreme heat exposed by the
declogger when it was newly mixed.
Manual mixing process involves stirring the chemical and filling the container
of declogger and degreaser by hand. Provided that the declogger solution while
transferring it to the container, in which low production quantities may not be a good
3
fit. The ratio of mechanization to workers will surely cater to the clients’ needs. The
flexibility to get the job done was within reach. The spillages on the floor while
packaging the chemical can damage any kind of footwear without carefulness. Mayo
Holdings Inc., as time goes by, was experiencing an increase in number of clients and
at the same time increased workload for workers involved in chemical mixing. The
general properties of chemical are affected since it is a strong and highly concentrated
solution, thus producing a poor state of homogeneity. The manpower involved in the
area are also in need of safety hazard control while doing the operation, particularly
since they are in the unsafe area.
The researcher’s conversion of mechanized
chemical mixing tank design for Mayo Holdings Inc. raised when merging all concerns
regarding what the improved way were to benefit the company to have a more
effective productivity, increase in production and income, and improved worker
performance.
Company Profile
Mayo Holdings, Inc., was established by the Ramos couple, (MAnny and
YOllie) and was approved by the Securities and Exchange Commission, (SEC), on June
15, 1993.The President & Chairman of the Board, Manuel, holds a bachelor’s degree
in Chemical Engineering from the Mapua Institute of Technology and was the South
East Asia Manager of W. R. Grace & Co., which used to be the biggest specialty
chemical company in the world, managing the operations in thirteen countries around
South East Asia. The Vice-President, Euleta, has a bachelor’s degree in Chemistry, also
from the same institute, and received several international scholarship grants related
to her field while working at the Department of Science & Technology, (DOST). The
general manager, Norman Rey, is a graduate of Business Management from the De La
4
Salle University; Food Technology from the Philippine Women’s University; and
diploma in Culinary Management, major in Patisserie at the Le Cordon Bleu in Sydney,
Australia. Anna Leah is the corporate secretary, has a bachelor’s degree in Commerce
from the St. Paul College of Quezon City, Major in Marketing and is a post graduate
diploma holder of Corporate Management from the Graduate School of Business at
the University Of Sydney, Australia. Erwin Rommel, the treasurer, has a B. S. degree in
Business Management and is currently managing the Luzon operations.
The company is involved in providing consultancies, it was estimated that the
production cost of chemical declogger and degreaser is fifty thousand pesos per
month, as the company is required to produce at least 300 pieces of 20kg filled
container of declogger and degreaser. Moreover, they also have specialty to the
following areas:

Kitchen Exhaust Systems (KES). It includes the design, fabrication,
installation, cleaning, maintenance and/or repairs of kitchen
exhaust systems (KES), in commercial malls and restaurants using
the specifications and standard operating and quality control
procedures of the International Kitchen Exhaust Cleaning
Association, (IKECA), of the USA.

Bio-Technology in the treatment of wastes. Bacteria-enzyme
products are used in the treatment of industrial and commercial
wastes that are friendly to humans and the environment. Biotechnology replaces the use of hazardous chemicals in the
prevention of clogging and maintenance of free-flowing kitchen
lines in commercial malls, restaurants, and commissaries.
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
AC handling. This refers to the design, fabrication, installation
and/or maintenance of air handling units and air-conditioning
equipment and systems in commercial malls and buildings.
MAYO INC. also has varied interests in leasing residential and office
condo units as well as contracting and supplying bio-technology products
(imported from the USA). These are supported by technical and maintenance
services for commercial kitchen drain and sewer lines, pig farm operation using
the European technology in pig breeding, trading, and other business
opportunities that are deemed of interest to the family.
Statement of the Problem
The effectiveness of the chemical products results to a large demand on the
market today and benefited the profit of the company, indicates increase in labor.
There is no time to lose, thus the Production Area must be operationally stable,
sustaining efficiency while ensuring the safe working environment. Conversion of
manual mixing to mechanized mixing process speeds up production and deliver
optimal efficiency. Considering the main relevant losses such as chemical waste,
product rework, safety and health risks of workers (eye irritation, severe chemical
burns, skin irritation and dissolving of clothing) of harsh manual chemical mixing
process, conduct of coordination with the engineering technologies can deal with
obstacles and improvement.
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The researchers sought to answer the following questions:
1. What are the parameters to be considered in designing mechanized chemical
mixer tanks that will develop solution to the existing operational conditions?
2. What is the most efficient alternative solution which will generate safety
opportunities to the workers and personnels?
3. How much is the investment needed to materialize the equipment?
Objectives of the Study
This study basically was to analyze the conversion of manual chemical mixing
process into mechanized mixing process for mass production at outstanding speeds
and performance to fulfil requirement that will solve existing complex problems.
Specifically, specific objectives of this study were as follows:
1. To determine the parameters to be considered in designing mechanized
chemical mixer tanks that would develop solution to the existing
operational
conditions.
2. To determine the most efficient alternative solution which would
generate safety opportunities to the workers and personnels;
3. To know how much the investment was needed to materialize the
equipment.
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Scope and Limitation of the Study
The study was conducted in Mayo Holdings Inc. chemical mixing facility at Brgy.
Milagrosa, Calamba City, Laguna, during the Academic Year 2018-2019. The study
focused on mechanization of chemical mixing production. The study also measured
requirements to improve existing equipment. Operators of Mayo Holdings Inc. were
the target beneficiaries of this research, specifically those who are working at the
Mixing Facility. This study included the capacity of the mechanized mixer tank
production based on the weigher installed per day. Only data available for specially
formulated chemicals based on material safety data sheets were considered. The study
involved the understanding of difficult manual mixing system and, in the case of
formulation, specific types of impeller were recommended. The mechanized mixer
tank was preferably place inside the establishment but 500 meters away from offices
because of the vibration sound that may be heard. With the alternative solutions
proposed for the project, the installation of mechanized mixer tank will be base from
the decision of the company.
Significance of the Study
This study regarding the conversion of manual chemical mixing process into
mechanized mixing process will be able to benefit individuals and groups, as
enumerated below.
Operators. The manpower would be able to do their job in less time and effort.
There is better repeatability and less human error. There would be safety in terms of
avoidance in too much heat exposure while transferring the mixed chemical solution
to each 20-liter container. Evaporation of chemical solution spillage and chemical
8
mixing exposure to the atmosphere would also be prevented. Moreover, it would also
improve morale of workers working in the area and triggers to perform their job in a
more convenient way. Lastly, it would improve productivity while helping uplift the
lives of operators.
Company. The Mayo Holdings Inc., despite additional clients who are the
potential customers of declogger and degreaser chemical solution, would not be in
urgent need of additional manpower for chemical mixing. By adding mechanized mixer
tanks to operation means less workers, it would also indicate less safety issues which
in turn will lead to financial savings. Moreover, investing in mechanized equipment
would create resource for the company; they would be able to increase volume of
production which would increase profitability.
Clients. This study would benefit the clients of Mayo Holdings Inc. like SM
Malls, Pancake House Inc., Teriyaki Boy Inc., and Robinsons Malls, which have
expressed for increased demand of chemicals needed for the treatment of industrial
wastes.
Local Manufacturing Companies. The needing of machinists would be
addressed since the researchers designed a mechanized mixing tank to fabricate the
small pieces that make up the tank. Production of locally made machineries would
create more jobs and profit to the workers. Pieces, usually transmission and engines,
are usually imported.
Academe. The study was helpful for Colegio de San Juan de Letran Calamba’s
vision of meeting its institutional quality of education for its students in terms of
sustained research that can be more strengthened, as the said study is eyed to be
effective for the Mayo Holdings Incorporated. This was also an assistance for the
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institution to provide a better academic image through the proof that Letran-Calamba
Mechanical Engineering students can use their studies to provide solutions to certain
cases.
Researchers. Awareness and access on mechanization technologies available
would help the researchers to acquire relevant knowledge regarding appropriate
machinery design. The researchers were given a chance to apply theories that they
have learned in the institution which improves learning retention and critical thinking
abilities.
Future Case Study Researchers. This case study could be a source of
information for those students who would be having a related trend of this research.
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RESEARCH METHODOLOGY
This section discussed the importance of research design and instruments to
gather relevant data using structured methodologies and procedures to have
visualization tools about the featured topic.
Research Design
This study on the conversion of manual chemical mixing to mechanized
chemical mixing process at Mayo Holdings Inc. employed the case study research
design. Descriptive research where nature of observation, case study and survey on
the inappropriate or outdated mixing performance of chemical declogger and
degreaser were considered and reviewed to seek research data. It was evaluated by
various parameters, mixing time, circulation time, maximum speed, capacity, and
present set-up. The design of mechanized mixer aimed at studying the possibility and
of adopting impeller in alternative to traditional manual chemical mixing. Also,
mechanized mixer tank was equipped with weighing indicators that would transform
production speeds of up to 10 weighments per hour and accuracy of 20 kg per
container. Furthermore, this study provided alternative solutions to the problem of
manual mixing process of the company, recommended the best solution, and
presented the cost-benefit analysis of the problem. Lastly, the importance of quality
and quantity in order to get results on breakdown elimination was greatly considered.
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Sources of Data
The researchers gathered data by two methods, by primary and secondary data
collection. In the primary data collection, the researchers gathered data by interviews,
conducting surveys, and ocular visits. In this way, the researchers gathered some
reliable data that was used in their study. In the secondary data collection, the
researchers gathered their data using internet, books, and some recent theses papers.
In this method, the researchers could have some background study about the topic
that of their study.
Research Instruments
The researchers used interviews, company data, and direct observation in
gathering relevant data of study.
Interview. Face to face interviews were conducted by the researchers.
It was a semi-structured and in-depth interview in which questions are
determined before the interview. An open-ended and complete information
gathering was pre-determined; such affords greater understanding of the
operating process. Such responses introduced necessary data for the target
mixing conversion process.
The following were the dates of interviews conducted and the
corresponding interviewee and information gathered:
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Table 1. Summary of in-depth interviews
Date
Interviewee/
Query
Data Gathered
Contact person
September 21,2018
Company Security
Person in-charge
Name of the HR
to Conduct for
Section Head
Case Study
submitted to ARD for
permission letter
September 24,2018
Ms. Lanie T.Orencia
Possibility of
Reply Form of area of
researchable
research
topics
October 8, 2018
Warehouse Crews
Interview about
Capacities of produced
safety operations,
specially formulated
Production
chemicals
quantity and
effectiveness.
October 22,2018
Engr.Mark Anthony
Proposal of
V.Gonzales
Research to be
Approval of Topics
conduct
October 26,2018
Mr. Julius V. Villavelez
Data Gathering
Material Safety Data
Sheets (MAYO
Declogger and
Degreaser)
October 29,2018
Sir Manny V. Ramos
Data Gathering
Production Cost per
month
November 5,2018
Warehouse Crews
Data Gathering
Sample of Chemicals
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Company Data. The researchers requested for the provision of relevant
data that were used to determine the design parameters. It was done by
sending a request letter to meet the desired objectives. Material Safety Data
Sheets were taken from Engineering Services Department.
Observation. A holistic understanding of the present set-up helped the
researcher determine existing problems of the company, specifically the mixing
facility, and how much time was spent on the production of the company. This
further helped in enabling to learn and interpret about the production of
chemical degreaser and declogger. Through observation, the researchers
modified the mechanization of chemical mixing process.
Data Gathering Procedure
This section discussed how the researchers gathered structure data—collected,
extracted, and analyzed—as additional information for this study. Data gathered
helped the researchers to have visualization tools in an easy way and insights and
trends about featured topic.
Library Research. The library could provide a wide range of their data. Library
consisted of books, journals, research, and thesis that could be the sources of the data.
Internet Browsing. Internet browsing could be also helpful to gather some data to
help, internet browsing could be the source of the data that the library cannot provide
or data that only in the internet could be the source. Internet browsing could be used
to gather related studies, related literature and other studies that could help the
researches do and make their research.
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Ocular Visits. Ocular visits perceived by eye inspection to determine and explore
ideas of study on a location of the participating company. This helped the researchers
to address relevant problems that need further studies.
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CHAPTER II
REVIEW OF RELATED LITERATURES
In this chapter, related literatures and studies relevant to the research are
presented. This chapter also discussed the definition of terms for better understanding
of the study.
Related Literatures
Metal Mixing Tank Systems
Because of its high corrosion resistance, 304 Stainless Steel is used in
pharmaceutical and chemical industries. 304SS tanks can be used at wide temperature
ranges with a high physical strength but are more expensive than most plastic tanks
because of the higher material costs and the work required to smooth the surface and
especially the welds. (http://www.wmprocess.com/mixing-tanks/, 19 October 2018).
Moreover: “Type 316 stainless steel is an austenitic chromium-nickel stainless
and heat-resisting steel with superior corrosion resistance as compared to other
chromium-nickel steels when exposed to many types of chemical corrodents such as
sea water, brine solutions, and the like. Since Type 316 stainless steel alloy contains
molybdenum bearing it has a greater resistance to chemical attack than 304. Type 316
is durable, easy-to-fabricate, clean, weld and finish. It is considerably more resistant to
solutions of sulfuric acid, chlorides, bromides, iodides and fatty acids at high
temperature. Stainless steels containing molybdenum are required in the manufacture
of certain pharmaceuticals in order to avoid excessive metallic contamination. The
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bottom line is that Type 316 stainless steel costs a little more upfront but could save a
whole lot on the back end – especially if enclosure is going to be used
outdoors”(https://www.nemaenclosures.com/blog/304-and-316-stainless-steel , 19
October 2018).
Chemical Mixing
When mixing chemicals, four important variables must be considered
before determining which type or system is the best for the process. The
volume plan to mix determines the type of mixer to be used, how it is placed
inside the vessel, and how it is installed. Choosing the appropriate impeller,
mixer speed, and mixer horsepower depends on how viscous the media is. For
example, media with a density that is thicker than water requires a different
mixing or pumping action to mix thoroughly for the desired result. This is
because denser chemicals will sink to the bottom, as lighter chemicals rise. For
optimal mixing, the weight or gravity of the mixture should be taken into
account.
(http://www.wmprocess.com/chemical-mixing-and-mixers/,
19
October2018).
High Viscosity Mixers
Multi- shaft mixers for high viscosity mixing. Center Mount paddle
sweep blade and a high-speed mixer is featured on typical high viscosity mixers.
This result to constantly moving mixture, whereas the lower speed anchor
provide mass blends and feeds impeller, while the high speed top mixer
dissolves. The consistency of two actions was done by side- to-side and top-totop mixing process. (http://www.wmprocess.com/mixers-and-agitators/ 19
October 2018).
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Selecting Impeller Size
Impellers are the component of the mixer that delivers flow.
Their purpose is to transfer the energy driven by the engine to the tank
contents as quickly and efficiently as possible. Each impeller type can be
classified by its flow pattern, whether it is an axial (parallel to the blade) or a
radial (perpendicular to the blade) pattern.
Viscosity. Viscosity is the primary factor to consider in the selection of
the impeller type. Viscosity affects several aspects of the design and selection
of impellers. Highly viscous liquids also require a longer mixing time, so that
this detail should also be considered when selecting an impeller. Baffles are
not necessarily considered preferable when mixing highly viscous materials
because they can impede top-to-bottom flow in these cases. In many cases, a
hydrofoil impeller blade is suitable for lower viscosity while an axial flow or
turbine pitched blade is better for highly viscous mixing. In addition, the density
of a substance is an important viscosity characteristic.
Tank Design and Placement. The size and dimension of the mixing tank
must be specified. The aspect ratio of the vessel is an important figure, and
when it is as close to unity as possible, an ideal mixing takes place. Incorrect
positioning of the impeller can lead to uniformity in the contents of the vessel
and staged flow patterns. While the contents of a vessel are in motion with
swirling, they are simply rotating instead of mixing with each other. Baffles are
flat plates on the inner wall of a mixing tank and can be very efficient in
disrupting vortexing in a mixer. Baffles also help content move from the top to
bottom of the tank. They are welded to the tank wall. The design of the tank is
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the main aspect in determining the quantity of rollers required for equal mixing
in an application. Volumetric specifications and the shape and positioning of a
mixer (vertical, horizontal) are both essential units in the calculation of the
impeller quantity. As the tank gets larger, more impellers need to be added to
mix properly. The dimensions of the impeller itself are determined primarily by
the desired mixing intensity of a specific application. Intensity is linked to the
diameter if more intensity is required for adequate emulsification and mixing.
Impeller Construction Materials. Stainless steel is a common and
suitable material for impellers in many different applications. Stainless steel is
exceptionally resistant to corrosion and contamination, which extends the life
of an impeller further. Cleanliness is a must, particularly in sanitary
applications. Stainless steel can easily be cleaned and maintained. Impellers
can be produced in different stainless-steel grades. Carbon steel, titanium, and
nickel alloys are also common choices. They can also be finished with different
coatings to meet the application's requirements and strengthened to extend
their life span (http://blog.mixerdirect.com/how-to-choose-a-mixing-impeller,
19 October 2018).
Chemical Reactivity Hazard
When chemicals react to other chemical substances or to certain physical
conditions, reaction occurs. The reactive properties of chemicals vary widely and play
an important role in the production of many chemicals, materials, products, and food
products used every day. If chemical reactions are not properly managed These causes
catastrophic response such as explosions and toxic fumes, reactions can lead to life
19
and death concern of
persons, damage to physical property, and serious
environmental effects.(https://www.osha.gov/SLTC/reactivechemicals/, 19October
2018).
Crucial Mechanical Design and service life of Mixer Tanks
Mixing should not be a mechanical problem but a process operation. Different
industries, however, it get into trouble beyond the mechanical design of the mixer
Some mixers work on long life span , some are 10 years, some can still work after
30years, for example—design failures can shorten life or even break parts. Often
before the equipment, the mixer's processing capabilities fail, but poor processing can
cause mechanical problems.
Equipment manufacturers usually know the limits of their equipment and
design under the conditions specified. However, requirements and conditions of the
process may possibly vary from those specified for the design during the life of a mixer.
It is therefore important to have comprehensive ideas on some of the mechanical
failures that can occur in mixing equipment.
Operators are aware of the risks of overloading a mixer, usually by mixing a
highly viscous material. Many mixers have considerable load and are designed to
handle a wide variety of materials.
Without overloading, some can mixers can handle with high viscosity
chemicals. The motor cannot use above 10% in water, however, motors designed with
85%-90% are therefore creates less disturbance. Mixing load factor on highly viscous
fluid is usually obvious; the fluid density in turbulent conditions directly affects the
motor load. A high-density fluid such as mineral slurry can overload a motor that is not
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designed for processing. In any case, gears, shafts, blades, and other basic components
should be chosen to match the maximum motor load. There can still be overloads and
damage
to
the
engine
or
reduce
the
life
of
other
components
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018).
Mechanical failures
For several reasons, a mixer parts such as a shaft, shaft seal, impeller blade, or
gear reducer can malfunction. There must be significant differences in actual process
conditions and innovative design criteria. In other researches, installation deficiencies
can lead to failures of equipment. Long life span of most mixers can manage; some
have 30 years life span.The “wet " parts of the mixer must be designed to handle
mechanical loads, conditions and vibrations. Most of the mechanical loads result from
the interaction of the mixer with the fluid. To rotate the impeller, a force is obviously
necessary. This force is represented by the torque that the shaft transmits from the
drive to the impeller. The moving fluid creates hydraulic forces perpendicular to the
shaft, in addition to the fluid forces resistant to the rotating impeller. These forces
create a bending moment on the shaft. A typical cantilever shaft that only supports the
mixer drive can have significant bending loads. Therefore, the selection of the shaft
diameter requires both the torque and the bending load. Torque is directly
proportional to fundamental power and inversely proportional to speed
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018).
Frequency Rate
A factor often overlooked in design is the natural frequency rate of the mixer
shaft, often referred to as the “critical speed. If the mixer shaft's natural frequency is
too close to the mixers operating speed, a critical problem is likely to arise. This
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intensity is similar to that produced by a tuning fork. A combination of shaft full length,
shaft and impeller weights and the shaft material elastic module establishes a
frequency at which the shaft vibrates. When external forces, such as the mixer's
operating speed, match the normal frequency, there is often a catastrophic failure.
Most large mixers are designed to work below the first natural mixer shaft frequency.
The operating speed of the mixer is usually limited to less than 85 percent of
the normal frequency to avoid vibration problems and issues. If the rotational speed
and frequency are too near, the resulting vibrations cause deflections, most of which
lead to a severely bent shaft. Recently, for example, a 6-inch steel shaft was bent to
such an extent that it only stopped when it hit an obstruction in the tank. Vibrations
without damage can lead to extremely large mechanical power. The frequency
calculation for the mixer shaft takes enriching knowledge of the shaft and roller details,
including information on the roller weights and the shaft bearings usually somewhere
inside the mixer. A total and complete calculation includes individual impeller weights,
distance from support bearings and support bearings.
The
manufacturer is best able to calculate the natural frequency. However, the mixer user
should be aware of the natural frequency, as variable frequency drives (VFDs) can be
over-speed and the mixer approaches the critical velocity. Unlike large mixers, mobile
units are often above the first natural frequency. These smaller mixers usually take
rapidly to pass through the natural frequency safely without incident. Problems can
arise, however, if the mixer runs for longer periods near the natural frequency, as can
be the case with VFDs and air machineries and motors. While the mixer operator can
instinctively react to remove the vibrations, it can be too late to prevent a bent shaft
or injury. Shaft frequencies must be avoided (http://www.dynamixinc.com/optimaltank-design, 17 October 2018).
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Mixer Mounting
The mounting is another factor in the mechanical design of the mixers. While
obvious mechanical design concepts may lead to a failure to support the mixer, other
deficiencies can be subtler and lead to mechanical failures that appear to be
unrelated. The mixer support design has to take into account all mechanical loads on
the mixer (http://www.dynamixinc.com/optimal-tank-design, 17 October 2018).
Liquid Level to Tank Diameter Ratio
The ideal liquid to tank diameter ratio for most mixing applications is mostly
0.8, but any close to 1:1 ratio is appropriate. For proper axial mixing in the tank, an
excessively lower ratio does not permit. A ratio of less than 0.6 should be prohibited.
If the ratio exceeds 1:4, double impellers should be used. When the ratio liquid to tank
diameter exceeds 2.0, the selection of tanks should be reassessed, since these slim
tanks are not the most cost- efficient mixing outcomes.
Vertical Cylindrical Tanks. Vertical cylindrical tanks are the most common
tank type in use. One important consideration for cylindrical tanks is to ensure
that they are either confused or offset to prevent swirling. Baffles are
generally not necessary in smaller tanks (less than 5,000 gallons in volume or
10' height). For larger tanks, however, installing baffles is much more costeffective than investing in a more expensive, heavier mixer
that
is
offset.
Rectangular Tanks. Rectangular tanks have an equivalent diameter, which can
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be calculated by taking and multiplying the square root of Length X Width by
1.13. A similar liquid level to the tank diameter equivalent of 0.8 is applicable.
When used for mixing, rectangular tanks can be effective, as these tanks are
self- controlled. Rectangular tanks are not recommended for solid suspension,
however, because solid packages are formed in the corners.
Cone or Round Bottom Tanks. Some tanks will have a round (dish) or cone
bottom. Below are some standard guidelines about approaching mixing for
these tanks.
1. Cone bottom: ideally the angle of the cone should be less than 15 °, but
anything less than the angle of 30 ° is allowed. If a cone is too deep, it becomes
much more difficult to mix well in it.
2. Round Bottom: for a round bottom, the same rules apply to a cone.
Generally, a round base is better for solid suspension, because there are no
sharp angles in the tank, so dead spots are eliminated.
3. Baffles: If the cone / round bottom tank is very deep, it is also possible to
place baffles inside this part of the tank to promote good axial mixing and
prevent swirling.
Most people appreciate the risk of overloading a mixer, usually by
mixing a material more viscous than the mixer can handle. Many mixers are
designed to handle a wide range of materials and have considerable overload
capacity. Some portable blenders and high-speed dispersers can handle
extremely high viscosity without overloading. Such mixers can only draw less
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than 10% of the motor power when operated in water.
However,
other
mixers are designed for 85% or 90% of the motor capacity and are therefore
less tolerant of disturbance conditions. Although high viscosity is an obvious
mixing load factor, fluid density directly affects the motor load in turbulent
conditions. A high-density fluid like mineral slurry can overload an engine
which is not designed for process conditions. In any event, gear reducers,
shafts, blades, and other basic components should be selected to match the
maximum engine load. Overloads can still occur and can damage the engine
or
reduce
the
lifetime
of
other
components
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018).
The Use of Baffling
When using cylindrical tanks, the use of baffling is necessary. If a stirrer is
centered in a blank cylindrical tank, it produces a very inefficient swirling motion. As
an example, imagine two particles whirling in a circular movement which always chase
and not mix.
There are two solutions to consider:
1. Install Baffles: the best option is to install baffles in the tank.
2. Mixer offset: mounting the mixer with an offset of about 1/6th of the tank
diameter prevents swirling. The inconvenience of this option is that unbalanced
forces create more stress on the mixer shaft and require a heavy-duty mixer.
This
is
cost-prohibitive
for
larger
shaft
applications
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018).
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Assessing Mixing Effectiveness
Mixing time is a useful mixing efficiency parameter and is used to characterize
bulk flow. The mixing time (tm) is the time required to achieve a certain degree of
homogeneity from the original separated state. It can be measured by injecting a
tracer into the tank and at a fixed point in the tank after its concentration. Commonly
used tracers include acids, bases, and concentrated solutions; pH samples and
conductivity cells are the corresponding detectors. You can also measure the mixing
time by measuring the temperature response after adding a small quantity of heated
fluid. If a small tracer pulse is added to the fluid in a stirred tank already containing
concentration tracer material. When circulation flows in the system, the tracer
concentration measured at a fixed point in the tank follows a pattern. A relatively high
concentration of each is detected before mixing is complete. The concentration peaks
are separated by approximately the average time taken for the fluid to pass through
a bulk circulation loop. In the stirred tank this period is called the circulation time (tc
). The desired degree of homogeneity is achieved after several circulations
(http://life.dlut.edu.cn/Bioprocess5.pdf, 20October 2018).
Horsepower Requirements for Mixing
Electric power is usually used to drive impellers into agitated tanks. The power
required for a given agitated speed depends on the resistance of the fluid to the
rotation of the impeller. The average power consumption per unit volume for small
vessels ranges from 10 kW to 1~2 kW for large vessels. Electric power is usually used
to drive impellers into agitated tanks. Friction in the motor gearbox including seals
26
reduces the energy transferred to the fluid; therefore, the electricity consumed by
the stirrer motors is always higher than the mixing power, depending on the drive
efficiency. The cost of energy for stirrers is an important consideration in process
economy (http://life.dlut.edu.cn/Bioprocess5.pdf, 20 October 2018).
Improvement of mixing
Sometimes, the mixing time cannot be reduced simply by increasing the power
input. Therefore, while increasing the agitator speed is an obvious way to improve the
circulation of fluid, other techniques may be necessary. Baffles should be installed; this
is routine and causes more turbulence. The impeller should be mounted below the
geometric center of the vessel for efficient mixing. The impeller is located
approximately one impeller diameter or one third of the tank diameter above the
bottom of the tank in standard designs. When circulation currents below the impeller
are smaller than the above. At the same time, fluid particles leave the impeller and
take different periods of time to return and exchange material.
Multiple impellers are another tool to improve mixing, although this requires
increased power input. Typical bioreactors used in aerobic cultivation are tall
cylindrical vessels with liquid depths much higher than the diameter of the tank. This
design produces a higher hydrostatic pressure on the bottom of the vessel and
provides a longer contact time with liquid for rising air bubbles. More than one
impeller is required for efficient mixing.
Fluid Viscosity
A resting fluid cannot withstand shearing forces, and if such forces act on a fluid
in contact with a solid boundary, the fluid flows over the boundary so that the particles
27
immediately in contact with the boundary have the same velocity as the boundary. All
this while successive fluid layers are parallel to the boundary move at an increasing
velocity.
Shear stress is set against the relative motion of these layers, the magnitude of
which depends on the speed gradient from layer to layer. For fluids that obey Newton's
viscosity law, take the direction of motion as the 'x' direction and vx as the velocity of
the fluid in the 'x' direction at a distance 'y' from the border, the shear
stresses.Meanwhile, the coefficient of dynamic viscosity (μ) can be defined as the shear
force per unit area (or shear stress) required to drag a layer of fluid at unit speed
through another layer at a unit distance in the fluid.
Mechanism of Viscosity
The viscosity of a fluid is caused mainly by two factors. First is intermolecular
cohesion force. Due to the strong cohesive forces between the molecules, any layer in
a moving fluid attempts to drag the adjacent layer to move at the same speed and thus
produces viscosity effects. As cohesion decreases with temperature, the viscosity of
the liquid also decreases. The second is molecular momentum exchange, where as
fluid particle’s molecular motion increases together with temperature, the viscosity
increases accordingly as well. Therefore, except in very special cases (e.g. at high
pressure), the viscosity of both liquids and gasses is no longer a function of
temperature.
28
Variation of Viscosity. This varies with temperature and pressure both; the
effect depends on the state of fluid (gas or liquid). A higher temperature means a
stronger random movement, which weakens the effective intermolecular attraction.
The viscosity of fluids is regulated by intermolecular attractive forces (i.e. cohesive
forces).Viscosity therefore decreases with increasing temperature (https://memechanicalengineering.com/viscosity/, 18 October 2018).
Minimum Rotational Speed
It is essential to ensure that the agitation speed is sufficiently high to achieve
complete solid -liquid dispersion. Determining the minimum agitation speed, Nmin, is
therefore important for mixing vessels. Skelland and Seksaria (1978), for example,
reported that an impeller speed of 1000 rpm is not enough for complete dispersion.
Hu et al. (2006) showed that increasing agitation velocity causes phase reversal. The
speed at which the dispersed phase is fully unified with most of the fluid has been
defined as the minimum agitation speed. (Huang and Armenante, 1992). Skelland and
Sekasaria (1978) also showed the dependency on interfacial tension of the minimum
agitation speed.
Density of Fluids
Liquid density and the difference in density between two immiscible liquids is
one of the parameters affecting phase inversion, minimum agitation, speed, and
mixing power consumption. Musgrove et al. (2000) indicated that although dispersed
phase density influences drop failure, it can be considered a secondary effect. The
power requirement in the laminar region is independent of fluid density, although the
viscosity is directly proportional (Doran, 1995). However, power does not depend on
29
viscosity for turbulent flow but is directly related to density (Doran, 1995). Johnstone
and Thring (1957) claim that the required power at a specified speed is a function of
interfacial tension for low differences in viscosity and density.
The
mixing time for non-mixable liquid mixing is directly related to the fluid viscosity and
density. The differences in the interface area can be described for viscosity and density
differences. They also explained that continuous phase density and the viscosity ratio
of the two phases may affect the size of the drop.
Mechanization of Automatic Mixing
In each area, mechanization is characterized by three levels: low, fair and high.
Low level of mechanization means that the manual power used exceeded 33%. Fair
means that the use of animal energy ranges from 34% to 100%. High means that the
use of mechanical power ranges from 67% to 100% (Rodulfo et al., 1998). The
mechanization level in agrarian industries, expressed in three main sources of power:
manual, man-animal, and mechanical. On average, human power dominates
operations by 56.53%. Mechanical operations are mainly used in milling, cutting or
shelling, preparation of land and mixing. The mechanization level in terms of available
power expressed as horsepower per hectare (hp/ha) is 1.68 hp/ha. This is relatively
low compared to other neighboring countries. The reason is the abundance of manual
labor that dominates the use of human power in industry. The high hp/ha of power
tillers and threshers indicate that mechanical power is increasing in chemical
preparation.The Philippines ranks 9th in terms of mechanization at 0.52 hp / ha in 1990
in comparison with other countries in Asia. This is again very low compared to 7.00 hp
/ ha in Japan, 4.11 hp / ha in the Republic of Korea and 3.88 hp / ha in the People's
Republic of China (RNAM, 1994).Many experiments today, be it on the bench scale,
pilot scale, or industrial scale, involve the mixing of one or more reagents to produce
30
a reaction or to solubilize solid particles into a liquid medium. The efficiency of the
mixing process can be instrumental in determining whether the overall process is
viable on any scale and can be the difference between the reaction and the difference
between high and low yield.
(http://www.pcaarrd.dost.gov.ph/home/momentum/agmachin/index.php?option=c
om_content&view=article&id=296:level-of&catid=126&Itemid=286,
27
October
2018).
Mixing Principles
The efficiency of a mixing process is determined by the liquid flow rate, which
determines how much of a reagent or additive is solubilized in the system. Two main
types of fluidic laminar flow (uniform and non-uniform) and turbulent flow exist. The
flow type within a system is determined by one of two main parameters, the
volumetric fluid flow rate and the mass flow rate, depending on the mixing type. About
these flow parameters, the volumetric fluid flow deals with solutions and is governed
by the amount of solution that flows past a defined point at a certain time, whereas
the mass flow rate is the mass movement amount that flows past a given point.
Many factors can also affect the flow rate. The main parameters that can affect
the flow rate are fluid viscosity, liquid density, and fluid friction in contact with the
mixing vessel. The type of flow-derived mixing can be very important depending on
the size and type of the vessel. In most cases, a turbulent flow is beneficial because it
allows a better mixing both laterally and vertically in a mixing vessel. This is not always
possible,
however,
so
sometimes
laminar
mixing
needs
to
be
(https://www.chemicalprocessing.com/articles/2003/284/ , 27 October 2018).
used
31
Laminar Flow
Laminar type mixing is the least efficient method of mixing and is often used in
large pilot scale equipment such as food mixers or in magnetic stirring. Magnetic
stirring through stirrer hotplates can reach turbulent flow, but only a laminar flow at
lower speeds. A laminar flow is where the fluid is mixed in layers that pass through
each other. These can be uniform or non-uniform and lead respectively to
axisymmetric and asymmetric flows. The fluid in a laminar flow follows a smooth path
and the fluid layers never interfere, so why this type of mixture is not always effective.
In laminar mixing, however, the velocity of the fluid is constant at any point in the fluid.
Turbulent Flow
A turbulent flow ensures greater mixing efficiency and is often produced at
high speeds, whether from a stirrer hot plate, a vortex mixer, a ball mill mixer or a highspeed mixer. A turbulent flow distorts the interface between the fluid layers in the
mixing vessels, breaks them down, and allows mixing in both lateral and vertical
dimensions, unlike
the laminar flow. Turbulent mixing often forms whirlpools; if the
reaction vessel you use has not formed a whirlpool, and then a turbulent flow has not
been achieved. Turbulent Flow mixing particularly useful for solubilization and mixing
of reactants because it allows all components to be mixed in all three dimensions of
the vessel. At much higher speeds, a turbulent flow occurs as the energy required to
break the interface is high, but at every point, the fluid velocity is not constant. The
point of turbulence of a flow is often defined by the Reynolds number
(https://www.chemicalprocessing.com/articles/2003/284/ , 27 October 2018).
32
Reynolds Number
The Reynolds number is a dimensionless value used to predict the fluid flow
patterns. This extends to the overall fluid flow and the mixing process flow. Reynolds
number combines the fluid density parameters, the fluid velocity, a linear dimension
measured in meters, the fluid's dynamic viscosity and the fluid's kinematic velocity to
output a number corresponding to whether a fluid has a laminar or turbulent flow
pattern. Simply put, the Reynolds number is controlled by the ratio of inertial forces
and viscosity forces inside the fluid. The value for turbulent flow depends on the type,
size, and shape of the particles in the fluid solution and therefore a variable amount
depends on the process.
Related Studies
Some unsolvable mixing problem involved the physical and chemical property.
Those properties might make the solution effective and desirable. One particularly
difficult property was viscosity. Viscosity is a non-Newtonian behavior that has the
effect of resisting fluid motion. The motion created by the manual operation of mixing
process in viscous fluids may dropdown before it moves the entire tank. This
contributes high potential of the fluids to remain unmixed because of inadequate fluid
motion. Fluids with more than 1000 Cp (1 Pa-s) is considered high viscous. One
approach that would be simple and would make the products easy to mix was using
large impeller. To achieve the desired result, mixing really matters therefore selecting
the right impeller including turbulence, mixing conditions at the bottom of the tank
must be considered. According to the workers of Mayo Holdings, chemical addition are
often problems, the chemical powders may be soluble and insoluble and as the
chemical powders diluted on water, extended mixing times was needed for intense
33
process breaking and homogeneity state to be completed. Another is poor mixing since
incomplete motion was handled manually; fluid in the bottom of the tank couldn’t
move. While in a study conducted by Ronald J. Wetman, principal researcher of mixer
mechanical design it is important to create improvements to match the best and costeffective mixing equipment is by modifying the existing mixing process. Perhaps
designing impeller produces uniformity on chemical mixing especially in viscous fluids.
The major concern to use a lower rotational speed may be a critical factor to cause the
fluid to rotate as high viscous fluids needs time to flow. The manual chemical mixing
process may fail; therefore, process development may should establish a range of
systematize process to produce a successful product. The study can be a great help to
mechanized improvements about chemical mixing. Further tests and study may reveal
the best solution to at least convert difficult mixing problems into optimal one.
34
Synthesis
As the requirement of the study, the researchers were able to gather
knowledge from the different literature from the library, books, recent thesis, internet,
for the better understanding and gain extra knowledge about the selected study. The
proponents are provided with the information needed in the Design of Manual
Chemical Mixer into Mechanized Chemical Mixer Tank at Mayo Holdings Inc. Brgy.
Milagrosa,Calamba City Laguna.
Based on the gathered information, there are different ways for successful
operations to mix chemicals through mechanical design to improve uniformity and
homogeneity of chemicals. One way is by applying process and mechanical criteria that
can be used for efficient and useful operation of the design further than the present
system. The problem of the company is how to mix the mixture into a homogenous
mixture that has no dregs and how to produce mixed chemicals in effective time
without 24-hrs delay before transferring in the container and maintain safer
workplace.
In general, it includes the process of impeller selection with rotating shafts and
motor. Flow pattern could be laminar or turbulent flow, which is important
consideration for the impeller to drive the chemicals hydraulic forces. Design variables
are used to determine the torque with required power. Lastly, for special purpose
mixers, customized design of elements was considered.
The literature will serve as the guide and consideration for the Design of
Manual Chemical Mixer into Mechanized Chemical Mixer Tank at Mayo Holdings Inc.
Brgy. Milagrosa,Calamba City Laguna to be useful to the company and gain some profit
into it.
35
Definition of Terms
304SS Stainless Steel. Grade 304 stainless steel is standard stainless composed of 18%
chromium and 8% nickel that you see on a wide variety of home applications, pans,
and cookery tools. Some of its characteristics is excellent toughness, high temperature
properties responding well to hot working.
Alkaline Solution. It is any base soluble with high Ph chemical property that can
neutralize extreme effect of concentration.
Baffle. It checks the flow of a liquid or vapour through the tank and conducive for total
mixing. It can prevent undesirable flow pattern of swirling.
Blending. It is used to describe miscible liquid mixing, but relatively gentle process
compares to mixing.
Breakdown. This refers to technical failure causing operating downtime above 10
minutes.
Chemical Mixing. Combining thoroughly of specialty chemicals into homogenous
product. It is usually associated on liquid-liquid and viscous materials
Declogger/Degreaser. A very strong, high concentrated alkali solution that will readily
dissolve fats, oil and grease inside drain pipes.
Gear Drive. A mechanical device requiring gears for operation that will transfer power
source from the driven gear.
Homogenous Mixture. Type of mixture that will have the same properties throughout
the process.
36
Immiscible Liquid. It is the property of substance that were able to form homogenous
mixture.
Impeller. It is a rotating component designed to mix fluids in the tank when there is
deformable interface to break. Mixing liquids and solids is very important if their
gradients in conditions such as temperature or concentration.
Mechanization. This refers to factor that will determine competitive advantages using
use machines, technology, and automation to dominate manual labor. It is also the
act of overcoming present challenges in the production and uses them to their fullest
capacities.
Mechanical Energy. It is the required energy with the motion of the object to rotate
the impeller, which in turn transmit the energy to the fluid to do work.
Mixing. It is used for dispersions of immiscible liquids or the formation of emulsions.
Radial Flow. Type of flow created to mix immiscible and very viscous fluids. Flow enters
axially and leaves the impeller radially.
Shear Stress. Friction due to fluid viscosity, acting parallel between mixed fluids.
Turbulence. Refers to the unsteady movement of flow or fluid fluctuations. The speed
of the fluid constantly changes, such as inside the wall of the tank, or in cases of fluids
with high viscosity.
Viscous Fluids. It is a real fluid which has high amount of viscosity, in this research the
fluid is the mixture of water and chemicals which offers higher resistance to shear
deformation.
Viscosity. It is the measure of “thickness” of fluid, perceived as resistance to pouring.
37
CHAPTER III
This chapter aimed to provide the detailed present system with complete
operational procedure. Presentation of alternative solutions was also highlighted in
this chapter.
TECHNICAL STUDY
Description of the Present Study
Mayo Holdings Inc. recently underwent an expansion project to their company
in order to supply to clients the chemical degreaser and declogger, a chemical product
which will thoroughly remove fat deposits from pipeline. To produce these chemicals,
mixing of strong, highly concentrated solutions was manipulated by human operator,
by using standard plastic drum-open type. Part of the raw products, with 5-10 parts or
50 gallons of water, was poured into the drum by means of hand. They were dissolving
the mixture per drum using a long medium (stainless paddle) for a 10-minutes duration
of continuous mixing, in which after having a mixed solution for the declogger, they
were subjected to wait for 24 hours before manually transferring the final mix solution
from drum to a 20 kg of container to avoid extreme heat exposed by the declogger
when it was newly mixed. Extreme handling of product while dispensing must be
fulfilled since it can discolor and dissolve clothing materials, leather, and other porous
materials. There are fifteen flat-bottomed plastic drums made of HDPE (high density
polyethylene) which has an exact inside dimensions of 23.4 in (595mm) diameter and
36.6 in (950 mm) height. These dimensions yield a volume of about 200 liters (55
gallons). Approximately 500-550 gallons was weighed weekly.
38
Focus of the Study
Mixing tank was the central feature used for hassle free storage of large
amount of chemicals in several industries. In the manual mixing of chemicals, manual
mixing may mean too long for the final mix and the operator is upon to perform unsafe
tasks. Simple mixing duties but it involves chemical reaction that is often dangerous.
Also, there is no overall bulk or convective flow therefore stagnant regions exist within
surface area. To satisfy chemical mixing duties and since there is need in production
efficiency for releasing on time to clients. A chemical mixer tank made of stainless steel
with impeller, powered by a motor seemed like a reasonable opportunity to pursue
the study.
39
Definition of product need, market
information
Conceptual design and evaluation, case
study
Design Analysis, physical model
Solid Works
Software
Prototype Production, Testing and
Evaluation
Manufacture
Figure 1. Manufacturing Process of Mayo Holdings Inc. Chemical Mixing Process
40
Mayo Holdings
Inc. Mixing
Facility
Manufactur
er
Chemica
l
Additive
s
DG07
40
Chemical
Degrease
r
Chemic
al
Declogg
er
Batching
AmpothergSoda Ash
e
Light
Soft
Water
Addition
Sodium
Trilon B
Metasilicate
Dispensing
24
Hrs.
55
Gallons
Liquid Mixing Heat Releasing
(10 minutes)
5.3
Gallon
s
Packaging
Delivery to
Clients
Figure 2. Schematic Flow Diagram of Mayo Holdings Inc. Present System
41
LEGEND:
Chemical Powders
Cart
Water Faucet
Drum (HPDE)
PPE Storage
Figure 3. Plant Layout
42
Analysis of the Present System
The present mixing system must be analyzed in order to determine the improvements
brought by each alternative solution. The analysation of the present system is divided
into three parts; the total capacity required, blending time, and distribution of mixed
products. A systematic presentation to help the readers easily understands the present
mixing system of Mayo Holdings Inc.
As the research was started last 2018, it was mentioned by one of the
personnel that the average quota per month was 300 piece of 20 kg filled containers
for declogger and degreaser. As of 2019, average quota for each chemical must
increase from the present quota of 300 pieces to 500 pieces of contained chemical
monthly due to demand of clients.
Capacity Required:
The present capacity demand is essential information whether the proposed
solutions have the capacity to meet the demand. Necessary data gathering was done
by the researchers. The researchers requested the company for the total capacity
needed to produce per month;
Consider 500 pieces of container,
(500 pieces/month) (20 kg. Filled container/ piece)
= (10,000 kg/ month), multiplied by two since there are two types of
chemical needed to be produced in the company.
20,000 kg/ month
43
Note:

Per day, they are mixing an average of five drums (almost 50 gallons each)

In mixing each drum, including the pouring of water and powder to be
dissolved, the average duration is 20 minutes per drum.
20
minutes
20
minutes
20
minutes
20
minutes
20
minutes
Figure 4. Present System Mixing Duration
Provided that,
Actual volume of solution per drum,
For height of chemical solution contained in each drum:
33. 2 in x 1 ft/12 in. = 2.77 ft x .3048 m/ 1 ft. = 0.84 m
For diameter of contained solution in each drum:
21.25 in x 1 ft/12 in = 1.77 ft x .3048 m/ 1 ft = 0.539 ≈0.54 m
44
Thus,
𝜋
𝜋
(𝑑 2 ) (h) = 4 (. 54 𝑚 2 )(.84 m)
4
Actual volume of solution per drum = 0.192 𝑚 3 x 1000 li / 𝑚 3
192 li x 1 gallon/ 3.785 li = 50. 73 gallons per drum
5 x 50.73 gallons (actual volume of solution per drum)
= 253. 65 gallons/ day
253.65 gallons/ day x 3.785 li / 1 gallon = 960. 169 liters
Therefore, the company has a capacity to produce 253. 65 gallons per day,
which is equivalent to 960. 169 liter per day.
Up to how many 20 kg filled containers will they be able to produce each day?
Density of chemical = 1.458 kg/ li.
(1.458 kg/ li)(960. 169 liter) = 1399.926 kg/ Day
(1399.926 kg/day) / 20 kg per piece
= 69.996 pcs / container per day
An average of 70 pieces of container/ day
45
Duration of mixing an average of 5 drums each day is,
= (20 minutes/ drum) (5 pc. of drum/ day)
100 minutes or 1 hour and 40 minutes
*In present system, there are 400 revolution to meet solubility and homogeneity (10
minute continuous mixing duration) , but additional 2 minutes happens whenever
there are suspension at the bottom of the tank ;therefore, there is 480 revolution for
12 minutes (40 rev. per minute) for 50.73 gallons in manual set up just to meet the
desired solubility of chemicals
*40 rpm in manual mixing is derived based on observing the actual mixing operation.
46
Scope: This OP applies to all Mayo Holding Inc. Operators that are involved in the
manual chemical mixing of chemical addition.
Purpose: This Operating Procedure (OP)* provides guidelines to ensure that
chemical (declogger and degreaser ) used in drain lines and pipe activities are
properly mixed, thus protecting equipment performance and total de-clogging of the
system.
Preparation of Raw Materials
Pouring of soft water into Drum
Additon of Raw Chemicals
Liquid Mix Processing(Manually Operated)
24 hours chemical heat releasing
Container Packaging
Shipping
Figure 5. Operating Procedures (OP)*
47
Presentation of Alternative Solutions
Based on the gathered data, the researchers came up with three alternative
solutions that would improve reliability on significant demands of chemical processing
under mechanical behaviour conditions.
Alternative No 1: Design of radial flow impeller agitator
Figure 6. Technical Design of Alternative No.1
48
Technical Description
The alternative solution under consideration would allow operators to
minimize risks on chemicals associated with their present system. The design of mixer
included standard impeller agitator generating radial flow patterns. The fluid moves
radially or tangentially to the impeller. The radial flow type produces the contents of
the mixing to move towards the side of the drum which, in turn, form either an up or
down direction. It is a four-bladed revolving impeller that moves full revolution at a
fixed distance of the liquid constructed from stainless steel. The roller which is
mounted on the wall will serve as adjustable device to level the impeller blade to the
opening of the drum.
Advantages

It could be easily fixed or repaired in terms of corrective maintenance.

There was easy maintenance because parts can be easily availed at the
market.

Manual labor was lessened due to adjustable roller and design of impeller,
therefore fewer operators are needed and unwanted downtime processing
decreases.
Disadvantages

There would be a spillage during packaging because another 24-hour break is
needed, so the packaging operations are thru manual operations.

Introduction of technical skills to operators would be offered for safety
operations.
49
Proposed Procedure of Alternative Solution No. 1
Responsible
Procedural Flow
Tasks
Start-up
Production Manager

Complies with all the
requirements
in
mixing operation
Batching Process
Mixing Operator

Collect raw materials
in single batch

Arrange raw materials
according
to
its
content

Prepare the mixture
that has the right
chemical composition

Monitor the water
supply on the drum

Ensure the right speed
and
mixing
time
related
to
the
operating procedure

Switches ON the
impeller motor
Degreaser
Sorting Process
Mixing Operator
Declogger
Raw Materials
Preparation
Pouring of Soft
water into drum
Liquid Mixing Proper
( Radial Flow)
Mixing Operator
Mixing Operator
Mixing Operator

Chemical Heat
Releasing
Mixing Operator
Wait
until
the
chemical
releasing
 completed

Packaging
Mixing Operator
Collect the mixed
products and transfer
to 20 Liter container
Figure 7. Proposed Procedures of Radial Flow Impeller Mixing Equipment
50
Figure 8. Schematic Flow Diagram (Radial Flow Mixing)
51
Design and Calculations for Alternative 1:
*Note: The HDPE Drum that was used in this alternative solution was based from the
present system of the facility.
(Based from the manufacturer’s data of HDPE Drum)
55 Gallon drum specifications and dimensions:
Weight = 40 lbs.
Diameter (𝐷𝑡 )= 22.5 in = 0.57 m
Height =33.5 in = 0.85 m
Six Dimensions and Typical Proportion:
(Reference: Handbook of Industrial Mixing; Science and Practice, Edited by Edward L.
Paul, Suzanne M. Cresto, 2004, p. 1247)
1. for the type of flow,
* To determine the desired transport of chemical and physical reactions of fluids
through important type of fluid flow
𝐃𝐚 𝟏
=
𝐃𝐭 𝟑
Where: 𝐷𝑡 = Diameter of Tank
𝐷𝑎 = Diameter of Impeller
This ratio is important and may be varied in range:
0.2 ≤
Da
≤ .5
Dt
(Turbulent flow)
52
0.7 ≤
Da
Dt
≤ .1
(Laminar flow)
Therefore:
1
1
𝐷𝑎 = 3 (𝐷) = 3 (. 5716) = 0.19 m
Scale up of the actual Process:
𝟎. 𝟐 ≤
𝑫𝒂
𝑫𝒕
≤. 𝟓
(𝑻𝒖𝒓𝒃𝒖𝒍𝒆𝒏𝒕 𝒇𝒍𝒐𝒘)
(b.) Side View
(a.) Bottom View
Figure No.9 Turbulent Flow Pattern Produce by Radial Flow Impeller
2. Fluid Level in the Tank,
Hf
Dt
, (normal range: 0.5- 1)
For Hf : Volume of Fluid (Vf )
Conversion of gal to m3: 1gallon=3.78 x 10−3 m3
53
Vf = (50.7 gal)(
0.191 = π(
3.78 x 10−3 m3
1 gal
) = 0.191 m3
0.57 2
) (hf )
2
hf = 0.70 m
H
Note: If D > 1 , addition of impeller is required
t
3. Bottom Clearance
c
1
=
Dt 3
Where: c = distance from impeller diameter to bottom of the tank
1
1
c = (Dt ) = (0.57) = 𝟎. 𝟏𝟗 𝐦
3
3
Therefore, the distance of impeller from the bottom of the tank is 0.19 m.
4. Width of the blade
w 1
=
Da 5
1
1
w = (Da ) = (0.19) = 𝟎. 𝟎𝟑𝟖 𝐦
5
5
5. Length of the blade
L 1
=
Da 4
1
1
L = (Da ) = (0.19) = 𝟎. 𝟎𝟒𝟖 𝐦
4
4
6. No. of impeller blades: 3
Manufacturer’s data: Operative range of 50-150 gallons capacity drum
54
0.5716m
0.84m
0.038m
0.048m
0.19m
Figure 10. Dimensions of Tank and Impeller
Required Power Consumption for turbulent flow and 55-gallon drum:
Pdriven = Power required = .50 HP (based from Engr. Ramos)
Use Pdriven = .50 Hp (based on market availablity)
For the Power of the driven,𝑷𝒅𝒓𝒊𝒗𝒆𝒏 :
For the Torque, T:
(See appendices for N used for 0.5 HP motor with respect to fluid viscosity)
For the torque of shaft with transmitted Hp:
T=
Where: P = transmitted Hp
30 P
N = shaft speed, in rpm
πN
T = torque, kN − m
55
For required rpm of motor related with the ideal mixing time (three minutes) of
alternative solution no.1:
a. provided that there is a 480 needed revolution in order to dissolve 50.73
gallons.
For multiplier or factor:
50. 73 gallons / 50. 73 gallons = alternate 1 capacity/ present set up capacity
= 1
1 x 480 rev =480
Therefore, 480 rev is required in order to dissolve 50.73 gallons of chemical
solution.
For ideal revolution per minute of each alternative solution in order to attain
solubility in just 3 minutes
[(40 rpm) (12 min)] / (50.73 gallons) = [ 𝑁1 ( 3 min)] / (50.73 gallons)
160 rpm = 𝑵𝟏
Thus,
T=
30 ( 0.5)(
0.746kW
)
Hp
π (160)
𝐓= 0.0222 kN-m,
Solving for the shaft diameter, 𝑫𝒔 : (Reference: Shafting formulas from Machinery’s
Handbook)
For the shaft under pure tension only:
SS =
16 T
π( D3 )
(For solid circular shaft)
Where:
Ss = Shear Stress, Kpa
D = diameter of shaft , m
56
From Maximum-Shear Stress Theory, 𝐒𝐬 (Equation):
Ssmax =
SY
Where: Sy = Yield Strength, kPa
FS
FS = Factor of Safety
For the Factor of Safety, (See appendices for the Design Factor of Safety
Related to Stress, Faires: p.279)
FS = 3 (Suddenly Applied, Heavy Shocks)
For the Sy of Material AISI No. 304, (See appendices for the Typical
Properties of Stainless Steels, Faires: p.568)
101.325𝑘𝑃𝑎
Sy = 35 psi(
14.7𝑝𝑠𝑖
)
𝐒𝐲 = 𝟐𝟒𝟏, 𝟐𝟓𝟎 𝐤𝐏𝐚
Ssmax =
3
241,250
3
16𝑇
3
= 80,416.67 kpa
16( 0.0222)
𝐷 = √𝜋( S
=√
𝜋( 80,416.67)
smax )
D = 0.0112 m =11.2 mm
Use, say, 15/16 𝐢𝐧𝐜𝐡 ∅ (Based on commercial sizes of shafts, inches (Faires: p.269)
Length of Shaft
1
1
Ls = Ht − (Dt ) Ls = 0.851 − (0.851) = 0.57 m
3
3
Length of Blade
1
1
(𝐷𝑇 ) = (0.5716) = 𝟎. 𝟏𝟒𝟑 𝐦
4
4
57
Table 2. Material and Specification of Alternative No. 1
Materials
Unit
Quantity
Specifications
HDPE Drum
piece
15
50 gallons/drum
Motor
Piece
1
0.5 HP
Impeller
piece
3
Three bladed
7.5” Radial Flow with
1/2” bore
Shafting
piece
1
15
16
in ∅ x 22.5 in,
(Overhung),
Stainless Steel
Mechanical Seals
piece
1
≤ 15𝑚/𝑠
Angular Steel Bar
piece
5
3
3
3
in x in x in x36 in
16
2
2
Round Bar
Piece
2
1 “∅ x 12 in
*Note: The HDPE Drum that was used in this alternative solution was based
from the present system of the facility
58
Benefit of the Project
The completion of the study would benefit Mayo Holdings Inc. to give solutions
on how the company can maximize the use of this alternative solution as it utilizes and
accelerate the mixing time than the conventional system, it will also be benefit to them
because the employee will have extra time to do another task.
59
Alternative Number 2: Design of three axial flow impeller with 200 gallons capacity
per drum
Figure 11. Technical Design of Alternative No. 2
60
Technical Description
From the features of the impeller type mixing equipment, the second proposed
alternate solution utilized axial flow impeller. The vessel was made up of HDPE (high
density poly propylene) plastic drum material. The DC electric motor was used to
rotate the shaft of impeller. There was a gear reducer attached to the electric motor
that could be used to achieve wide range of speeds. This allows for fast and
mechanized mixing without requiring a lot of time and effort. Axial flow impeller
generated through the axis of the impeller shaft. The narrow and twisted blade design
produced a centrifugal force while maximizing flow rates and pattern to achieve
homogeneity and solid suspension on the bottom of the tank. The impeller diameter
is 33% of the drum diameters. The fluid mixing time speeds up since there was 200
gallon of fluid capacity per drum. It gives an indication of typical mix say 100 kg (4 bags
of raw products) for declogger and 107 kilos for degreaser and 150 gallons of water
per drum will be mixed for only one day. This means that the mixer was producing 20
gallons of liquid per minute per drum or 590 gallons more than the first alternative
solution. There was a clearance between the impeller and the bottom of the tank.
61
Advantages

Non-critical machinery, since material used is HDPE plastic.

It requires less frequent monitoring because of capacity it can convey.

Low safety risk, designed impeller creates flow that avoid spillages and
unwanted dispense even at critical speeds and chemical property.

It was time efficient for the reason that there is no need to wait for 24
hours.

If downtime occurs by one system, the operation and production of the
remaining two systems continues.
Disadvantages
 It requires a motor with a bigger size.
 Plastic drum may thermally react to chemicals affecting final product
properties.
62
Proposed Procedure of Alternative Solution No. 2
Responsible
Procedural Flow
Production Manager
Start-up
Batching Process
Mixing Operator
Tasks

Complies with all the
requirements
in
mixing operation

Collect raw materials
in single batch

Arrange raw materials
according
to
its
content

Prepare the mixture
that has the right
chemical composition

Monitor the water
supply on the drum

Ensure the right speed
and
mixing
time
related
to
the
operating procedure

Switches ON the
impeller motor
Degreaser
Sorting Process
Declogger
Raw Materials
Preparation
Pouring of Soft
water into drum
Liquid Mixing Proper
( Axial Flow)
Chemical Heat
Releasing
Mixing Operator
Mixing Operator
Mixing Operator
Mixing Operator
Mixing Operator

Wait
until
the
chemical
releasing
 completed

Packaging
Mixing Operator
Collect the mixed
products and transfer
to 20 Liter container
Figure 12. Proposed Procedures of Axial Flow Mixing Equipment
63
Figure 13. Schematic Flow Diagram of Axial Flow Mixing Equipment
64
Design and Calculations for Alternative No.2
For the HDPE drum:
(Based from the manufacturer’s data of HDPE drum)
𝑉𝑡 = 900 𝐿𝑖𝑡𝑒𝑟𝑠 (237.75𝑔𝑎𝑙𝑙𝑜𝑛𝑠)
𝐷𝑡 = 1100 𝑚𝑚
Thickness, t = 0.015 m
Inside Diameter, 𝐷𝑡 = 𝐷𝑜 − 2𝑡 = .932 − 2(0.015) = .90 𝑚
𝐻𝑡 =1000 mm = 1m
Six Dimensions and Typical Proportion:
(Reference: Handbook of Industrial Mixing; Science and Practice, Edited by
Edward L. Paul, Suzanne M. Cresto, 2004, p. 1247)
1. For the type of flow,
𝐃𝐚 𝟏
=
𝐃𝐭 𝟑
Where: 𝐷𝑡 = Diameter of Tank
𝐷𝑎 = Diameter of Impeller
This ratio is important and may be varied in range:
0.2 ≤
0.7 ≤
Da
≤ .5
Dt
Da
Dt
≤ .1
(Turbulent flow)
(Laminar flow)
65
Therefore:
1
1
𝐷𝑎 = 3 (𝐷) = 3 (1.1) = 0.367 m
Scale up of the actual Process:
𝟎. 𝟐 ≤
𝑫𝒂
𝑫𝒕
≤. 𝟓
(a.) Side View
(𝑻𝒖𝒓𝒃𝒖𝒍𝒆𝒏𝒕 𝒇𝒍𝒐𝒘)
(b.) Bottom View
Figure 14. Turbulent Flow Pattern Produce by Axial Flow Impeller
2. Fluid level in the tank,
𝐻𝑓
𝐷𝑡
, (normal range: 0.5- 1)
For 𝐻𝑓 : Volume of Fluid (𝑉𝑓 )
66
𝑉𝑓 = 𝜋𝑟 2 ℎ𝑓
Conversion of 𝑔𝑎𝑙 𝑡𝑜 𝑚3 : 1gallon=3.78 𝑥 10−3
𝑉𝑓 = (200 𝑔𝑎𝑙) (
0.756 = 𝜋(
3.78 𝑥 10−3 𝑚 3
1 𝑔𝑎𝑙
) = 0.756 𝑚3
1.1 2
) (ℎ𝑓 )
2
ℎ𝑓 = 0.80 m
𝐻
Note: If 𝐷 > 1 , 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝑖𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝑡
3. Bottom Clearance
c
1
=
Dt 3
Where: c = distance from impeller diameter to bottom of the tank
1
1
𝑐 = (𝐷𝑡 ) = (1.1) = 𝟎. 𝟑𝟕 𝒎
3
3
Therefore, the distance of impeller from the bottom of the tank is 0.38 m
4. Width of the blade
𝑤
1
=
𝐷𝑎 5
1
1
𝒘 = (𝐷𝑎 ) = (0.367) = 𝟎. 𝟎𝟕𝟑 𝒎
5
5
5. Length of the blade
𝑳
=
𝟏
𝑫𝒂 𝟒
1
1
L = (Da ) = (0.367) = 𝟎. 𝟎𝟗𝟐 𝒎
4
4
6. No. of impeller blades: 4
Manufacturer’s data: Operative range of 150-200 gallons capacity drum
67
1.1m
1m
0.073m
0.092m
0.37m
Figure 15. Dimensions of Tank and Impeller (Axial Flow)
Required Power Consumption for turbulent flow and 200 gallon drum:
𝑃𝑑𝑟𝑖𝑣𝑒𝑛 = Power required = .50 HP (based from Engr. Ramos)
Use 𝑃𝑑𝑟𝑖𝑣𝑒𝑛 = .50 𝐻𝑝 (𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑚𝑎𝑟𝑘𝑒𝑡 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑖𝑡𝑦)
For the Power of the driven,𝑷𝒅𝒓𝒊𝒗𝒆𝒏 :
For the Torque, T:
(See appendices for N used for 0.5 HP motor with respect to fluid viscosity)
For the torque of shaft with transmitted Hp:
T=
30 P
πN
Where: P = transmitted Hp
N = shaft speed, in rpm
T = torque, kN − m
68
For required rpm of motor related with the ideal mixing time (three minutes) of
alternative solution no.2:
200 gallons / 50. 73 gallons = alternate 2 capacity/ present set up capacity
= 3.942
3.942 x 480 rev = 1892.16
Therefore1892.16 rev is required in order to dissolve 200 gallons of chemical
solution.
For ideal revolution per minute of each alternative solution in order to attain
solubility in just 3 minutes
[(40 rpm)(12 min)] / (50.73 gallons) = [ 𝑁2 ( 3 min)] / (200 gallons)
630. 79 rpm = 𝑵𝟐
T=
0.746kW
)
Hp
30 ( 0.5)(
π (630)
𝐓=𝟓. 𝟔𝟓 𝒙𝟏𝟎−𝟑 kN-m,
Solving for the shaft diameter, 𝑫𝒔 : (Reference: Machine Design II by Jose R.
Francisco, PME))
For the shaft under pure tension only:
16 T
SS = π( D3) (For solid circular shaft)
From Maximum-Shear Stress Theory, 𝐒𝐬 (Equation):
Ssmax =
SY
FS
Where: Sy = Yield Strength, kPa
FS = Factor of Safety
69
For the Factor of Safety, (See appendices for the Design Factor of Safety
Related to Stress, Faires: p.279)
FS = 3 (Suddenly Applied, Heavy Shocks)
For the Sy of Material AISI No. 304, (See appendices for the Typical
Properties of Stainless Steels, Faires : p.568)
101.325𝑘𝑃𝑎
Sy = 35 psi(
14.7𝑝𝑠𝑖
)
𝐒𝐲 = 𝟐𝟒𝟏, 𝟐𝟓𝟎 𝐤𝐏𝐚
Ssmax =
241,250
3
16𝑇
3
𝐷 = √ 𝜋( S
smax
3
= 80,416.67 kpa
=√
)
16( 5.65 𝑥10−3 )
𝜋( 80,416.67)
𝐃 = 𝟎. 𝟎𝟕𝟗 𝐦 =70.9 mm =2.79”
𝟏𝟓
Use, say, 2
𝟏𝟔
𝐢𝐧𝐜𝐡 ∅ , (Based on commercial sizes of shafts, inches,Faires: p.269)
Length of Shaft
1
1
Ls = Ht − 3 (Dt ) = 1.44 − 3 (.90)
𝐋𝐬 = 𝟏. 𝟏𝟒 𝐦
Length of Blade
1
1
(𝐷𝑇 ) = (0.1.1) = 𝟎. 𝟐𝟕𝟓 𝐦
4
4
Blending Time = 3-20 minutes
70
Alternative No. 2: Design of three axial flow impeller with 200 gallons capacity
Material and Specification
Table 3. Material and Specification of Alternative No. 2
Materials
Unit
Quantity
Specifications
HDPE drum
piece
3
200 gallons
Motor
piece
3
0.50 HP
3
4 bladed /piece,
Impeller
piece
7.5” Axial Flow with
3/8” bore
15
Shafting
piece
3
2 16 𝑖𝑛 ∅ 𝑥 45 𝑖𝑛,
(Overhung), Stainless
Steel
Mechanical Seals
piece
3
≤ 15𝑚/𝑠
Angular Steel Bar
piece
12
3
1
1
𝑖𝑛𝑥 1 𝑖𝑛 𝑥1 𝑖𝑛 𝑥 36𝑖𝑛
16
2
2
Angular Steel Bar
piece
12
3
1
1
𝑖𝑛𝑥 1 𝑖𝑛 𝑥1 𝑖𝑛 𝑥 72𝑖𝑛
16
2
2
Angular Steel Bar
piece
12
3
1
1
𝑖𝑛𝑥 1 𝑖𝑛 𝑥1 𝑖𝑛 𝑥 42𝑖𝑛
16
2
2
Flat Bar
piece
6
1
1
𝑖𝑛 𝑥 1 𝑥 3.5 𝑓𝑡
8
2
Start Switch
Piece
3
120V AC/ 60 Hz
Rubber Sealant
Piece
3
0.60 𝑚 2
71
Benefit
The variety of chemicals will easily load and mix well in the drum based on the
designed capacity. The chemical mixture can easily transfer out through the dispense
under the tank which can prevent any accidents and wastages. Additional manpower
will not be necessary, but it will continue to improve company profits through the
rising of productivity. This will replace the conventional system in mixing large scale
of chemical products simultaneously.
72
ELECTRIC MOTOR
SHAFTING
AXIAL FLOW
IMPELLER BLADE
BLADES
HDPE TANK
DISPENSE
BALL VALVE
STEEL SUPPORT
Figure 16. Components of Axial Flow Impeller Mixing Equipment
73
Figure 17. Equipment layout of axial flow impeller and maximize into three drums
with 200 gallons capacity per drum
74
Alternative Number 3: Design of Double Dynaflow Impeller Agitator
Figure 18. Isometric View of Double Dynaflow Impeller Mixing Equipment
75
Figure 19. Technical design of Alternative No.3
76
Technical Description
The third proposed alternative solution holds the efficiency goal to
ensure all components are well mixed at limited energy input. It was designed to
install It is designed to install double shaft with three bladed dyna-flow (hydro
flow) impeller type. Dyna-flow (hydro flow) has a camber that increases the
efficiency of the impeller and reduces its power/pumping ratio, this type of
impeller was well selected on a shear sensitive application. It was the most
important part that rotates by heavy-duty motor. To avoid vibration, proper base
was attached to the motor. There was a shaft t connecting the motor and
impeller blade. A level indicator was included to see if impeller is moving and the
fluid was disturbed or not. There was inlet pipe to fill the tank of raw materials
and outlet pipe for the mixed product. There would be 304 stainless steel shafts,
impeller, pipes, and vessel for installation to guarantee mechanical strength and
long-life spans. Four standard bases will support the weight of the machine.
Advantages

The hydroflow impeller produces mixing intensity that is parallel to the shaft so
there is no solid suspension left on the bottom of the tank, therefore achieving
homogeneity of final mix.

Fewer operators are needed since impeller design will take
responsibility of the mixing process.

The stainless steel is strong and durable, it is not prone to react with the
property of chemicals to be mixed, and construction material used is 304
stainless steel tanks.
77

Its safety dispense is designed appropriately to avoid 24 hours downtime due
to heat exposure of finish mix, right after mixing, it can be processed for
packing in container.

It has a tank cover which is useful to prevent chemical debris and safety.

The use of stainless steel as a material of the tank is an advantage for
preventive maintenance since the company formulates cleaning
its
reagents
for metal equipment.

It has a tank cover which was useful to prevent chemical debris and safety.
Disadvantages

It requires a new facility layout.

There is high maintenance cost.

It may be dangerous when a serious unsafe act befalls.

Operation and production stops if there is trouble or maintenance to be
performed.
78
Proposed Procedure of Double DynaFlow Mixing Equipment
Responsible
Procedural Flow
Start-up
Production Manager
Batching Process
Mixing Operator
Degreaser
Sorting Process
Raw Materials
Preparation
Pouring of Soft
water into drum

Complies with all the
requirements
in
mixing operation

Collect raw materials
in single batch

Arrange raw materials
according
to
its
content

Prepare the mixture
that has the right
chemical composition

Monitor the water
supply on the drum
Mixing Operator
Declogger
Mixing Operator
Mixing Operator

Ensure the right speed
and
mixing
time
related
to
the
operating procedure

Switches ON the
impeller motor

Wait
until
the
chemical
releasing
completed
Mixing Operator
Liquid Mixing Proper
( Double DynaFlow)
Chemical Heat
Releasing
Mixing Operator


Packaging
Tasks
Mixing Operator
Collect the mixed
products and transfer
to 20 Liter container
Figure 20. Proposed Procedures of Double Dynaflow Impeller Mixing Equipment
79
Figure 21. Schematic Flow Diagram (Double DynaFlow Impeller Mixing)
80
Design Calculations
For desired capacity of alternate solution no. 3 , it was targeted to exceed the total
no. of filled containers, that a present set up can produce, by range of 100 to 150 % in
just 3 minutes.
The researchers decided to get the mean percentage between 100 % and 150 %,
(100 + 150 )/ 2 = 125 %
125 percent of 70 filled containers per day in present set up,
1.25(70) = 87.5 additional number of filled containers that can be produced.
By convention:
it stands to round it off into highest place value,to have and additional of 90
finished products compared to the present set-up.
Also consider:
125 percent of the average capacity (253. 65 gallons) that can be produced
in mixing per day
Is 317. 06 gallons
Therefore, the needed capacity that this alternate solution can handle is
317. 06 gallons + 253. 65 gallons = 570. 71 gallons
The desired capacity for alternate solution no. 3 = 600 gallons
For the capacity and height of water to be filled in the tank before putting in
the powder chemical:
81
*In present set up, it was mentioned by one of the warehouse staff that they are
pouring firstly, 75% of the total capacity of the drum before putting in the powder to
be dissolved.
Level indicator of water to be poured in the present set up:
33.2 in = 0.84 m
=
0 .75(.84 m)
=
0 .63 m
For volume of water to be poured in the present set up:
=
.75 (50.73 gallons)
=
38.04 gallons
For attainment of alternative solution no. 3 (600 gallons capacity, provided
that there will be a clearance of solution from the top)
The proposed height of tank is 55” and diameter is 65, in which the height (10
inches) from the bottom is in conical shape.
For the volume of cylindrical portion of the tank:
Height: 45 in x
2.54 𝑐𝑚
1 𝑖𝑛
114.3 cm x
= 114.3 cm
1𝑚
100 𝑐𝑚
𝐇𝐭 = 1.143 m
Diameter: 65 in x
2.54 𝑐𝑚
1 𝑖𝑛
= 165.1 cm
82
1𝑚
165. 1 cm x
100 𝑐𝑚
𝐃𝐭 = 𝟏. 𝟔𝟓𝟏
𝜋
4
𝜋
(𝑑 2 )(h) = 4 (1. 651 𝑚 2 )(1.143 m)
= 2.447 𝑚3 x
= 2447 li x
1000 𝑙𝑖
1 𝑚3
1 𝑔𝑎𝑙𝑙𝑜𝑛
3.785 𝑙𝑖
𝐕𝐭 = 𝟔𝟒𝟔. 𝟓𝟎
For the volume of the conical bottom of the tank:
Height = 10 in x
2.54 𝑐𝑚
1 𝑖𝑛
= 25.4 cm x
1𝑚
100 𝑐𝑚
=0 .254 m
Given that the diameter is 1.651 m,
1
3
𝜋
[ 4 (1.651 𝑚)2 (0.254)] = 0. 181 𝑚3
= 0 .181 𝑚3 x
= 181 li x
1000 𝑙𝑖
1 𝑚3
1 𝑔𝑎𝑙𝑙𝑜𝑛
=
3.785 𝑙𝑖
47. 82 gallons
47.82 gallons + 646.50 gallons equivalent to 694.32 gallons will be deducted from the
final chemical production.
Based on the computation, the clearance of solution from the top of the tank results
to 94.32 gallons.
= 94.32 gallons x
3.785 𝑙𝑖
1 𝑔𝑎𝑙𝑙𝑜𝑛
= 357 𝑙𝑖 x
1 𝑚3
1000 𝑙𝑖
83
0 .357 𝑚3 =
𝜋
4
(1. 651 𝑚 2 ) (h)
Height =. 167 m (height of solution clearance from the top of tank)
For the capacity and height of water
1.143 m = height of cylindrical portion
0.167 m = height of clearance of chemical solution from the top
0.254 m = height of conical portion
1.143 m - 0.167 m = 0.976 m
0.976 m + .254 m = 1.23 m, should be the total height of solution from bottom.
For cylindrical portion:
𝜋
1000 𝑙𝑖
4
𝑚3
[ (1.6512 ) (0.976)] x .75 = 1.567 𝑚3 = 1.567 𝑚3 x
=1567 li x
1 𝑔𝑎𝑙𝑙𝑜𝑛𝑠
3.785 𝑙𝑖
= 414.003 gallons
For conical portion:
47.82 gallons x .75 = 35. 865 gallons
So, the capacity of water to be filled first in the tank before the powder should be
414.003 gallons + 35. 865 gallons = 449. 868 gallons
84
Six Dimensions and Typical Proportion:
(Reference: Handbook of Industrial Mixing; Science and Practice, Edited by
Edward L. Paul, Suzanne M. Cresto, 2004, p. 1247)
1. For the type of flow,
𝐷𝑎
𝐷𝑡
1
=3
; 3Da =
3Da =1.65
Dt = Diameter of Tank
𝑫𝒂 = 𝟎. 𝟓𝟓
𝟎. 𝟓 ≤
𝑫𝒂
𝑫𝒕
≤. 𝟕
Where: Da =
Diameter of Impeller
(𝑳𝒂𝒎𝒊𝒏𝒂𝒓 𝒇𝒍𝒐𝒘)
Figure 22. Turbulent Flow Pattern Produced by Dynaflow Impeller
2. Fluid level in the tank,
𝐻𝑓
𝐷𝑡
, (normal range: 0.5- 1)
For 𝐻𝑓 : Volume of Fluid (𝑉𝑓 )
𝑉𝑓 = 𝜋𝑟 2 ℎ𝑓
Where:
𝐻𝑓 = 𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐹𝑙𝑢𝑖𝑑
𝐷𝑡 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑇𝑎𝑛𝑘
𝑉𝑓 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐹𝑢𝑖𝑑
85
Conversion of 𝑔𝑎𝑙 𝑡𝑜 𝑚3 : 1gallon=3.78 𝑥 10−3
𝑉𝑓 = (600 𝑔𝑎𝑙) (
2.26 = 𝜋(
3.78 𝑥 10−3 𝑚 3
1 𝑔𝑎𝑙
) = 2.26 𝑚3
1.65 2
) (ℎ𝑓 )
2
𝐡𝐟 = 1.06 m
𝐻
Note: If 𝐷 > 1 , 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝑖𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝑡
Therefore, addition of impeller blade is required
3. Bottom Clearance
𝒄
𝟏
=
𝑫𝒕 𝟑
Where: c = distance from impeller diameter to bottom of the tank
Distance of impeller from the bottom side
1
1
𝑐 = (𝐷𝑡 ) = (1.651) = 𝟎. 𝟓𝟓𝟎𝟑 𝒎
3
3
Distance of Impeller from the top side
1
1
𝑐 = (𝐷𝑡 ) = (1.651) = 𝟎. 𝟓𝟓𝟎𝟑 𝒎
3
3
Distance of impeller from the bottom
1
1
𝑐 = (𝐻) = (1.397 𝑚) = 𝟎. 𝟒𝟔𝟔 𝒎
3
3
Distance of impeller from the top
𝑐=
1
1
(𝐻) = (1.397 𝑚) = 𝟎. 𝟑𝟒𝟗 𝒎
4
4
Therefore, the distance of impeller from the bottom of the tank is 0.466 m.
86
4. Width of the blade
𝑤
1
=
𝐷𝑎 5
𝑤=
1
1
(0.55033) = (0.55033) = 𝟎. 𝟏𝟏𝟎 𝒎
5
5
5. Length of the blade
𝐿 1
=
𝐷𝑎 4
1
1
𝐿 = 4 (𝐷𝑎 ) = 4 (0.55033) = 𝟎. 𝟏𝟑𝟖𝒎
6. No. of impeller blades: 3
H= 1.397m
𝐶𝑇𝑂𝑃 = 0.349m
𝐶𝐵𝑂𝑇𝑇𝑂𝑀 = 0.466m
ℎ𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝑏𝑙𝑎𝑑𝑒 = 0.0931m
𝑊𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝑏𝑙𝑎𝑑𝑒 = 0.1165m
𝐷𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 0.550m
Baffles = 0.138m
𝐷𝑡𝑎𝑛𝑘 =1.651m
Figure 23. Dimensions of Tank and Impeller (Dynaflow)
87
Manufacturer’s data: Operative range of 600-1000 gallons capacity drum
For the Power of the driven,𝑷𝒅𝒓𝒊𝒗𝒆𝒏 :
Required Power Consumption for turbulent flow and 200 gallon drum:
𝑃𝑑𝑟𝑖𝑣𝑒𝑛 = Power required = 2 HP (based from Engr. Ramos)
Use 𝑃𝑑𝑟𝑖𝑣𝑒𝑛 = 2 𝐻𝑝 (𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑚𝑎𝑟𝑘𝑒𝑡 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑖𝑡𝑦)
For required rpm of motor related with the ideal mixing time (three
minutes);
600 gallons / 50. 73 gallons = alternate 3 capacity/ present set up capacity
= 11.827
3.942 x 480 rev = 5676. 96 rev is required in order to dissolve 600 gallons of
chemical solution
[(40 rpm)(12 min)] / (50.73 gallons) = [ 𝑁3 ( 3 min)] / (600 gallons)
𝑵𝟑 = 1892. 37 rpm , use 1900 rpm
For the Torque, T:
For the torque of shaft with transmitted Hp:
T=
T=
Where: P = transmitted Hp
30 P
πN
N = shaft speed, in rpm
30 ( 2)( 0.746kW/Hp
π (1900)
T = torque, kN − m
𝐓= 7.12 X 𝟏𝟎−𝟑 kN-m
Solving for the shaft diameter, 𝑫𝒔 : (Reference: Shafting formulas from Machinery’s
Handbook)
For the shaft under pure tension only:
SS =
16 T
π( D3 )
(For solid circular shaft)
Where:
Ss = Shear Stress, Kpa
D = diameter of shaft , m
88
From Maximum-Shear Stress Theory, 𝐒𝐬 (Equation):
Ssmax =
SY
Where: Sy = Yield Strength, kPa
FS
FS = Factor of Safety
For the Factor of Safety, (See appendices for the Design Factor of Safety
Related to Stress, Faires: p.279)
FS = 3 (Suddenly Applied, Heavy Shocks)
For the Sy of Material AISI No. 304, (See appendices for the Typical
Properties of Stainless Steels, Faires: p.568)
101.325𝑘𝑃𝑎
Sy = 35 psi(
14.7𝑝𝑠𝑖
)
𝐒𝐲 = 𝟐𝟒𝟏, 𝟐𝟓𝟎 𝐤𝐏𝐚
Ssmax =
241,250
3
16𝑇
3
= 80,416.67kpa
3
16( 𝟕.𝟏𝟐 𝐗 𝟏𝟎−𝟑 )
𝐷=√
=√
𝜋( Ssmax )
𝜋( 80,416.67)
D = 0.077m =76 mm = 2.99”
Use, say, 3 𝐢𝐧𝐜𝐡 ∅ (Based on commercial sizes of shafts, inches (Faires: p.269)
Shaft Length
1
1
Ls = Ht − (Dt ) Ls = 139.7 − (139.7)
3
3
𝐋𝐬 = 𝟎. 𝟗𝟑𝟏𝟑 𝐦
Length of Blade
1
4
(𝐷𝑇 ) =
1
4
(139.7) = 𝟎. 𝟑𝟒𝟗𝐦
89
Alternative No. 3: Design of Double Dynaflow Impeller Agitator
Material Cost
Table 4. Material and Specification of Alternative No. 3
Materials
Unit
Quantity
Specifications
Steel sheets
piece
12
Stainless Steel 304
48 in x 96 in
Motor
piece
1
2 HP
Impeller
piece
2
4-bladed /piece, 39” Dyna
Flow with 1.7” bore
Shafting
piece
1
(Overhung), Stainless Steel
1
1 in ∅ x 45 in
4
Mechanical Seals
piece
1
≤ 15𝑚/𝑠
Angular Steel Bar
piece
8
3
1
1
inx 1 in x1 in x 120in
16
2
2
I Steel Bar
piece
5
3
1
1
inx 1 in x1 in x 120in
16
2
2
Flat Steel Bar
piece
3
Start Switch
Piece
1
120V AC /60Hz
Rubber Sealant
Piece
3
0.60𝑚 2
Power Chord
Piece
1
10 m
1 in x 1 1 x 120in
8
2
90
Benefit of the Project
The completion of the study would benefit Mayo Holdings Inc. give solutions
on how the company can meet the required production quota per month product, as
it uses the alternative solution no. 3 with 600 gallons capacity.
91
Figure 24. Equipment Layout of Double Dynaflow Impeller Mixing Equipment
92
ELECTRIC MOTOR (HIGH
SPEED)
SHAFTING
DYNAFLOW / HYDROFOIL
IMPELLER BLADE
STAINLESS STEEL
COVER
Fluid /Chemical
Feed
BAFFLES
20KG
CONTAINER
Ball Valve
DISPENSE
WEIGHING
APPARATUS
STAINLESS STEEL
TANK
STEEL BRACING/
SUPPORT
Figure 25. Components of Double Dynaflow Impeller Mixing Equipment
93
Recommendation of Best Alternative Solution
To identify the most beneficial alternative of the study, the researchers
considered the Total Project Cost, Rate of Return (ROR) and Payback Period of each
alternative solution. Based on the gathered data, analysis of principle and operation
and technical aspect of each alternative ; the researchers chose design of axial flow
impeller mixing equipment as the best alternative solution among the presented three
alternative solutions due to many reasons. First and foremost, by analysis it has the
operation needed to efficiently provide necessary suspension of solids and it has
design that can thoroughly dissolve sold suspensions of chemicals. Afterwards, it is
economical in terms of its total project cost, maintenance cost and operating cost. The
total investment cost for the the design of axial flow impeller is Php 219,369.00 only.
And the maintenance cost is very ideal since it saves a lot of space for the company.
Lastly, although three equipment operating simultaneously at the same time it treats
the chemicals at outstanding speed of three minutes and by batches, thus, permitting
the number of operators to maximize further responsibilities. But most importantly, it
was recommended for it was very effective in continuous production, in case of failure
of one mixing system, there are two remaining machines operating which is the main
concern of Mayo Holdings Inc.
94
Implementation of Maintenance Plan
A. Raising of funds
B. Presentation of the study
C. Request of funds of study to the accounting office
D. Quotation of cost of materials
E. Acquisition of materials
F. Hiring of contractors
G. Installation
H. Test run
I. Design adjustment
J. Normal operation
6. Chapter II
7. Company Visit/ Data
Gathering / Creation of
research Methodology
8. Chapter III( Formulating
Research Design)
9. Proposal Mock Defense
10. Prososal Defense
11.Semestral Break
12. Data Analysis
13.Design Calculation of
Alternative Solutions
14. Chapter IV
15. Analysis of
Findings/Conclusion and
Recommendation
16. Submission of Final paper to
Editor
17.Submission of Final Paper
(Turnitin Software)
18.Final Oral Mock Defense
19. Submission of Final
Research Paper( Hard Bound)
20. Final Oral Defense
5.Conducting Literature Review
1.Selection of Research Topic
2. Problem Identification
3. Chapter I
4. Company Visit/ Meeting with
the HR
ACTIVITIES
AUGUST
1 2 3 4
SEPTEMBER OCTOBER
1 2 3 4 1 2 3 4
NOVEMBER DECEMBER JANUARY FEBRUARY MARCH
APRIL
MAY
1 2 3 4
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
95
Figure 26. Schedule of Action Plan
96
Chapter IV
This chapter discusses the system of business organization that is best suited for
the proposed study, the manpower planning which is critical to the management and
economy, direct and indirect labor and job qualifications before the project will be
implemented.
ORGANIZATIONAL /MANAGEMENT ASPECT
Manpower Requirement
Since human resources department of Mayo Holdings Inc. enables the
company to have the right kind of staff and organization, they should also have the
right kind of manpower at the right places and time to perform job related to the
business objectives. Considering the production manager and mixer operator in the
mixing facility, retainment in the labor environment through internal arrangement
will be affected. Human resources allocation will also promote development
opportunities to workers to on the areas that will have a serious change, but addition
of at least one supervisory position with technical skills in machineries operation will
play apart in reinforcement of technical coordination. Together with the team is the
technician who will be responsible for the safe conditioning and troubleshooting of
the mechanized mixer tank.
The personnel handling the production of chemical declogger and degreaser
will be the similar to the manual mixing process.
Figure 25.
Organizational
Chart of Mayo
Holdings Inc. –
Engineering
Department
97
.
98
Direct and Indirect Labor
To make the project study feasible, a direct labor to produce the finished
products and indirect labor which includes services for the functioning of general
business is needed for the production of finished products
DUTIES AND RESPONSIBILITIES
Production Manager

Responsible for managing and organizing production strategies
and schedules;

Ensures daily production standards (data and reports) to meet
all production goals;

Provides information at daily production meetings regarding
current status, including issues, causes, and preventative
techniques used to prevent further issues;

Approves and directs the issuance of process operations and
specifications which relate to product development functions;

Maintains awareness of applicable chemical governmental
regulations and standards, and assists in implementation as
needed;

Accomplishes
operational
standards
by
contributing
information to strategic plans; and

Takes specific preventive actions and put solutions into place;
and

Properly communicates all of the information to the
maintenance supervisor.
99
Operations and Maintenance Supervisor

Trains, motivates, and supervises the mixing operator to ensure
finished goods (mixed products) meet specifications;

Organizes relevant training sessions on operations and
preventive maintenance;

Inspects machines and equipment to ensure specific operational
performance and optimum utilization;

Verifies material specifications and requirements based on
procedures;

Attends meetings with the Production Managers to discuss
production and process issues and assists in addressing these
issues, as needed;

Maintains reliability of equipment by restoring, repairing, and
implementing operations maintenance; and

Monitors expenditures and financial standards.
Office Clerk

Performs administrative duties;

Assists the scheduling and coordinating of suppliers related to
raw materials;

Maintains a neat and orderly environment office as assigned;
and


Files confidential records and documents.
100
Technician

Observes safety and security policies pertaining to chemicals
and equipment;

Plans and organizes on-time scheduled trainings;

Ensures
recording
of
complete
transactional
and
troubleshooting data;

Assembles and installs small and large equipment components;

Repairs or recommends for replacement defective
components;

Conducts overall machine inspection; and
Assembles and/or disassembles the machine according to
schedules.
Mixer Operator

Develops and maintains control on raw materials, in-process
batches, components, and tire curing parameters;

Reports to the operations and maintenance supervisor;Follows
the accurate measurement of formula;

Loads ingredients into the mixer following the product recipe,
procedures and guidelines to complete continuous production;

Ensures and monitors final product is meeting specifications;

Sanitizes the facility and equipment as required;

Performs basic machine troubleshooting; and

Sustains safety environment at all times.
101
Job Qualifications
Production Manager

Bachelor’s degree in any Engineering-related field

Professional Certifications are preferred

Strong technical knowledge on electrical and mechanical (heating
systems) aspects

Minimum of five to ten years comparable work experience

Manufacturing environment familiarity preferred

Previous management experience preferred
Operations and Maintenance Supervisor

Bachelor’s degree in Engineering related field

Proven experience as maintenance supervisor

Excellent communication and interpersonal skills

Must have knowledge on performance management and
budgeting

Ability to ensure operational and safety compliance

Can supervise and train technicians

Requires strong verbal/written communication and computer skills,
Clerk
basic knowledge of construction materials and practices, and the
ability to organize multiple projects simultaneously

Proficient in use of computers, office equipment, and software
102

Must be willing to work overtime and some weekends as needed

Standing - 6 to 8 hours daily
Technician

2 years vocational degree preferred

At least one year in manufacturing environment

Must be knowledgeable in industrial machinery and equipment

Provide reports on technical problems

Conduct tests, equipment inspection

Develop solutions and assist engineers to modify complex problem
Mixer Operator

GED or high school diploma is required

Six months of manufacturing experience is preferred

Ability to communicate, read, and write

Ability to understand different units of measurements and
information

Follow instructions with minimal supervision

Willingness to work in a team environment

Must be able to lift up to 40 pounds frequently.

Able to work Over Time and/or weekends.
103
CHAPTER V
ECONOMIC STUDY
This chapter represents the computation of expenses and cost estimates in
making the research study. It includes the economic study of computation of total
costs of materials, operating costs and contingency costs
Engineering Economy Assumption
1. The percent of total material cost and total operating cost was included as
contingency cost.
2. Assumed total project cost was computed to be the summation of total
investment cost, total operating cost and total contingency cost.
3. Assumed installation cost is based from the company for Alternative 1 , Alternative
2 and Alternative 3.
4. Assumed maintenance cost for the installation of three axial flow impeller with
200-gallon capacity per drum is Php 15,000.00 quarterly or Php 45,000 a year.
5. Assumed economic life of the alternatives is 10 years.
6. Salvage value is 10% of economic cost.
7. The study period covers five-year duration.
8. The accepted Alternative Rate of Return of the company is 540% with an accepted
payback period of 2-3 months
104
Selection of Alternatives
Alternative No.1: Design of radial flow impeller agitator
Table 5. Material Cost of alternative No. 1
Materials
Unit
Quantity
Unit Price (Php)
Total Price (Php)
HDPE drum
pieces
15
NA
NA
Motor
piece
1
Php 2,407.00
Php 2407.00
Impeller
piece
1
Php 19,344.00
Php 19,344.00
Shafting
piece
1
Php 4,050.00
Php 4,050.00
Mechanical
piece
1
Php 1,115.00
Php 1,115.00
piece
1
Php 332.00
Php 332.00
Round Bar
pieces
2
Php 770.00
Php 1540.00
Power Chord
piece
1
Php 250.00
Php 250.00
Roller Wheel
pieces
4
Php 220.00
Php 880.00
Start Switch
piece
1
Php 345.00
Php 345.00
Seals
Angular Steel
Bar
Total
Php 30,253.30
(Prices collated as of February 2019)
*Note: The HDPE Drum that was used in this alternative solution was based
from the present system of the facility.
105
A. Total Material Cost = Php 30,253.30
B. Investment Cost
Note: For the installation cost, the expenses and representation of installing the
project was not associated with the researchers and part of the scope and
limitation of the study. It is part of the duties and responsibilities of the
company.
Total Installation Cost = 50 %( Material Cost)
= 50% (30,253.30)
= Php 15,126.65
Total installation cost=Php 15,126.65
For the total investment cost,
Total investment= total material cost+ total installation cost
Total investment=Php 30,253.30 + Php 15,126.65
Total Investment Cost = Php 45,378.00
C.Operating Cost (1-year period)
Utility
Energy Consumption Cost
Using 0.50 Hp electric motor
Rated Power of the motor = 0.373kw
Price of Power per kWh (Meralco as of February 2019 billing month) = Php
10.42/kwh
Daily Operation (0.33 hrs/day)
Price of daily power consumption = (.373) (10.42) (0.33) = Php 1.283/day
106
Annual Consumption Cost
𝑃𝑟𝑖𝑐𝑒𝑎𝑛𝑛𝑢𝑎𝑙 = 1.283(26) (12)
Total Electricity Consumption Cost (Annual) = Php 400.30
Labor Cost
The site has 2 warehouse men on their operation;
Rate per staff = Php 350/day
𝐸𝑚𝑝𝑙𝑜𝑦𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡𝑎𝑛𝑛𝑢𝑎𝑙
= (2) (350) (26)(12)
Total Labor Cost (Annual) = Php 218,400.00
Total Operating Cost
Total Operating cost = Total Electricity Consumption cost + Total Labor Cost
+
Total Installation Cost
= 400.296 + 218, 400 + 15,126.65
Total Operating Cost= Php 233,927.00
E. Contingency Cost
Contingency Cost = (Total Material Cost + Total Operating Cost) (12%)
= (30,253.30 + 233,927)
= 264,180.24 (12%)
= Php 31,701.70
Total Contingency Cost = Php 31,701.70
Total Investment Cost = Material Cost + Installation Cost
= 30,253.30 + 15,126.65
Total Investment Cost = Php 45,380.00
107
FOR TOTAL PROJECT COST
Project Cost
Total Project Cost = (Total Investment + Total Operating Cost + Total
Contingency Cost
= 45,380.00 + 233,927 + 31,701.70
Total Project Cost= Php 311,008.65
Working Capital
1. Maintenance Cost
The maintenance cost was assumed to be Php 2,500.00 as stated by
Engr. Ramos. The present maintenance cost would be significantly reduced
since there would be less manpower requirement. Also, the maintenance
procedure would be conducted once the system has as failure or concern
regarding monitoring and controlling of equipment.
Table 6. Maintenance Cost of Alternative No.1
NUMBER OF
LABOR
PERSONNEL
NUMBER OF
DAYS OF WORK
2
3
Php 2,500.00
PERSONNEL
COST
Maintenance/
Technician
TOTAL
Php 15,000.00
*Consider 2 technicians operating on 6 working days;
Maintenance Cost = (Php 2,500.00)(2)(3)
Maintenance Cost= Php 15,000.00/month
Maintenance Cost Quarterly = (15,000) (4)
𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐂𝐨𝐬𝐭 𝐀𝐧𝐮𝐚𝐥𝐥𝐲 = 𝐏𝐡𝐩 𝟔𝟎, 𝟎𝟎𝟎
108
2. Depreciation Cost
Depreciation Cost=
𝐼𝐶−𝑆𝑉
𝐿
Where: DC= Depreciation Cost
IC= Investment Cost
SV= Salvage Value =10% of Investment Cost
L= 10 years
𝐷𝐶 =
30,253.30 − 0.10(30,253.30)
10
Depreciation Cost =Php 2,722.797
Total Working Capital
Total Working Capital = Maintenance Cost + Depreciation Cost
+
Operating Cost
= 60,000+ 2,722.797 + 233,927.00
Total Working Capital= Php 296,649.797
Increase in Sales
*Based from Engr. Ramos maximum of 3 drums per day was able to
produce because of 24-hr heat releasing of newly mixed products, this
was simultaneous to mixing and packaging of finished products.
Increase in Sales= 𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 − 𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐
For the sales of Present System (𝑆𝑎𝑙𝑒𝑠𝑡ℎ𝑒𝑜 ):
𝑆𝑎𝑙𝑒𝑠𝑡ℎ𝑒𝑜 = (5 drums) (
13 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠
1
20 𝑘𝑔
) (1 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟 )(
𝑃ℎ𝑝 70.00
1
)
109
𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐 = Php 91,000.00/ order
*Working days = 26 days/month, production and packaging
was only every 2 days; manufacture to clients is last day of the
week or 4 days / per month:
Salestheo =
Php 91,000
day
x
4 days
1 month
x
12 months
1 year
𝐀𝐧𝐧𝐮𝐚𝐥 𝐒𝐚𝐥𝐞𝐬𝐭𝐡𝐞𝐨 = Php 4,368,000 .00
For the sales of Alternative Solution (𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 ) :
*Since the required capacity is 255 gal/day with maximum run time of
20 minutes and 3 minutes per drum, it can be maximized to 6 drums /
day.
(𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 ) = (6 drums) (
13 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠
1
20 𝑘𝑔
) (1 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟 )(
𝑃ℎ𝑝 70.00
1
(𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 )= Php 109,000.00/order
𝐴𝑛𝑛𝑢𝑎𝑙 𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑎𝑙 =
𝑃ℎ𝑝 109,000.00
𝑜𝑟𝑑𝑒𝑟
𝑥
4 𝑜𝑟𝑑𝑒𝑟
1 𝑚𝑜𝑛𝑡ℎ
𝑥
12 𝑚𝑜𝑛𝑡ℎ𝑠
1 𝑦𝑒𝑎𝑟
Annual Salesactual =Php 5,232,000.00
Increase in Sales= 𝑨𝒏𝒏𝒖𝒂𝒍 𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 − 𝑨𝒏𝒏𝒖𝒂𝒍 𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐
= Php 5,232,000.00 – Php 4,368,000.00
= Php 864,000.00
Additional Increase per year
Additional Increase per year = Annual Increase in sales - Total Working Capital
= Php 864,000.00 – Php 296,649.797
Additional Increase per Year = Php 567,350.20
)
110
Rate of Return
Rate of Return= (
Additional Increase per year
Total Project Cost
) (100%)
567,350.20
= (𝟑𝟏𝟏,𝟎𝟖𝟖.𝟔𝟓)(100%)
Rate of Return = 182.42%
Payback Period
Total Project Cost
Payback Period=Additional Increase per year
311,088.65
=567,350.203
Payback Period=0.54 years ≈ 6.58 months
Since the total project cost would be recovered during the 5-year duration, the project
is acceptable.
111
Alternative No. 2: Design of three axial flow impeller with 200 gallons capacity
A.Material Cost
Table 7. Material Cost of alternative No. 2
Materials
Unit
Quantity
Unit Price (Php)
Total Price (Php)
HDPE drum
gallons
3
Php 18,000.00
Php 54,000.00
Motor
HP
3
Php 2,407.00
Php 7221.00
Impeller
piece
3
Php 15,500.00
Php 46,500.00
Shafting
pieces
3
Php 6268.00
Php 18,804
piece
3
Php 1,115.00
Php 1,115.00
piece
12
Php 1520.00
Php 4560.00
piece
12
Php 2280.00
Php 6840.00
piece
12
Php 1330.00
Php 3990.00
Flat Bar
piece
6
Php 692.00
Php 2076.00
Start Switch
Piece
3
Php 115.00
Php 345.00
Rubber Sealant
Piece
3
Php 265.00
Php 795.00
Mechanical
Seals
Angular Steel
Bar
Angular Steel
Bar
Angular Steel
Bar
Total
A. Total Material Cost= Php 146,246.00
Php146, 246.00
112
B. Investment Cost
Total Installation Cost = 50% (Material Cost)
= 50% (146,246)
Total installation cost= Php 73,123.00
For the total investment cost,
Total investment= total material cost+ total installation cost
Total investment= Php 146,246 + 73,213
Total Investment Cost = Php 219,369.00
C. Operating Cost (1-year period)
Utility
Energy Consumption Cost
Using 0.50 Hp electric motor
Rated Power of the motor = 0.373kw
Price of Power per kWh (Meralco as of February 2019 billing month) = Php
10.42/kwh
Daily Operation (20 minutes or 0.33hrs/day)
Price of daily power consumption = (.373) (10.42) (0.33) = (Php 1.28/day) (3
tanks)
Price of daily power consumption = Php 3.85 / day
Monthly Consumption Cost (26 days of operation)
𝑃𝑟𝑖𝑐𝑒𝑎𝑛𝑛𝑢𝑎𝑙𝑙𝑦 = (3.85) (26) (12)
Total Electricity Consumption Cost (Annual) = Php 1201.20/year
113
Labor Cost
The site has 2 warehouse men on their operation;
Rate per staff = Php 350/day
𝐿𝑎𝑏𝑜𝑟 𝐶𝑜𝑠𝑡𝑑𝑎𝑖𝑙𝑦
= (2) (350) (26)(12)
Total Labor Cost (Annual) = Php 218,400.00
Total Operating Cost
Total Operating cost = Total Electricity Consumption cost + Total Labor Cost +
Installation cost
= 1,201.20 + 218, 400 + 73,213.20
Total Operating Cost= Php 292,814.20
D.Contingency Cost
Contingency Cost = (Total Material Cost + Total Operating Cost) (10%)
= (146,246+292,814.20) (12%)
= 439,060.20 (12%)
Total Contingency Cost = Php 52,687.20
FOR TOTAL PROJECT COST
Total Project Cost
Project Cost = (Total Investment + Total Operating Cost + Total Contingency
Cost
= 219,369+292,814.20+52,687.20
Total Project Cost = Php 565,050.40
114
Working Capital
Maintenance Cost
The maintenance cost is assumed to be Php 15,000.00 as stated by
Engr. Ramos. The present maintenance cost would be significantly reduced
since there would be less manpower requirement. Also, the maintenance
procedure would be conducted once the system has as failure or concern
regarding monitoring and controlling of equipment.
Table 8. Maintenance Cost of Alternative No. 2
NUMBER OF
LABOR
PERSONNEL
NUMBER OF DAYS
OF WORK
2
3
Php 2,500.00
PERSONNEL
COST
Maintenance/
Technician
TOTAL
Php 15,000.00
Maintenance Cost = (Php 2,500.00) (2)(3)
Maintenance Cost= Php 15,000.00/month
Maintenance Cost 𝑎𝑛𝑛𝑢𝑎𝑙 = (15,000) (12)
𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐂𝐨𝐬𝐭 𝐚𝐧𝐧𝐮𝐚𝐥 = 𝐏𝐡𝐩 𝟏𝟖𝟎, 𝟎𝟎𝟎. 𝟎𝟎
Depreciation Cost
Using Straight Line Depreciation Method:
Depreciation Cost=
𝐼𝐶−𝑆𝑉
𝐿
Where: DC= Depreciation Cost
IC= Investment Cost
115
SV= Salvage Value =10% of Investment Cost
L= 10 years
𝐷𝐶 =
303,981 − 0.10(303,981)
10
Depreciation Cost =Php 27,358.29
Total Working Capital
Total Working Capital = Maintenance Cost + Depreciation Cost+
Operating cost
= 180,000 + 27,358.29 + 292,814.20
Total Working Capital= Php 500,172.50
Increase in Sales
*Based from Engr. Ramos maximum of 5 drums per day was able to
produce because of 24-hr heat releasing of newly mixed products, this
was simultaneous to mixing and packaging of finished products.
Increase in Sales= 𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 − 𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐
For the sales of Present System (𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐 ):
𝑆𝑎𝑙𝑒𝑠𝑡ℎ𝑒𝑜 = (5 drums) (
13 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠
1
20 𝑘𝑔
) (1 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟 )(
𝑃ℎ𝑝 70.00
1
)
𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐 = Php 91,000.00/ order
*Working days = 26 days/month, production and packaging
was only every 2 days; manufacture to clients is last day of the
week or 4 days / per month:
Salestheo =
Php 91,000
day
x
4 days
1 month
x
12 months
1 year
𝐀𝐧𝐧𝐮𝐚𝐥 𝐒𝐚𝐥𝐞𝐬𝐭𝐡𝐞𝐨 =Php 4,368,000 .00
116
For the sales of Alternative Solution No.2 (𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 ) :
*Since 3 equipment running simultaneously with 200 gallons per tank;
equal to 10 drums
For the sales of Alternative Solution No.2 (𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 ) :
*Since the equipment is operating with 600 gallons equal to 10 drums
(𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 ) = (10 drums) (
13 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠
1
)(
20 𝑘𝑔
1 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟
)(
𝑃ℎ𝑝 70.00
(𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 )= Php 182,000.00/order
𝐴𝑛𝑛𝑢𝑎𝑙 𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑎𝑙 =
𝑃ℎ𝑝182,000.00
𝑜𝑟𝑑𝑒𝑟
𝑥
3 𝑜𝑟𝑑𝑒𝑟
1 𝑚𝑜𝑛𝑡ℎ
𝑥
12 𝑚𝑜𝑛𝑡ℎ𝑠
1 𝑦𝑒𝑎𝑟
𝐀𝐧𝐧𝐮𝐚𝐥 𝐒𝐚𝐥𝐞𝐬𝐚𝐜𝐭𝐮𝐚𝐥 = Php 6, 552, 00.00
Increase in Sales= 𝑨𝒏𝒏𝒖𝒂𝒍 𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 − 𝑨𝒏𝒏𝒖𝒂𝒍 𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐
= Php 6,552,000 – Php 4,368,000.00
Increase in Sales = Php 2,184,000.00
Additional Income
Additional Income= Increase in sales - Total Working Capital
= Php 2, 184,000.00– Php 500,172.49
Additional Income per Year = Php 1,683,827.50
Rate of Return
Additional Income
Rate of Return= ( Total Project Cost ) (100%)
=(
1,683,827.50
565,050.40
Rate of Return = 298%
)(100%)
1
)
117
Payback Period
Total Project Cost
Payback Period=Additional Income
565,050.40
= 1,683,827
Payback Period=≈ .34 years ≈ 4.02 month
Since the total project cost would be recovered during the 5-year duration, the project
is acceptable.
118
Alternative No. 3: Design of Double Dynaflow Impeller Agitator
A.Material Cost
Table 9. Material Cost of alternative No. 3
Materials
Unit
Quantity
Unit Price (Php)
Steel sheets
pieces
12
Php6,500.00
Php78,000.00
Motor
piece
1
Php 3,500.00
Php 3500.00
Impeller
pieces
2
Php11,500.00
Php21,000.00
Shafting
piece
1
Php 4250.00
Php 4250.00
Mechanical
Seals
Angular Steel
Bar
piece
1
Php 1,115.00
Php 1,115.00
pieces
8
Php 1520.00
Php12,160.00
I Steel Bar
piece
5
Php 1330.00
Php 6650.00
Flat Steel Bar
piece
3
Php 692.00
Php 2076.00
Start Switch
pieces
1
Php345.00
Php 115.00
Rubber Sealant
piece
3
Php 265.00
Php 795.00
Power Chord
piece
1
Php 250.00
Php 250.00
Total
A.Total Material Cost= Php 129,911.00
Total Price (Php)
Php129,911. 00
119
B.Investment Cost
Total installation cost= 50 % (Total Material Cost)
= 50 % (Php 129,911.00)
Total installation cost = Php 64,955.50
For the total investment cost,
Total investment= total material cost + total installation cost
Total investment= Php 129,911.00 + Php 64,955.50
Total investment Cost = Php 194,866.50
C. Operating Cost (1-year period)
Utility
Energy Consumption Cost
Using 2 Hp electric motor
Required Power of the motor= 1.5 kW
Price of Power per kWh (Meralco as of February 2019 billing month)
=Php 10.42 /kWh
Daily Operation (.33hr/day) or Maximum of 20 minutes/day
Price of daily power consumption= (1.50) (0.33) (10.42) = Php 5.16/day
𝑃𝑟𝑖𝑐𝑒𝑎𝑛𝑛𝑢𝑎𝑙 = 5.16(26)(12)
𝑷𝒓𝒊𝒄𝒆𝒂𝒏𝒏𝒖𝒂𝒍 = 𝑷𝒉𝒑 𝟏𝟔𝟎𝟗. 𝟗𝟐/𝒚𝒆𝒂𝒓
Total Electricity Consumption Cost (Annual) = Php 1609.92.00
120
Labor Cost
The site has 2 warehouse men on their operation;
Rate per staff= Php 350.00 / day
𝐸𝑚𝑝𝑙𝑜𝑦𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡𝑑𝑎𝑖𝑙𝑦 = (2 𝑠𝑡𝑎𝑓𝑓)(350)(26)(12)
Total Labor Cost (Annual) = Php 218,400.00
Total Operating Cost
= Total Electricity Cost (Annual) + Total Labor Cost (Annual)
+ Total Installation Cost
= Php 1609.92 + Php 218,400.00 + Php 64,955.50
Total Operating Cost =Php 284,965.42
D.Contingency Cost
Contingency Cost= [Total Material Cost + Total Operating Cost] [12 %]
= (Php 129,911.00 + 284,965.42) (0.12)
= (Php 414,876.42) (0.12)
Total Contingency Cost = Php 49,785.17
FOR TOTAL PROJECT COST
Total Project Cost= (Total Investment Cost) + (Total operating cost) + (Total
contingency cost)
= Php 194,866.50 + Php 284,965.42+ Php 49,785.17
Total Project Cost= Php 529,617.09
121
Working Capital
1. Maintenance Cost
The maintenance cost was assumed to be Php 2,500.00 as stated by
Engr. Ramos. The present maintenance cost would be significantly reduced
since there would be less manpower requirement. Also, the maintenance
procedure would be conducted once the system has as failure or concern
regarding monitoring and controlling of equipment.
Table 10. Maintenance Cost of Alternative No.3
PERSONNEL
NUMBER OF
PERSONNEL
NUMBER OF
DAYS OF WORK
LABOR
COST
Maintenance/
Technician
2
6
Php 2,500.00
TOTAL
Php 30,000.00
*Consider 2 technicians operating on 6 working days;
Maintenance Cost = (Php 2,500.00) (2)(6)
Maintenance Cost= Php 30,000.00/month
Maintenance Cost𝐴𝑛𝑢𝑎𝑙𝑙𝑦 = (30,000) (12)
Maintenance Cost Annually = 𝐏𝐡𝐩 𝟑𝟔𝟎, 𝟎𝟎𝟎
2. Depreciation Cost
Depreciation Cost=
𝐼𝐶−𝑆𝑉
𝐿
Where: DC= Depreciation Cost
IC= Investment Cost
SV= Salvage Value =10% of Investment Cost
122
L= 10 years
DC =
Php 194,866.50 − 0.10(Php 194,866.50)
10
Depreciation Cost = Php 17,537.985
Total Working Capital
Total Working Capital = Maintenance Cost + Depreciation
Cost+Operating Cost
= Php 360,000 + Php 17,537.985 + Php 284,965.42
Total Working Capital= Php 662,503.405
Increase in Sales
*Based from Engr. Ramos maximum of 5 drums per day was able to
produce because of 24-hr heat releasing of newly mixed products, this
was simultaneous to mixing and packaging of finished products.
Increase in Sales= 𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 − 𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐
For the sales of Present System (𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐 ):
𝑆𝑎𝑙𝑒𝑠𝑡ℎ𝑒𝑜 = (5 drums) (
13 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠
1
20 𝑘𝑔
) (1 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟 )(
𝑃ℎ𝑝 70.00
1
)
𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐 = Php 91,000.00/ order
*Working days = 26 days/month, production and packaging
was only every 2 days; manufacture to clients is every last day
of the week or 4 days / per month:
Salestheo =
Php 91,000
order
x
4 order
1 month
x
12 months
1 year
𝐀𝐧𝐧𝐮𝐚𝐥 𝐒𝐚𝐥𝐞𝐬𝐭𝐡𝐞𝐨 = Php 4,368,000 .00
123
For the sales of Alternative Solution No.3 (𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 ) :
*Since the equipment is operating with 600 gallons equal to 10 drums
(𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 ) = (10 drums) (
13 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟𝑠
1
20 𝑘𝑔
) (1 𝑐𝑜𝑛𝑡𝑎𝑖𝑛𝑒𝑟 )(
𝑃ℎ𝑝 70.00
1
)
(𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑢𝑎𝑙 )= Php 182,000.00/order
𝐴𝑛𝑛𝑢𝑎𝑙 𝑆𝑎𝑙𝑒𝑠𝑎𝑐𝑡𝑎𝑙 =
𝑃ℎ𝑝182,000.00
𝑜𝑟𝑑𝑒𝑟
𝑥
3 𝑜𝑟𝑑𝑒𝑟
1 𝑚𝑜𝑛𝑡ℎ
𝑥
12 𝑚𝑜𝑛𝑡ℎ𝑠
1 𝑦𝑒𝑎𝑟
𝐀𝐧𝐧𝐮𝐚𝐥 𝐒𝐚𝐥𝐞𝐬𝐚𝐜𝐭𝐮𝐚𝐥 = Php 6, 552, 00.00
Annual Increase in Sales= 𝑨𝒏𝒏𝒖𝒂𝒍 𝑺𝒂𝒍𝒆𝒔𝒂𝒄𝒕𝒖𝒂𝒍 − 𝑨𝒏𝒏𝒖𝒂𝒍 𝑺𝒂𝒍𝒆𝒔𝒕𝒉𝒆𝒐
= Php 6,552,000 – Php 4,368,000.00
Annual Increase in Sales = Php 2,184,000.00
Additional Increase per year
Additional Increase per year = Annual Increase in sales - Total Working Capital
= Php 2,184,000.00 – Php 662,503.405
Additional Increase per year = Php 1,521,496.595
Rate of Return
Rate of Return= (
𝐴𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
=(
𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑗𝑒𝑐𝑡 𝐶𝑜𝑠𝑡
1,521,496.595
529,617.09
)(100%)
Rate of Return =287.28 %
) (100%)
124
Payback Period
𝑻𝒐𝒕𝒂𝒍 𝑷𝒓𝒐𝒋𝒆𝒄𝒕 𝑪𝒐𝒔𝒕
Payback Period=𝑨𝒅𝒅𝒊𝒕𝒊𝒐𝒏𝒂𝒍 𝑰𝒏𝒄𝒓𝒆𝒂𝒔𝒆 𝒑𝒆𝒓 𝒚𝒆𝒓
529,617.09
=1,521,496.595
Payback Period=0.348 years ≈ 4.18 months
Since the total project cost would be recovered during the 5-year duration, the project
is acceptable.
125
Summary of Economic Findings
Table 11. Summary of Economic Findings
TOTAL PROJECT
COST
ADDITIONAL
INCREASE PER
YEAR
RATE OF
RETURN
Alternative
No.1
Php 311,088.65
Php 567,350.203
182.42%
Alternative
No.2
Php 565,050.40
Php 1,683,827.00
298 %
Alternative
No. 3
Php 529,617.09
Php1,521,465.595
287.28%
PAYBACK
PERIOD
0.54 years
0.34 years
0.35 years
Considering the table above of the method used for economic analysis, the
resulting amount is shown for each alternative. The summary of the results used
methods such as additional income, rate of return (ROR) and payback period (PbP)
For the additional income, all three alternatives have acceptable and positive
values but, Alternative No. 2 has the highest amount.
For the ROR method, Alternative No.2 is the most practical for having 298 %
followed by Alternative No.3
For the payback period, Alternative No. 3 is considered most acceptable
alternative for having the least length of time needed to recover the investment.
126
Comparison of Best Alternatives
Comparing each alternative provide information toward informed
decisions. To determine the best alternative solution for problem, rate of return,
cost-benefit analysis and payback period were determined.
The rate of return (ROR) method is the ratio of the annual increase in
sales to total investment or total project cost multiplied by 100. An increase in sales
or additional income is considered profitable if the computed rate of return is greater
than the assumed present rate of return.
The payback period determines the length of time it will take an initial
amount of investment on a project will return or length of time to recover the sum of
the original investment. If the money invested is totally recovered before the
duration period, the project is therefore acceptable.
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CHAPTER VI
SUMMARY, CONCLUSIONS, AND RECOMMENDATIONS
This chapter presents the summary, conclusions, and recommendations of the
study which states the reasonable and possible solutions and shares the best
alternative solutions for industry application.
Summary
Mayo Holdings Inc. is a well-known company in bio technology in the treatment
of industrial and commercial wastes operating in Laguna. It is currently owned by
Manny and Yolly B. Ramos. It specializes in use of hazardous chemicals in clogging and
maintenance of kitchen lines, but it encountered relevant losses and inefficient
production considering the large demand on market and safety risks of workers. Seeing
this problem, the researchers conducted study about engineering technologies
specifically design of mechanized chemical mixer tanks on how to improve the existing
mixing system of the said company.
In summary, the main variables known to affect mixing performance are (1) the
design of the mixing system (geometry mechanism); (2) tank size; (3) the fill level; (4)
the speed of rotation of the mixing equipment; and (5) the material properties of the
ingredients being mixed
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The researchers came up with three alternatives which aim to improve mixing
process and mass production and performance which will lead to financial income.
These alternatives were based on gathered data from multiple viable sources.
Alternative 1 (Design of Radial Flow Impeller Agitator), Alternative 2 (Design of three
axial flow Impeller with 200 gallons capacity per drum), and Alternative 3 (Design of
Double Dynaflow Impeller Agitator) were all carefully considered.
The best alternative solution recommended is Alternative No. 2 since it is
economical in terms of its total project cost, maintenance cost, and operating cost,
which was deemed most beneficial by analysis on process and technical aspect of
operation. The study considered the design of equipment and it’s components as well
as the materials to be used.
The researchers gathered data and consulted mechanical, electrical, and civil
engineers so that this study would come up feasible. The researchers also considered
safety in the design.
Conclusions
In this project study, the researchers concluded that mechanization of chemical
mixing process plays an important role to achieve optimum efficiency as different
problem arises. The conclusions made are constructed in parallel with the objectives
of the study. The researchers raised to the following conclusions:
1. The concept of fluid mechanics related to the properties of a given capacity of
substance was used to determine the parameters in different application.
Together with selection of impellers in laminar or turbulent operations, height
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of tank, impeller diameter, tank diameter, length of impeller, and width of
impeller were among the parameters carefully analysed. Turbulent impellers
cause the tank fluid to flow parallel to the impeller’s rotation. Radial flow
impellers cause the tank fluid to flow perpendicular to the impeller’s rotation
of axis.
The property that best describes and has the most important distinction
is the type of flow between a solid such as steel and viscous fluid. The blend
time required to achieve specified degree of estimated 95% uniformity was
derived from the critical speed of the present system. The parameters used are
determined for each specific alternative that is required to develop solutions
to existing operational conditions. The three alternative solutions use HDPE
drum, stainless steel 304 tank, components of rotating shaft, impeller, and
electric motor.
Even with complete geometric similarity, it is expected that the model
is to be less efficient than the prototyping. The main interest in torque is as
means for evaluating the power that must be supplied to impeller. Laminar and
turbulent flow to help understanding the rate of turbulence in the flow process.
2. In chemical mixing, the flow patterns as well as the high speed of the motor is
critical. Applying the mechanized designs for each alternative solution using a
rotating component which was responsible of mixing throughout, the safety of
workers in terms of production was effectively achieved. During the mixing of
fluids, it is essential to avoid chemical extreme heat exposure, the second and
third alternative solutions can dispense an average of 600 gallons per day
without subjected delay in a span of 20 minutes.
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3. The investment cost for the alternative solution no.1 is equivalent to the total
project cost and working capital that were used by the equipment. The
materials are economically safe and bought for the good operation and
handling of the system. The investment cost of Alternative No.1 (Design of
radial flow impeller agitator) reached Php 607,658.45. For the best solution
which was Alternative No. 2 (Design of three axial flow impeller with 200
gallons capacity per drum) the investment cost required is Php 1,065,222.90
and for the total Alternative No. 3(Design of Double Dynaflow Impeller
Agitator) reached Php 1,192,120.495
Recommendations
The following are the researchers’ recommendations to further develop the
research study:
1. With limited availability of components, the final design mixing machine
requires minimal tools for assembly, so it is recommended to use the other
parts that can be hand-drilled or hand tightened as this further eliminates the
need for expensive tools.
2. The other power and transmission concepts could be tested, such as
combustion engine. This is since the motors are often expensive and would end
up consuming a very large portion of the financial analysis. Further, it requires
source of electricity which must come from a private electric consumption
company in the Philippines. There are also environmental concerns associated
with both options, so it is recommended to try using automotive batteries
which may be less expensive to operate.
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3. The shaft and impeller must be detachable to each other to allow for easy
cleaning of the mixer.
4. The other conventional materials of the mixing system, such as HDPE drums,
can be a resource to the design of mechanized chemical mixer alternative
solution no.1. Drying of inner surface of the drum must be applied and secured
with cover, so it can be storage of raw chemicals.
5. The pulley system in a detachable stair 3 with ratio of altitude of tank set up
such as alternate 3, whether its prime mover is manual or mechanized, is
recommended for convenient transport of the chemicals.
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LITERATURE CITED
Books
Handbook of Industrial Mixing; Science and Practice, Edited by Edward L. Paul,
Suzanne M. Cresto, 2004, p. 1247
Machine Design II , Jose R. Francisco, PME,CEM;2014 Lecture Edition
Machine Design by Robert H. Creamer, p.159- 160
Online References
Metal Mixing Tank Systems
(http://www.wmprocess.com/mixing-tanks/, 19 October 2018)
“(https://www.nemaenclosures.com/blog/304-and-316-stainless-steel , 19
October 2018)
Chemical Mixing
(http://www.wmprocess.com/chemical-mixing-and-mixers/, 19 October2018)
High Viscosity Mixers
(http://www.wmprocess.com/mixers-and-agitators/ 19 October 2018)
Selecting Impeller Size
(http://blog.mixerdirect.com/how-to-choose-a-mixing-impeller, 19 October
2018)
Chemical Reactivity Hazard
(https://www.osha.gov/SLTC/reactivechemicals/, 19 October 2018)
Crucial Mechanical Design and service life of Mixer Tanks
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018)
Mechanical failures
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018).
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Frequency Rate
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018)
Mixer Mounting
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018)
Liquid Level to Tank Diameter Ratio
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018)
The Use of Baffling
(http://www.dynamixinc.com/optimal-tank-design, 17 October 2018)
Assessing Mixing Effectiveness
(http://life.dlut.edu.cn/Bioprocess5.pdf, 20October 2018)
Horsepower Requirements for Mixing
(http://life.dlut.edu.cn/Bioprocess5.pdf, 20 October 2018)
Improvement of mixing
(https://me-mechanicalengineering.com/viscosity/, 18 October 2018).
Mechanization of Automatic Mixing
(http://www.pcaarrd.dost.gov.ph/home/momentum/agmachin/index.php?o
ption=com_content&view=article&id=296:level-of&catid=126&Itemid=286,
27 October 2018).
Mixing Principles
(https://www.chemicalprocessing.com/articles/2003/284/ , 27 October 2018
Laminar Flow, Turbulent Flow
(https://www.chemicalprocessing.com/articles/2003/284/ , 27 October
2018).
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APPENDIX A
Note: Use the above mixing graph for basic mixing sizing.Intended for use in
recommendations
Proper Mixing Horsepower and Speed
135
APPENDIX B
Shock and Fatigue Factors
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APPENDIX C
Common Available Sizes for Steel Circular Shafts (English Unit)
APPENDIX D
Typical Properties of Some Stainless Steels
137