Automated Biochar Injection System

The goal of the project is to design a mobile BioChar (BC) injection system that will accept and inject BC into pressurized water lines in an accurate, controlled, and recorded manner in tandem with existing systems on the UIdaho Clean Water Machine with minimal adaptation of current systems.

=Problem Definition=

Deliverables
A system that will store the BC and maintain storage at consistent conditions

A system that will modify any purchased BC to specific parameters for the injection system

A method of transporting the BC to the influent water pipes

Automated and manual controls of the injection system 

Graphical I/O touch screen display 

A system for wetting and mixing the BC so the BC stays suspended for the specified contact time

A frame that will integrate and interface seamlessly with the existing frame on the Clean Water Machine

Functional Requirements
Deliver wet or dry BC with 15% accuracy, within 1.5 mg, and no under-dosing Operate quieter than 60 dB when at maximum capacity</li> Detect and account for variability in moisture content, consistency, and temperature</li> Must keep BC at constant conditions (temperature, moisture content, texture) </li>

Mechanical Requirements
 Strength: 

Load sensor shall withstand a range of 0.5 mg - 5 g </li> Hopper must handle load of at least 208 kg/m^3 of BC </li> Pipe will withstand flow rate and pressure of 15 gal/min and 25 psi respectively</li>

 Space/Weight: 

Must fit on 40ft trailer with Clean Water Machine for transport</li> Machine footprint must not exceed 10 ft x 10 ft</li> Must have openings in frame for maintenance and access</li> The total BC injection system shall weigh no more than 300 lbs </li> Clean Water Machine, trailer set-up, and BC mechanism will not weigh more than 26000 lbs</li>

 Mounting: 

System shall be modular to allow for disassembly for travel</li> System shall mount to the current Clean Water Machine frame</li>

 Appearance: 

Labeled and laser-etched controls and hardware </li> LED’s included as indicators and decoration</li> Clear material is preferred especially in areas of change and flow</li> <li>Neutral single colors (greens, blues, black, metal finish etc.; match logo of Clean Water Machine) </li>

 Durability: 

<li>System shall be designed to operate for 1 year without any scheduled maintenance </li> <li>Refill hopper no more than once every three days <li>No more than one 5-minute operation/maintenance check per day</li> <li>Tear down and rebuild in half a day to completely disassemble and reassemble</li> <li> Full operational capabilities in environments with ambient temperatures of 32°F to 110°F and humidity from 20-90%</li> <li> All electrical components shall be IP67 </li> <li> All material shall withstand corrosion and contact with water </li> <li>All components (including bearings) shall have 90% reliability</li> <li>Components will withstand at least 5 years of constant use</li>

Electrical Requirements
<li>Input will be 120V or 240V</li> <li>Controls shall operate at 24V and 4-20mA</li> <li>Pi will be powered by 5V 2.1A USB</li> <li>Touch-screen controls must last 12 hours of constant use while disconnected from main voltage source </li> <li>Pi back-up battery must last 12000 mAh</li> <li>Touch-screen controls must last 24 hours without recharging </li>

Software Requirements
 Functionality: 

<li>Standard WIFI 802.11 </li> <li>At least two USB 3.0 busses</li> <li>Must integrate with existing system</li> <li>Display must have 10-finger touch capacity capability</li> <li>In-field programmability (empty buttons created for programming dosage of additional chemicals) </li> <li>Setting to switch between Automatic and Manual controls</li>

 User Interface: 

<li>Display flow-rate at inlet and outlet (gal/min) </li> <li>Display hopper capacity (grams), temperature (ºF), moisture content (%), and BC dose rate (g/mL) </li> <li>Hopper capacity error/warning message and indicator at 15% capacity </li> <li>Performance indicators for malfunction and normal operation</li>

Production
<li>Prototype must be built for testing by February 1, 2019 </li> <li>Two physical devices created by May 10, 2019</li> <li>Cost to build a POC prototype shall not exceed $2500</li>

=Design Considerations=

=Project Learning=

=Final Design=

=Validation=

=Team Members=

=Additional Documentation=

Project Schedule



Meeting Minutes



Presentations



Client Interview