A Presentation On

Proposed Dissertation Work

DESIGN AND ANALYSIS OF SLUDGE

COLLECTOR HEAD SHAFT FOR WASTE
WATER TREATMENT PLANT

Presented By
NITEEN MULMULE
Enrollment No. 0103ME12MT08
M-Tech (Industrial Design), IV-Sem.
LNCT, Bhopal

Under the Supervision of

Dr. V. N. Bartaria
H.O.D., Department of
Mechanical Engineering
LNCT, Bhopal

CONTENT
Introduction

& Objective of Present Work

Literature Review
Theoretical Analysis and Data Collection
Problem Identification & Methodology
Computational Study
Proposed Solution
Result Analysis
Conclusion

Water and sewage treatment systems are well known. For more than
50 years, rectangular clarifiers (rectangular concrete tanks) have been
used in the treatment and purification of sewage, sewer drain, and
drinking water. They are used to remove those materials which are
either not biodegradable or cannot be chemically treated during the
water purification process.
Systems include motor-driven sprockets which move two parallel
chains which have flight members attached there. The flight members
scrape the floor of rectangular clarifier tank in one direction,
gathering all solid waste materials which have fallen to the floor of
the tank and moving them to a cross collector located at one end of
rectangular tank.
The power transmitted from motor to head shaft which transmitted
power to follower stub shaft.

Major components in sludge collector system of waste water

treatment plant.

Flig
ht
Head
Shaft
Motor

Bull
Sprocke
t
Driven
Shaft

Concrete tank
Chain

Bearing

Chain
Sprocke
t

Objective of present work: The objective of current project is to

replacement of solid head shaft design to combination of solid and
hollow shaft design.

Benefits

of proposed new head shaft design.

-Reduction in weight.
-Better strength.
-Cost reduction.
-Manufacturing time reduction.

Since five decade various research and development work done on

sludge collector of waste water treatment plant and few of them also
patented.
Under US patent US6279752 B1, Joseph R. Hannum (Aug 28,
2001) invented waste water treatment system for use in a rectangular
clarifying tank using solid head shaft design.

Under US patent US5454942 A, Bertil A. Ljungberg (Oct 3, 1995)

invented purification of liquids, including water, milk and the like,
utilizing an air floatation basin and a skimming device for removal
of floating sludge. using solid head shaft design.

Under US patent US6260716 B1, Henri Fontaine, Erick

Breton(Jul 17, 2001) invented removing operation of scum,
sludge or other matters floating at the surface of water, waste
water, sewage or the like in a clarifying tank, and more
particularly to a scum sweeper used for performing such an
operation, and a system using such a scum sweeper to sweep
surface floating matters into a collector channel or pipe in a
clarifying tank, using solid head shaft design.

Under European patent EP0198334 A2, Joseph Robert Hannum(Oct

22, 1986) invented water clarifier and sewage treatment device
comprising a rectangular tank including a floor, a pair of side walls
and a pair of end walls, spindles secured to the side walls, sprockets
received on said spindles, a pair of chains meshing with the sprockets,
a pair of which sprockets is connected by a drive shaft and driven by
drive means while the other ones are idler sprockets, and a plurality of
flight members secured to the chains for scraping the floor of the tank,
using solid head shaft design.

Hollow Vs

solid shaft:
Section Modulus = I/c
where I = Moment of Inertia
c = Distance to extreme fiber
Hollow shaft: O.D. = 6.625, I.D. = 5.761 (6 Schedule 40)
Weight = 28.57 pounds/ft.
Moment of Inertia for hollow shaft = 0.049087 x (OD 4 ID4) = 40.4904
Section modulus for hollow shaft = 0.049087 x (OD4 ID4) x 2U
OD
= 12.2
4.99 dia. Solid shaft weight = 66.65 pounds/ft.
Moment of Inertia for 4.99 solid shaft = 0.785398 x R 4 = 30.4349
Section modulus for 4.99 solid shaft = 0.785398 x R 4 /R = 12.2
Result: 57% material saving for the same section modulus

The major problem in replacement of solid shaft is the creation of

key way in long solid shaft.
The key way is important feature of head shaft to mount the chain
sprocket.

The identified problem can be solved by design the head shaft in to

combination of hollow and solid shaft.
The concept model shown below.

Hollow shaft
(Dia. 6.625,
Thk. 0.4325
Solid
shaft
(Dia.
4.5)

Solid
shaft

Schematic Diagram of load on Bull sprocket and

Chain Sprocket:

Torque Hand Calculation:

Maximum torque developed at bull sprocket
= (Bull sprocket PCD/2)* Max Tangential force
= (33.25/2)*1920
= 31920 lb.in
Maximum torque at by drive end and non drive end sprocket.
= (Sprocket PCD/2)* Max Tangential force
= (22.23/2)*2860
= 31788.9 lb.in

Note: Referring water treatment standard data.

Standard Bull sprocket PCD uses in 4.5 Dia shaft = 33.25
Standard chain sprocket PCD uses in 4.5 Dia shaft = 22.225
For 15 Hp Motor & 5 Row Flight conveyer. Max load applied on
bull sprocket = 1920 lb. and Max. loaad applied on chain
sprocket = 2860 lb. each side.

Resultant force calculation based load angle:

Chain Sprocket

Bull Sprocket

+Y

+X
Fr

Fa
Fr

Fa
= 2700

= 1800

Forces Along two perpendicular axis i.e along X (Horizontal) and

along Y (Vertical)
Reaction Force Fr= Applied Force Fa

Fx = Fr+Fa cos
Fy = Fa sin
Resultant Fr = (Fx2 + Fy2 )
Angle of Resultant = tan-1 (Fy/Fx)

Loading condition for simulation:

Load Case

Chain Sprocket
Resultant
Y
X
warpin Resultant
angle
compon compon
Force
g
Force on
Torque
(deg)
ent
ent
(lbf) angle sprocket
(lb-in)
from + X force(lb force
(deg)
(lbf)
axis
f)
(lbf)
-2860
2860
90
4044.6508
315
2860
31788.9
Bull Sprocket

Load Case

Result
Resultan
ant
Y
X
warpin
t angle
Force
Force
compone compone
g angle
(deg)
(lbf)
on
nt
nt force
(deg)
from + X
sprock
force(lbf)
(lbf)
axis
et (lbf)
1920
180
3840
90
3840
0

Torque
(lb-in)

31920

Computational Study

The CAD packages Solid works is used to automate the

drafting/designing/engineering processes & technical operations.

The FEA packages Ansys 15.0 is used to analyze the head shaft design.
Solid works data imported to Ansys Workbench.

For simulation Contact region created.

Patch confirming method has been used to mesh generation.

Model has been meshed using tetrahedral mesh element.

Meshed Zoom view.

Meshed Zoom view.

Meshed Zoom view.

Boundary Conditions.

Boundary Condition: Support provided on both end of the model

Boundary Condition: At both chain sprocket 4044.6508 lbf load

applied at an angle of 315 degree. (Referring loading condition)
table)

Boundary Condition: At Bull sprocket 3840 lbf load applied at an

angle of 90 degree. (Referring loading condition table)

Material selected 316L SS.

Material Properties shown below

Young's
Poisson's Density
Modulus
Ratio
(lb/in3)
(psi)

2.90E+07

0.3

0.289

Ultimate
Yield
Shear
Endurance limit
Tensile
Strength Strength
(Stress)
strength
(psi)
(psi)
(psi)
(psi)

24700

14079

72000

21242

Result Analysis:

Von- Mises stress Plot shows safe design.

After neglecting concentrated stress, Max Von- Mises Stress

observed less than 12000 psi.

Maximum displacement is less than 0.08 inches.

Displacement in X-direction.

Displacement in Y-direction.

Displacement in Z-direction.

Twisting about Z axis is 0.5 degree.

Conclusion :

THANK YOU