project
TRANSCRIPT
ONLINE TEMPARATURE MONITORING OF
ELECTROWINNING PROCESS USING
MICROCONTROLLER
STUDENT : SHALET K S, REG NO:13MMT1045
PROJECT GUIDE : DR. V G SRIDHAR , SMBS
OBJECTIVE
2
The objective of this project is to develop an on-line temperature
monitoring and control system for bipolar electro-winning processes done
for zinc extraction using LM35.
SCOPE OF WORK
3
Scope of this project is to develop a prototype of online temperature
monitoring and control system of an electro-winning process in laboratory
conditions by using electronics components in order to make it cost
effective.
LITERATURE SURVEY
4
1. A good comparison between uni-polar and bipolar electro-winning cell modeling is made
in[1]. Serially connected bipolar electrodes are not wire connected, just immersed in electrolyte
hence uses much lower DC current comparatively.
2. Advances and trends in primary and small secondary batteries with Zinc anodes and
manganese dioxide or air cathodes[2]. T he study tells Zinc cells can produce more service than
lithium cells.
3. A remote monitoring system for temperature, voltage, current and power
measurements[3]uses three sensors. Voltage sensor, Current sensor and temperature sensor.
LM35 is the temperature sensor used here because of the advantage of delivering tension as
linear function of the temperature input.
54. Heat exchange due to air flow is measured by a thermocouple and an LM35. Hence
constant temperature shows a variation and respective voltage can be measured.
Thermocouple has high response time than LM35. Due to inherent character of ADC
thermocouple output cannot be digitized[4].
5. Energy Saving by Automatic Control of Power in Simple Home Appliances[5] uses
different sensors and the sensor used for temperature measurement is LM35.
6. The application of soil temperature measurement by LM35 temperature sensors[6]. Here
the theoretical equation between sensor output voltage and Celsius temperature also carried
out.
7. Research on the elevator door control system based on the image processing
technology[7]. Here image acquisition chip of elevator used is 0V7620 and the image is
transmitted to the main controller ATmega32 and the control action is done.
8. Fabrication of MEMS based temperature sensor, controlling and monitoring is done by
Lab-VIEW. From sensor to ADC and then to PC via wireless data acquisition device[8].
6METHODOLOGY
Step by step method of
measuring monitoring and
controlling the temperature
of the process
ATMEGA 16
LM35 (sensor)
ADCLCD DISPLAY
PC
TEC
(actuator)
POWER SUPPLY
7805
DRIVER
PROCESS
USB
PO
RT
PORT
KEYPAD
Block diagram representation of control and monitoring
system for temperature 7
13SL. NO COMPONENTS DIAMENTION (cm) NO
1 Basement 47 X 30 X 4.6 1
2 Glass beaker 14.3 X 14.3 X 16 4
3 Heat sink (big) 10 X 6.5 X 1.8 4
4 Heat sink (small) 6.5 X 4.5 X 1.8 4
5 TEC hole 4.4 X 4.9 4
6 Zinc electrode 16 X 1 (dia) 4
7 Graphite electrode 15 X 2 ( dia) 4
8 Electrode holder 33 X 3.7 X 1.1 2
9 Fan 8 X 8 X 2.5 4
10 Billet 4 X 4 X 1.1 4
DESIGN SPECIFICATIONS
Table 1. Specification of process components
14SL. NO COMPONENTS SPECIFICATION No
1 Dotted PCB board 140 X 90 (mm) 1
2 ATMega 16 (base) 40 Pin - DIP 2
3 LCD 16 X 4 (mm) 1
4 ULN 2003 (base) 5X5X5 (cm) 2
5 USB module TTL 4 pin connector 1
6 Keypad 70 X 77 X 1 (mm) 1
7 TEC 40 X 40 X 3.8 (mm) 4
8 LM35 10mv/ °C 4
9 Mosfet IRFZ533 (heat sink) 4
10 Resistors 15, 5.2, 8.2(k), 68, 47(ohm) 11, 5, 1, 5, 5
11 Berg strips - M - 3, F - 1
12 Pot 10k 1
13 2 pin connectors - 18
14 Relay 12v 8
15 SMBS power supply 450 watt, 24 pin 1
Table 2. Specification of electronic components
15
MCU 1 MCU 2
PORT A
PA0 - TT1 PA0 - ELV1
PA1 - TT2 PA1 - ELV2
PA2 - TT3 PA2 - ELV3
PA3 - TT4 PA3 - ELV4
PA4 - TV1 PA4 - 12VM
PA5 - TV2 PA5 - 3.3VM
PA6 - TV3 PA6 - 5VM
PA7 - TV4 PA7 - LL
PORT B
PB0 - RS PB0 - S1
PB1 - RW PB1 - S2
PB2 - EN PB2 - S3
PB3 - EL1 PB3 - EL2
PB4 - BZ PB4 - SS
PB5 - MOST PB5 - MOSI
PB6 - MISO PB6 - MISO
PB7 - SCK PB7 - SCK
PORT C
PC0 - LD0 PC0 - KP1
PC1 - LD1 PC1 - KP2
PC2 - LD2 PC2 - KP3
PC3 - LD3 PC3 - KP4
PC4 - LD4 PC4 - KP5
PC5 - LD5 PC5 - KP6
PC6 - LD6 PC6 - KP7
PC7 - LD7 PC7 - KP8
PORT D
PD0 - COM PD0 - F1, F2
PD1 - COM PD1 - F3, F4
PD2 - TEC1M PD2 - TEC3M
PD3 - TEC2M PD3 - TEC4M
PD4 - TEC1V PD4 - TEC3V
PD5 - TEC2V PD5 - TEC4V
PD6 - S4 PD6 - PS ON
PD7 - EL3 PD7 - EL4
MCU DESIGNIn the control unit two ATMega 16 are used. The table reveals each pin connections of
both controllers
21EXTRACTED ZINC
• 2.8g of ZnSO4 in 100ml of distilled
water.
• 1.2g of Zinc extracted after
Electro winning process in
Chemistry lab.
ZINC
22VOLTAGE (volt)
TEMPERATURE (degree Celsius )
TIME (cumulative sec)
0 29 0
3 29 6
3 30 4
3 31 2
3 32 1
3 33 1
3 34 1
3 35 1
3 36 1
3 37 1
3 38 1
3 39 1
3 40 1
3 41 1
3 42 1
3 43 1
40
Temperature
verses time at
constant
voltage forzinc deposition
Complete extraction
23TEMPERATURE
(degree Celsius)TIME
(minute)DEPOSITION
(gram)
27 60 5.2
30 60 6.4
35 45 8.2
40 20 9.3
45 20 9.3
50 20 9.2
55 20 9
60 20 8.1
65 20 7.5
70 20 6.4
Readings During Electro - winning Process at Different Temperature
20 g of Zn SO4 in 750 ml of
distilled water. After processing
9.3g of Zn is extracted.
Required amount is 9.6g.
24
Temperature verses time graph
2730
35
40
45
50
55
60
65
70
5.2 6.48.2 9.3 9.3 9.2 9 8.1 7.5 6.4
1 2 3 4 5 6 7 8 9 10
Temperature v/s deposition
Temperature (°C) Deposition (gm)
Temperature verses deposition graph
2730
35
40
45
50
55
60
65
70
60 60
45
20 20 20 20 20 20 20
1 2 3 4 5 6 7 8 9 10
Temp v/s Time
Temperature (°C) Time (min)
CONCLUSION AND FUTURE WORK25
Successfully done with the control unit of online temperature control and monitoring of
electro winning process. By automatic monitoring and control of tank temperature it is
possible to reduce the time lag and inaccuracies of monitoring of temperature, reduce the
power consumption by making temperature at optimum value. Integrated the mechanical,
electronics and software sections and processing will be doing in future.
REFERENCE
26
[1] Ralph Bittner, Antonio Pagliero, Lautaro Sal, Mauricio Valemuel, Electric Field and Potential
Determination for Electro-winning Cells with Bipolar Electrodes Finite Difference Models, IEEE,
1998.
[2] Brooke Schumm, Advances and Trends in primary and Small Secondary Batteries with Zinc
Anodes and/or Air Cathodes, IEEE, 2000.
[3] E. Barakat, N. Sinno, C. Keyrouz, A remote monitoring system for voltage, current, power and
temperature measurements, Physics Procedia 2014.
[4] Beatriz Ariadna Jacome Hernandez1, Esperanza Medina Hernandez2, Jesus Yalja Montiel
Perez3, Arrangement Of Temperature Sensors As A Wind Sensor, IEEE Associate.
27
[5] Kazi Mahtab Kadir, Md. Saleh Forhad, Mahran Muhammad Fadlullah, Niamul Quader, Md. Masudur
Rahman AI-Arif, Maruf Ahmed Dhali, Energy Saving by Automatic Control of Power in Simple Home
Appliances, IEEE, 2011.
[6] Cuihong Liu, Wentao Ren, Benhua Zhang,Changyi Lv, The application of soil temperature
measurement by LM35 temperature sensors, International Conference on Electronic & Mechanical
Engineering and Information Technology, 2011.
[7] Xi Zeng, Guo-jun Zhao, Yuan-ping Wang, Chao-rong Wang, jun-hui Wang, Research on the elevator
door control system based on the image processing technology, International Conference on Electrical and
Control Engineering, 2010.
[8] Abhishek Mallik and Sauvik Das Gupta MODELLING OF MEMS BASED TEMPERATURE
SENSOR AND TEMPERATURE CONTROL IN A PETROCHEMICAL INDUSTRY USING LabVIEW.
International Conference on Computer and Automation Engineering, 2009.