Landy's Kalk Reactor

[landy]

It been a while since I posted a build thread.

This project was started a few months ago as a warm up to fabricating a new sump.

It turned out pretty awesome ( or at least I think so ).

Anyways, I fabricated a calcium reactor years back that was then repurposed as a kalk reactor, and has served me well for many years.

Pictured just taken out of service.



In designing a new reactor, I wanted to eliminate a few things I didn't like.

First and foremost, the lid. I have grown to hate the thumb screw lid.

Next is the mixing method. I don't like having a pump mix the kalk, plus the added points for potential leaks.

Lastly, using the lid as a connection point for anything, this adds to the pain in refiling.





I need the unit to be pressure rated as I force fresh DI water from a reservoir with a masterflex peristaltic pump into the reactor, in turn forcing saturated water to the tank.

Most the commercially available option rely on gravity for the second half.








The design was forged in Autodesk fusion 360, here are some screen shots.





The reactor is 1" type 1 white PVC, the tubing is 6" OD cast acrylic.

the parts will milled on a 4x4 cnc router.




Once machined, the parts were glued with Weldon 42, and wet sanded.








And here is a shot of it in action.




please share any comments, and let me know if you have any questions.


thank you for viewing


landy

[dattack]

Beautiful. How were you able to cut the threads on the cnc for the larger piece?

[Gorgok]

Thats real pretty. I really like the 'all the crap goes in the base' design of it and wonder why that hasn't become the standard (it may well become it now)... Well other than it no longer being submersible maybe (not counting the fan).

The stirrer looks wimpy, but that is just appearance wise, i assume it functions based on the last pic.

[dartier]

Originally Posted by dattack

Beautiful. How were you able to cut the threads on the cnc for the larger piece?

That is exactly what I was thinking ... wow, nice CNC work.

Dennis

[BigDave]

Interesting. I never thought about using a fan for spinning a magnetic stirrer. That's a great idea.

Great CAD and mill work as well.

[landy]

Originally Posted by dattack

Beautiful. How were you able to cut the threads on the cnc for the larger piece?

Thank you!

The process is called thread milling. It takes a specific bit. I used a single point 6tpi stub acme thread for the lid. The first test cut I used regular 60 degree threads, but felt the acme threads would be better suited for this application.

Originally Posted by Gorgok

Thats real pretty. I really like the 'all the crap goes in the base' design of it and wonder why that hasn't become the standard (it may well become it now)... Well other than it no longer being submersible maybe (not counting the fan).

The stirrer looks wimpy, but that is just appearance wise, i assume it functions based on the last pic.

Yes, defiantly not submersible. A kalk reactor, imo shouldn't need to live in the sump. most do in fear of overflowing I would assume. I'm not worried, this reactor will hold pressure.

I ordered a few different stir bars to test. The one pictured actually does well, but i think there is room for improvement.

tonight i will get a picture of it stirring.

Originally Posted by dartier

That is exactly what I was thinking ... wow, nice CNC work.

Dennis

Thank you!!

Originally Posted by BigDave

Interesting. I never thought about using a fan for spinning a magnetic stirrer. That's a great idea.

Great CAD and mill work as well.

I cant take credit for this, its all over the internet


landy

[coseal]

very nice! love your work, have been watching your post for years on here.the use of pvc really gives it that extra bump! rivals any production reactor i have seen. what mix of bits did you use for the milling? and your vacuum table under your spoilboard looks well done! are you using inserts in each one of those grid blocks?

sorry to get off topic.... i think the "process" is just as interesting as the "product"

[Vinny Kreyling]

Nice Skills & design.

[Audi_Guy]

Originally Posted by landy

I cant take credit for this, its all over the internet

landy

Do you mind sharing the fusion 360 files ??

[landy]

revised

[landy]

Originally Posted by coseal

very nice! love your work, have been watching your post for years on here. the use of pvc really gives it that extra bump! rivals any production reactor i have seen. what mix of bits did you use for the milling? and your vacuum table under your spoilboard looks well done! are you using inserts in each one of those grid blocks?

sorry to get off topic.... i think the "process" is just as interesting as the "product"

Thank you for the kind works, I'm blushing .

But seriously,

PVC is my new go to material, really like the stuff. At first it didn't machine all that well, but I have been slowly figuring out the correct bits, feeds, and speeds to produce a finish I can work with.

As for bits, lets see.


top: 90 degree chamfer bit
middle: 1/4 plastic specific upcut bit
bottom: stub acme thread mill bit.


Funny you ask about the vacuum spoil board. i removed the MDF test version this weekend and started work on the new PVC version!!
this is a full sheet of type1 in grey .75" actually measured .8" to start out.


The grid blocks are for a 1/4 closed cell foam gasket/oring that is used to seal the flat parts to the table. All the holes will be thread milled to 3/8-16 for pinning material when machining both sides.

This pictures is after the second face mill operation.
Had to remove .065 to get the sheet flat. took a total of 3 passes.



thanks again!!!

Originally Posted by Vinny Kreyling

Nice Skills & design.

thank you Sir

Originally Posted by Audi_Guy

Do you mind sharing the fusion 360 files ??

Probably not, but no fault in asking



And to finish this post out.


Here is a shot of the stir in action. Its hard to tell, but some of the kalk has settled on the outskirts.

The new stir bars should show up this week. I'm sure one a little larger with do the trick. Admittedly, when the current one was ordered i must not have read the description that well, as i was expecting something larger...


Thanks again, and keep the comment & questions coming!


landy

[BigDave]

Which CNC machine is that.

I recently started looking at diy machines lately. I keep bouncing back and forth between a CNC or a 3d printer. Personally I'm leaning toward the CNC as I do woodwork also.

[coseal]

Nice machine! I see you got the new linear rails they are offering..

And type1 PVC spoilboard!! Man you don't play around =)

[landy]

Originally Posted by BigDave

Which CNC machine is that.

I recently started looking at diy machines lately. I keep bouncing back and forth between a CNC or a 3d printer. Personally I'm leaning toward the CNC as I do woodwork also.

The kit is sold by "cncrouterparts.com" very nice and capable machine.
3d printers are neat, but no substation for a 3 axis machine capable of machining aluminum.

Originally Posted by coseal

Nice machine! I see you got the new linear rails they are offering..

And type1 PVC spoilboard!! Man you don't play around =)

I had purchased the original pro kit in January, when they came out with the linear bearing kit, they gave me a deal I could not pass up on the upgrade.

The bearings take an awesome machine to the next level.

As for the PVC spoil board. that was always the intention. I just needed to proof out the design in MDF as the PVC is pricey!!

Should have the grid cut this weekend.

thanks again

landy

[BigDave]

Thanks to you I'm looking at cnc machines again. I kept looking at 3d printers, but have never liked some of the qualities of the prints. I do woodworking and keep kicking back and forth about getting one. I have an old lathe I want to convert to a 4th axis if I get one.

Sent from my VS987 using Tapatalk

[Isayso]

Great thread,and also great work
Excellent job , I wish I had cnc machine

Years ago I built a magnetic stirrer using a Fan,
to stir fish food with Selcon and phyto,
Thus is the link
http://youtu.be/aR9sFDTyVDI

[landy]

Originally Posted by BigDave

Thanks to you I'm looking at cnc machines again. I kept looking at 3d printers, but have never liked some of the qualities of the prints. I do woodworking and keep kicking back and forth about getting one. I have an old lathe I want to convert to a 4th axis if I get one.

Sent from my VS987 using Tapatalk

Dave,

I don't think you will regret it. Nothing wrong with 3d printers, but I would get the cnc router first .

Funny you mention a lathe, I had been looking for the right one for about 2 years. Finally found it last weekend! Drove to Tucson for the purchase. Its a 1952 Logan 11X36. I will be doing a restoration at some point, but its in nice shape.

Originally Posted by Isayso

Great thread,and also great work
Excellent job , I wish I had cnc machine

Years ago I built a magnetic stirrer using a Fan,
to stir fish food with Selcon and phyto,
Thus is the link
http://youtu.be/aR9sFDTyVDI

Nice! that is exactly the same concept used on this reactor. Do you still use the stir plate you made?




I finally go around to testing the other stir bars.

Original on the left, test subjects to the right.




Draining down the reactor to make the swap was easy. The last port on the right side of the reactor is currently setup with a whipline and a 1/4 turn JG ball valve. You just crack the seal on the lid and open the ball valve into a container and drain off what you need to.


This port could also be used to dose carbon, as I think some do that.


I tried both the new stirbars, and the results were no different that the original small one. In changing them out I did discover that the kalk that was not mixing is a much smaller amount that I had thought. It is around the edges of the tube and @ a steep angle. So I don't think is really matters.


On a CNC side note. the PVC vacuum spoil board is almost complete! Should be back up and running by Sunday!



Every single one of those holes has been thread milled to 3/8-16. That operation alone took a little under 8hrs to complete...


landy

[Vinny Kreyling]

Atsa lotta holes!!

[BigDave]

Not to derail the thread too much, but I decided on a smaller DIY CNC for the first one. I'll put a 400watt spindle and NEMA 17's to keep the cost down. If I enjoy it, then I'll slowly upgrade it or use it to cut parts for a bigger machine.

My lathe is an older 1950's Craftsman woodworking lathe. It's a 10323070.

I love older tools. They just seem to last better.

I'm not too surprised that there wasn't any difference in your magnets. It always seems to me that faster rpm's seem to mix things better than bigger paddles.

[ramasule]

Dust Deputy!

[landy]

Working on version 2 of the kalk reactor, or is it version 3?

It has been working flawlessly for over a year now, so hey; why not mess with it right?







Nothing fundamental has changed. Just integrated the titanium disk for the stir bar, and got rid of all the screw-in fittings.

made for a much cleaner look!

thanks

landy

[coseal]

"just integrated the titanium...." lol! lookin great man!

i have that same tap and die set!

[outy]

love the low wattage, but your work is great.

measured mine at 1.6 for the avast motor that's now clicking.

The 4w microwave turntable replacements are only 10 bucks or I would love a stirrer like that.