International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 1, Jan-Feb 2016, pp. 172-179, Article ID: IJMET_07_01_018 Available online at http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=7&itype=1 Journal Impact Factor (2016): 9.2286 (Calculated by GISI) www.jifactor.com ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication PARAMETRIC OPTIMISATION OF GENERATED WASTE PLASTIC FUEL PARAMETERS WITH THE HELP OF TAGUCHI METHOD Raj Kumar M.Tech Scholar Department of Mechanical Engineering Bhaba Engineering Research Institute Bhopal M.P Asst. Prof. Yogesh Kumar Tembhurne Asst. Prof. Department of Mechanical Engineering (B.E.R.I Bhopal M.P.) ABSTRACT In the modern world the responses has changes quickly due to the need of person and requirements. As we know that the consumption of plastic & polythene are increases day by day which is a serious issue of the time concerning to environmental effect. Over a 100 million tones of plastics are produced annually worldwide, and the used products have become a common feature at over flowing bins and landfills. Because Plastics have woven their way into our daily lives and now pose a tremendous threat to the environment For minimizing hazardous effect of this on environment so many steps has been taken by the scientist and research has going on in the support of that i am going to introduce a technique of pyrolysis by the help of which we can convert the plastic and polythene waste in a useful fuel. The waste plastics are subjected to distillation,, pyrolysis, thermal cracking and depolymerisation distillation to obtain different value added fuels such as petrol, kerosene, and diesel, lubericating oil etc and use as a normal fossil fuels in the vehicle which helps in two aspects of need. (i). It minimizes the hazardous effects on environment. (ii). It helps in to produce fuel and minimizes the fuel crisis in some extends. In my dissertation of fuel production through waste polythene and plastic with the help of ziolite as a catalyst in that first of all i prepare a mild steel closed air tight vessel having a lid on the top of it along with the hole which is attached by a long galvanize steel pipe then i filled the container up ¾ of its height with the waste plastic and polythene then by using external source of heater temperature of closed chamber is arises up to 300 o C-450 o C from room http://www.iaeme.com/ijmet/index.asp 172 editor@iaeme.com
Parametric Optimisation of Generated Waste Plastic Fuel Parameters with The Help of Taguchi Method temperature on which the pyrolysis takes place which converts the waste plastic or polythene in useful fuel whose texture,odorcolor, and all other properties like flash point,fire point, cloud point, pour point, viscosity, are almost near to the petrol.after that the outcome fuel from a waste plastic or polythene is used as a normal fuel in a 100 CC bike and found the fuel gives more millage as compare to petrol about 6-8 km. Which increases the efficiency of the engine by 15-20%.& by using Taguchi Technique I optimize the various parameters which affects the production of plastic fuel.by using advance technique I found the catalyst is most affecting parameter whose contribution is 75.25 % and second one is time12.93% and the least is time whose contribution is 9.09%. Keywords: Pyrolysis, Plastic Waste, Taguchi Method, S/N Ratio, Zeolite Catalyst, Temperature, Time. Cite this Article: Raj Kumar and Asst. Prof. Yogesh Kumar Tembhurne. Parametric Optimisation of Generated Waste Plastic Fuel Parameters with The Help of Taguchi Method, International Journal of Mechanical Engineering and Technology, 7(1), 2016, pp. 172-179. http://www.iaeme.com/currentissue.asp?jtype=ijmet&vtype=7&itype=1 INTODUCTION Polymer Polymer are the natural or synthetic molecules that are composed of a large number of smaller monomers, which have reacted to form long chain. The most basic polymers are made from the same monomers the name of this substance is made by adding prefix Poly to the name of monomer. Polymers can be classified into a number of ways which are described below. Figure 1 Plastic materials are cannot be decomposed easily in a short period of time. These plastic wastes can be classified as industrial and municipal according to their origins; these groups have different qualities and properties. The level of waste plastic continuous increase it is generating environmental problems worldwide. classification of plastics includes high-density poly-ethylene,( High-Density Polyethylene Milk, detergent & oil bottles, toys, containers used outside, parts and plastic bags).low- http://www.iaeme.com/ijmet/index.asp 173 editor@iaeme.com
Raj Kumar and Asst. Prof. Yogesh Kumar Tembhurne density polyethylene (LDPE, Many plastic bags, shrink-wraps, garment bags or containers)., polypropylene and polystyrene. Also, plastics are classified by their chemical structure of the polymer's backbone and side chains. Some important groups in these classifications are the acrylics, polyesters, silicones, polyurethanes, and halogenated plastics. Poly Propylene. Refrigerated containers, some bags, most bottle tops, some carpets, and some food wraps. There are two main types of plastics: thermoplastics and thermosetting polymers. These waste plastic convert to useful oil and reduces the many problems increasing in world. METHODOLOGY Pyrolysis process for conversion of waste plastic into fuel: Pyrolysis is the chemical decomposition of organic substances by heating the word is originally coined from the Greek-derived elements pyro "fire" and lysys "decomposition". Pyrolysis is usually the first chemical reaction that occurs in the burning of many solid organic fuels, cloth, like wood, and paper, and also of some kinds of plastic. Anhydrous Pyrolysis process can also be used to produce liquid fuel similar to diesel from plastic waste. Pyrolysis technology is thermal degradation process in the absence of oxygen. Plastic waste is treated in a cylindrical reactor at temperature of 300ºC 350ºC.Now a days plastics waste is very harmful to our nature also fo human beings.plastic is not easily decomposable its affect in fertilization, atmosphere,mainly affect on ozone layer so it is necessary to recycle these waste plastic into useful things.so we recycle this waste plastic into a useful fuel. Taguchi Method: The method presented in this study is an experimental design process called the Taguchi design method. Taguchi design, developed by Dr.Genichi Taguchi, is a set of methodologies by which the inherent variability of materials and manufacturing processes has been taken into account at the design stage. Although similar to design of experiment (DOE), the Taguchi design only conducts the balanced (orthogonal) experimental combinations, which makes the Taguchi design even more effective than a fractional factorial design. By using the Taguchi techniques, industries are able to greatly reduce product development cycle time for both design and production, therefore reducing costs and increasing profit. The objective of the parameter design is to optimize the settings of the process parameter values for improving performance characteristics and to identify the product parameter values under the optimal process parameter values. The parameter design is the key step in the Taguchi method to achieving high quality without increasing cost. The steps included in the Taguchi parameter design are: selecting the proper orthogonal array (OA) according to the numbers of controllable factors (parameters); running experiments based on the OA; analysing data; identifying the optimum condition; and conducting confirmation runs with the optimal levels of all the parameters. Taguchi method the experimental procedure included experimental design by Taguchi method, welding materials, welding equipment and welding procedure. Taguchi method can study data with minimum experimental runs. In this paper, the design of experiment work can be decided by this method. Steps of Taguchi method are as follows: http://www.iaeme.com/ijmet/index.asp 174 editor@iaeme.com
Parametric Optimisation of Generated Waste Plastic Fuel Parameters with The Help of Taguchi Method 1. Identification of main function, side effects and failure mode. 2. Identification of noise factor, testing condition and quality characteristics. 3. Identification of the main function to be optimized. 4. Identification the control factor and their levels. 5. Selection of orthogonal array and matrix experiment. 6. Conducting the matrix experiment. 7. Analysing the data, prediction of the optimum level and performance. 8. Performing the verification experiment and planning the future action. Experimental Setup Plastic Fuel http://www.iaeme.com/ijmet/index.asp 175 editor@iaeme.com
Raj Kumar and Asst. Prof. Yogesh Kumar Tembhurne OBSERVATION TABLE 1 COMPERISION HDPE OIL WITH PETROL AND DEISEL OIL: Fuel properties HDPE PETROL DIESEL Density 795.45 kg/m3 711 to 737 kg/m3 820 to 900 kg/m3 Viscosity 0.775 poise 1.5 to 4 poise 1 to 3.97 poise Specific gravity 0.776 0.82 0.81 to 0.96 Flash point( o C) 23 22 26 Fire point ( o C) 27 25 29 Cloud point ( o C) Below 2 1 to 3 2.5 to4 Pour point ( o C) -4.5 to -5-4 to -20-2 to -12 Colour Yellow, light transparent Brown transparent Dyed blue OBSERVATION TABLE 2 COMPERISION LDPE OIL WITH PETROL AND DEISEL OIL: Fuel properties LDPE PETROL DIESEL Density 530.35 kg/m3 711 to 737 kg/m3 820 to 900 kg/m3 Viscosity 0.652 poise 1.5 to 4 poise 1 to 3.97 poise Specific gravity 0.655 0.82 0.81 to 0.96 Flash point ( o C) 24 22 26 Fire point ( o C) 28 25 29 Cloud point ( o C) Below 0 1 to 3 2.5 to 4 Pour point ( o C) -2 o C -4 to -20-2 to-12 Colour Pale yellow Brown transparent Dyed blue Table 4 Control parameters and their levels Control parameters Level 1 Level 2 Level 3 CATALYST(gm) 10 30 50 TEMPERATURE (degree C) 433.67 314.33 303.33 TIME (minute) 43.67 34 26.67 Evaluation of S/N ratios The control factors that may contribute to reduced variations can be identified quickly by looking at the amount of variation present as a response. Taguchi created a transformation of repetition data to another value which represents measure of variation present. This transformation is Signal to Noise ratio. Thus Signal to noise ratio is measure of amount of observed variation present relative to the observed average of quantity of fuel, the results are analyzed first by calculating the signal-tonoise (S/N) ratio for each performance characteristics for each experiment. Calculating the average of S/N value for each factor and plotting them for each level http://www.iaeme.com/ijmet/index.asp 176 editor@iaeme.com
Parametric Optimisation of Generated Waste Plastic Fuel Parameters with The Help of Taguchi Method Table 5 L9 Orthogonal array S. No. Catalyst (gm) Temperature (degree C) Time (minute) 1 10 428 45 2 10 424 44 3 10 419 42 4 30 316 35 5 30 313 33 6 30 314 34 7 50 306 29 8 50 307 27 9 50 297 24 The S/N ratio that condenses multiple data points within a trial depends on the type of characteristics being evaluated. Accordingly, S/N ratios may be Higher the best (HB), lower the best (LB) or nominal the best. The equations for Higher the best (HB), lower the best (LB) are presented below: Higher the better Table 6 S/N RATIO Run Number CATALYST TEMP. TIME Quantity (ml) S/N Ratio 1 1 1 1 102 103.084 2 1 2 2 104 100.387 3 1 3 3 105 93.097 4 2 1 2 112 105.356 5 2 2 3 115 105.356 6 2 3 1 117 106.229 7 3 1 3 120 106.735 8 3 2 1 123 107.229 9 3 3 2 127 107.789 TABLE 7 Results of the ANOVA CF DOF SS MS %C A 2 121.128 60.564 75.24 B 2 14.64 07.32 9.09 C 2 20.82 10.41 12.93 Error 2 4.391 2.1955 2.72 Total 08 160.979 http://www.iaeme.com/ijmet/index.asp 177 editor@iaeme.com
Raj Kumar and Asst. Prof. Yogesh Kumar Tembhurne Pie chart for percentage contribution Pie chart for percentage contribution 2.72 12.93 9.09 75.24 Catalyst Temperature Time Error RESULT AND DISCUSSION By heating the close combustion chamber with heater of two thousand Watt in a temperature range of 200 to 450 degree Celsius we get approx 560 ml fuel oil. By heating of combustion about 45 minutes the layer of oil appears on the water level. After two hour we get 500 ml of fuel oil. By using 10 ml of this fuel in 100 cc Bajaj bike its runs bike one minute at average speed of 45 km/h.it is concluded that the waste plastic Pyrolysis oil represents a good alternative fuel. CONCLUSION By using this fuel oil in 100 cc bike it increases efficiency of bike by 15 to 20% as compared to petrol used in the bike. Engine fuel with waste plastic oil exhibits higher thermal efficiency. By comparing the density of HDPE oil with petrol its gives approximately same value. Also comparing the density of LDPE oil WITH diesel oil its gives approximately same value. It could be concluded, that thermal pyrolysis of plastic waste leads to the production of fuel oil, valuable resource recovery and reduction of waste problem. Thermal pyrolysis of waste plastic waste has also several advantages over other alternative recycling methods. It has been shown that the conversion at lower temperature in the presence of catalyst into liquid is a feasible process. According to ANOVA analysis the most effective parameters with respect to percentage calibration is Catalyst, temperature, time contribution indicates the relative power of a factor to reduce variation. For a factor with a higher percent contribution, a small variation will have a great influence on the performance. The percent contributions of the plastic fuel parameters on the percentage calibration According to ANOVA this, catalyst was found to be the major factor (75.24) affecting the percentage calibration, whereas time was found to be the second factor (12.93 %),least one is temperature 9.09%. http://www.iaeme.com/ijmet/index.asp 178 editor@iaeme.com
Parametric Optimisation of Generated Waste Plastic Fuel Parameters with The Help of Taguchi Method REFERENCES [1] Mani M., Subash C. and Nagarajan G., Performance emission and combustion characteristics of a DI diesel engine using waste plastic oil, Applied Thermal Engineering, 29,2738 2744 (2009). [2] Murugan S., Ramaswamy M.C. and Nagarajan G., The use of tyre Pyrolysis oil in diesel engines, Waste Management, 28, (12),2743-2749 (2008) [3] Rajesh Guntur and Deva Kumar M.L.S., Experimental evaluation of a diesel engine with blends of diesel-plastic Pyrolysis oil, International Journal of Engineering Science and Technology, 3(6), (2011) [4] Agarwal Avinash Kumar, Biofuels (alcohols and biodiesel) applications as fuels internal combustion engines, Journal of Energy and Combustion Science, 33,233 71 (2007) [5] Nnamso S. Akpanudoh, KarishmaGobin, George Manos*, Catalytic degradation of plastic waste to liquid fuel over commercial cracking catalysts Effect of polymer to catalyst ratio/acidity content, Journal of Molecular Catalysis A: Chemical 235 (2005) 67 73 [6] Murtha NH., patel M. premnath V. plastic materials flow analysis for India, resources, conservation and recycling 2006. [7] SivasankerS. Catalysisin petroleum refining. Catalysis; 2002:362-376. [8] SinghB, SharmaN. Mechanisticimplications of plasticde gradation. Polymer Degradation and St ability 2008;93:561-584.Angyal A, Miskolczi N, Bartha L (2007). Petrochemica. [9] Senthilkumar Tamilkolundu and Chandrasekar Murugesan, The Evaluation of blend of Waste Plastic Oil- Diesel fuel for use as alternate fuel for transportation, 2nd International Conference on Chemical, Ecology and Environmental Sciences,(ICCEES'2012) Singapore April 28-29, (2012) [10] Nerın C., Domeno C., Moliner R., Lazaro M.J., Suelves I., Valderrama J.J. (2000) Anal. Appl. Pyrolysis, 55, 171-183. [11] Hajekova E., Mlynkova B., Bajus M., Spodova L.J. (2007) Anal. Appl. Pyrolysis, 79, 196-204. http://www.iaeme.com/ijmet/index.asp 179 editor@iaeme.com